Volume 04 No. 10 | March 2019 | ` 150
Pages 124 | RNI No. MAHENG/2015/64267
Whatever industry sector you’re in? Aerospace, Automotive, Electronics, Medical or woodworking
ANCA Machine Tools Private Ltd 8/1 , Dr. M H Marigowda Road, Arekempanahalli , (Wilson Garden ), Bangalore - 560027, Karnataka, India T: +91 (80) 6759 2100, M: +91 96637 6991 E: indiainfo@anca.com
anca.com
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CEO CORNER
Publisher & Printer Shirish Dongre
CEO Shekhar D.
Editor
Indian Machine Tools Industry : Future is industry 4.0
Shilpa Dongre
Assistant Editor Shweta Nanda
The Indian machine tools industry, though highly fragmented, is projected to grow at 5.5 per cent annually through 2019, driven particularly by expanding demand in China and other developing countries. With presence of several small, medium and large suppliers, including international and regional players, the companies engaged in machine tools manufacture compete in product differentiation, service portfolio and pricing.
Marketing Team Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, Vinod Surve, Kamlesh Balkrishna, Kavita Chaudhari
Digital Marketing Kailash P.
Designer & Layout Arun P. Shinde, Nandan S. Moghe, Dinesh S. Gawade
Online Division Ganesh Mahale
Circulation Executive Satish Kadam, Amol Ranshur Branch Offices (Zonal)
NORTH (Delhi & NCR regions) Sandesh Jain : 09810837877 / 09871602777
SOUTH (Chennai & Coimbatore) Y. V. Raghu : 09566141224 Bangalore E Vikram : +91 9591488434 Vaman : +91 9686721340
The industry is growing at an exponential rate and is presently estimated at around 6,000 crore, he said the manufacturers will need to develop capabilities to cater to the demand and investments in this area could yield long-term benefits. industry has advanced significantly in hardware and software applications. The future includes automation of processes into manufacturing and engineering sectors. Reduced manual intervention in process control using machine tool control system and smart tooling would be the key to optimise cost, reduce scrap and improved machine utilisation. India’s growth story can only be further enhanced by aligning objectives and policies that function together to place the country as a manufacturing base. It is also crucial to encourage the use of high-end manufacturing processes and technologies in digital factories that can encourage Additive Manufacturing and other forward-looking initiatives for the sector. Reducing import duties on strategic capital equipment like Additive Manufacturing machinery will also encourage the industry and the country to stay competitive in a global market.
Hyderabad E Vikram : +91 9591488434
EAST (Kolkata & Other regions) Kamlesh B. - 09819464242
WEST (Maharashtra & Gujarat) Pune Shilpa K. - 09833373371
In recent past, Industry 4.0 has evolved rapidly from a distant, esoteric concept to something companies now believe is real and tangible. Industry 4.0 is a collective term for the new technologies that are significantly changing the manufacturing landscape. These technologies include 3D printing, sensors, advanced robotics, Internet of Thing (IoT), simulation, augmented reality, Artificial Intelligence (AI), Big Data and Advanced Analytics. The Indian machine tool industry needs to embrace and work around these emerging trends.
Nashik Abhijit B. Joshi : 09890002333 Rajkot (Saurashtra) Swapnil Bhatia: 09227909005
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.mtwmag.com
CEO
Printed & Published by Shirish Dongre on behalf of DIVYA MEDIA PUBLICATIONS PVT LTD., Printed at Anitha Art Printers 29/30, Oasis, Next to Vakola Market, Santacruz(E), Mumbai-400055, published from 303/304, Harmony Tower, N.S.Road, Court Naka, Thane West, Thane-400601. Editor : Shilpa Dongre
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www.mtwmag.com
PURELY A MATTER OF FORM
CAM GRINDING The many decades of experience in cam grinding are apparent in the non-cylindrical grinding machines of the JUCAM series: The control system with a learning function, the C-axis with a direct drive and many special solutions give camshafts, cam pieces and individual cams of all sizes and shapes a perfect finish.
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Contents
MARCH 2019
COVER STORY
SCHMERSAL: Protecting human & machine assets for safer workplaces BUSINESS NEWS
INFOCUS
20
36
INDUSTRY INSIGHT
Gleason to acquire Faessler Honing Business from Daetwyler Group
22
ELGi launches ‘State of the Future Art’, a signature initiative to drive futuristic technology and nurture innovation
24
44
48
ANCA Motion brings CyGrind to TIMTOS
2019
COMPANY PROFILE
26
INSIDE STORY
U-Tech Utpadan enters into an agreement with BFW
32
Renishaw announces introduction of the QuickLoad rail system
34
FIBRO India inaugurates its second phase of operations 10
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52
122 www.mtwmag.com
Contents
MARCH 2019
AMT SECTION
55
57
58
60
TECH TRENDS
76 72
Wind Energy providers look East
80 High Precision Gap Monitoring in Plant & Machinery
Machine Safety in the Age of Digitisation
98
94 Telescopic Rails & Industrial Automation: How to Increase Performance in Production Systems
CASE STUDY
ESPRIT is the Formula for Success for Metri-Tech
PRODUCTS SHOWCASE
117 “Torpedo” High 119
Diamond cut Performance Range Tools: knurled control knobs with collar or flange Precision Ball Screw Spline-PBSA Series Steady Volt Servo Voltage Stabilizers
118
106 Renishaw & Hartford combine to deliver intelligent, ‘Smart Factory’ solutions 12
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118
Welding Fume Extractor, King ExtractorII-MU 3
119 120
Super compact safety module www.mtwmag.com
Editorial Board
Editorial Index A
K
Ador Welding
66, 118
Kinefac Corporation
ANCA
24, 104
KYOCERA SGS Precision Tools
B Birla Precision
60 61
117 L
C
LANXESS
Crane-Bel International Mr. Arun Mahajan General Manager AMT- The Association For Manufacturing Technology
Mr. A.P. Jayanthram Ex-Managing Director, Heidenhain India
Mr. GK Pillai Managing Director & CEO Walchandnagar Industries Ltd
88
44 M
D DOLD Electric
120
DP Technology
55
Mastercam
62
Micro-Epsilon
80
Mitsubishi Electric
112
E Elesa and Ganter
119
ELGi Equipments
22
EMAG
92
ESPRIT
98
Effica Automation Ltd.
Ms.Samina Khalid Marketing Manager Renishaw Metrology Systems Ltd.
Mr. Rupesh Paparaju Director, Bettinelli Automation Components Pvt. Ltd.
Phillips Machine Tools
Faccin SPA FARO FIBRO India
72 26, 90
32
R Renishaw
F Mr. Arjun Prakash Managing Director
P
32, 74, 106
Rocklinizer
64
ROLLON INDIA
94
34 S
G GEM Equipments Gleason
120 20
Schmersal Group 36,76, 122 Seco Tools
97
Shavo Technologies 50, 116 H
Mr. Dinesh Khambhayta President MTMA-RAJKOT
Manjit Singh Matharoo General Secretary Association of Ludhiana Machine Tool Industries
Mr. Suhas Belapurkar Director - Sales & Marketing ( Industrial Products) Sanjay Tools & Adhesives
STUDER
Hangsterfer’s
57
Hardinge Asia
58
Heidenhain India
48
Superslides & Ballscrews 118 U Unity Controls
I igus
102
24
U-Tech Utpadan
119 26
Contact : For editorial contribution E-mail: shweta@divyamediaonline.com For advertising material E-mail: advt@divyamediaonline.com
Mr. P.K. Balasubbramaniian President VBS Corporate Support
14
Mr. B.P. Poddar Vice President - Sales & Marketing FEMCO Fatty Tuna India Pvt. Ltd.
MACHINE TOOLS WORLD
MARCH 2019
Mr. Jayant Vaidyanathan VP - Sales & Application Tsugami Precision Engineering India Pvt. Ltd.
For accounts E-mail: accounts@divyamediaonline.com For online advertising E-mail: ganesh@divyamediaonline.com
www.mtwmag.com
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Check out our latest developments at
Stand C74
BUSINESS NEWS
Gleason to acquire Faessler Honing Business from Daetwyler Group Gleason Corporation today announced the signing of a definitive agreement with Daetwyler Industries AG and MDC Max Daetwyler AG to acquire all assets of Daetwyler’s Faessler gear honing business. Under the Faessler brand, Daetwyler has been producing gear honing machines, related workholding and tools for the high-precision hard finishing of gears. The business operations of the Faessler division, which has approximately 70 employees, will be acquired by a new Gleason subsidiary, Gleason Switzerland AG,
and will continue to operate at its current locations in Bleienbach and Dietikon, both located in Switzerland. Gleason will retain
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Shirish Sunderrao Dongre Yes A3/604, Chavandal Tower, Parsik Nagar, Kalwa West Thane - 400605
4. Publisher's Name Whether citizen of India Address
: : :
Shirish Sunderrao Dongre Yes A3/604, Chavandal Tower, Parsik Nagar, Kalwa West Thane -400605
5. Editor's Name Whether citizen of India Address
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Shilpa Shekhar Dongre Yes A2/603, Chavandal Tower, Parsik Nagar, Kalwa West Thane -400605
6. Name and Address of individual who own the
:
Divya Media Publications Pvt. Ltd. 303/304, Harmony Tower, N. S. Road,Court Naka, Thane (W) 400601
I, Shirish Sunderrao Dongre, hereby declare that the particulars given above are true to the best of my knowledge and belief. Sd / Shirish Dongre Publisher
Date: 1-03-2019
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Faessler’s existing management team and expects Faessler’s current employees to join Gleason. The transaction is structured as an asset deal whereby substantially all assets and certain contractual relationships of the Faessler business shall be transferred by way of a bulk transfer according to the Swiss Merger Act. It is subject to employee notice periods and other customary closing conditions. It is expected to be completed in April 2019. Commenting on the acquisition, John J. Perrotti, President and Chief Executive Officer of Gleason Corporation, said, “Faessler is a leader in honing technology for gears and ideally complements Gleason’s existing product line for gear hard finishing solutions. Faessler’s established presence in the global marketplace and
Gleason’s extensive sales and service organization will create great synergies for existing and new customers”. Ralph Daetwyler, Chief Executive Officer of Daetwyler Global Tec Holding, said “We are pleased to have a company such as Gleason with its long tradition in gear technology and the gear production equipment market become the new owner of this business. We are proud of the accomplishments of the Faessler team, and we believe the potential for Faessler’s continued growth and success by being part of Gleason, with its market leadership and global reach, is truly exciting.”
For more information Web: www.gleason.com www.mtwmag.com
BUSINESS NEWS
ELGi launches ‘State of the Future Art’, a signature initiative to drive futuristic technology and nurture innovation ELGi Equipments, welcomed over 200 employees, students and industry representatives to the 1st edition of Technology Day 2018, at the Le Meridien, Coimbatore. The event witnessed the unveiling of ELGi’s ‘State of The Future Art’– a signature initiative focused on fostering innovation. “ELGi’s goal is to be the No. 2 player in the global air compressor market by 2027. Our technology breakthroughs will transform the conventional boundaries of compressor technology with a relentless focus on increasing performance and energy efficiency. The ‘State of the Future Art’ is an ELGi initiative aimed at identifying and developing advanced technology and nurturing innovation,” said Dr. Jairam Varadaraj,
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Managing Director, Elgi Equipments. Air compressor technology has evolved over the years, from air billows to advanced compressor product innovation, to reach breakthrough levels of performance and efficiency. Since its inception, ELGi has adopted innovation as a key differentiator, keeping pace with global compressor technology trends and evolving customer needs. Technology Day 2018, celebrated on the 15th of
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December every year, is a platform to engage and build collaboration between young engineering minds and industry experts. The day-long event recognized the significant contribution and complex engineering achievements of ELGi’s technology team. As part of the first ever Technology Day, ELGians showcased major technology breakthroughs through a series of presentations, product displays, knowledge sharing and interactive panel discussions. Keynote speakers, Dr Tessy Thomas, DirectorGeneral, Aeronautical Systems (DG-Aero) of the Defence Research and Development Organisation (DRDO) and Mr. Shailesh Zinge, Marketing, Sales and Product Planning, Cummins India addressed the audience, highlighting how product innovation is poised to disrupt the technology landscape.
Bringing industry and academics together. ELGi has closely partnered with a network of key universities in India to develop engineering and technology specialists of the future. This year, as part of Technology Day 2018, ELGi invited engineering students to author papers on compressor efficiency, reliability and performance enhancements. Over the past month, ELGi employees, the world over, have been engaged in internal contests which encourage breakout thinking and innovative ideation for product excellence. All the winners, across categories, were felicitated during the event.
For more information Web: www.elgi.com www.mtwmag.com
BUSINESS NEWS
ANCA Motion brings CyGrind to TIMTOS 2019 Set to be the third largest exhibition for the machine tools industry, Taipei International Machine Tool Show (TIMTOS) is expected to have over 50,000 visitors this year. ANCA Motion is helping to bring OEM and machine builders into the era of the ‘Smart Factory’ with its range of motion control CNC solutions. From cylindrical grinding, to laser cutting applications, to the proven technology of the LinX linear motors – ANCA Motion will have a full range of products on display at TIMTOS. Naveen Nadesan, Global Marketing Manager at ANCA Motion comments: “Simply put, we love motion. With over 40 years’ experience in the grinding industry, we know our customers’ needs intimately. It is an exciting era with new technology disrupting the market and making the concept of a Smart Factory a realistic and achievable goal. We are excited to help our customers understand how a premium CNC solution can deliver a range of
benefits.” ANCA Motion’s newly developed CyGrind CNC solution challenges the conventional approach to cylindrical grinding. The CyGrind Cylindrical Grinding software strikes a perfect balance between flexibility and user friendliness, which when combined with advanced features of the CNC control, delivers a high-end solution for precision cylindrical grinding. This capability has been further enhanced with the newly released off-centre & non-round grinding options. The modern user interface allows the operator to easily define and visualise the geometry segments as well as all process parameters using a logical process-driven flow.
The software includes a simulation mode allowing a visual review of the process prior to grinding. CNC features developed specifically for grinding processes, such as Live Offset and ANCA Motion’s unique in-cycle MPG Feed, improve productivity and operator confidence when setting up and running a cylindrical grinding job. CyGrind offers the complete package, providing extensive functionality and user friendly software, making it the most comprehensive on the market.
For more information, Website: www.anca.com
STUDER wins supplier award for “Best Quality” The Shuanghuan Company in China employs several thousand people. It offers innovative solutions worldwide for mechanical gear systems. The Shuanghuan Company manufactures reduction gears for robots, vehicle transmissions and gears for trains, among other things, on the high-precision cylindrical grinding machines from the Swiss technology leader. Shuanghuan maintains a longstanding, intensive partnership with STUDER. There are 45 STUDER machines in the 24
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halls of the Shuanghuan Company. STUDER delivered several new machines in 2018 alone. Every two years the Shuanghuan Company presents awards such as “Punctual Delivery”, “Innovation” or “Best Steel Producer”. Fritz Studer AG has received the award for “Best Quality”. Shuanghuan’s reasons: STUDER products are characterized by high stability, a low error rate and significant improvements in efficiency. The handling of delivery,
MARCH 2019
Rolf Grossenbacher, Overseas Sales Manager, Fritz Studer AG, proudly presents the “Best Quality” supplier award, conferred by the Shuanghuan Company.
training and technical support are particularly excellent, and the frequency of
faults during working time is extremely low, and this has been acknowledged at all levels of Shuanghuan. “This award is a great honor for STUDER and motivates us in our efforts to create a real competitive advantage for our customers with innovative products that meet the highest quality requirements,”, says Rolf Grossenbacher, Overseas Sales Manager at Fritz Studer AG.
For more information Web: www.studer.com www.mtwmag.com
BUSINESS NEWS
U-Tech Utpadan enters into an agreement with BFW U-Tech Utpadan had recently entered into an agreement with M/s.BFW – the Largest Machine Builder in India to manufacture and supply Chip Conveyors and Coolant Systems that meet BFW’s requirements. Just a few months later, the new U-Tech Utpadan manufacturing facility, specially set up under this agreement, commenced production. The new modern assembly facility and a fullfledged fabrication shop were inaugurated at the hands of Mr. Ravi Raghavan, MD & CEO, BFW, on the 24th of February, 2019. Mr.L.S.Umesh, CEO and
Director of M/s.Ace Manufacturing was also present. The project cost, over a crore of rupees, has been part financed by BFW under a soft loan arrangement. For U-Tech Utpadan, a part of the Bangalore based 60 crore U-Tech Group, this is a big step forward in its growth story. Under the ‘JIT’ model, U-Tech Utpadan
will manufacture and stock BFW requirements, supplying the same to the BFW production line just in time, reducing inventory costs. Being in the same city, the physical proximity of UTech Utpadan’s new facility to the BFW manufacturing plant will also help reduce transportation costs. The U-Tech Utpadan
plant will work at peak capacity with the major production being utilized by BFW. Shortly, plan is also to supply to BFW, specially packaged, self-contained, ready to install plug and play Coolant Systems – which BFW can supply directly to its customers. Mr. Anant Deshpande, Executive Director, will be heading this new project. He will have the able guidance of Mr. H.A. Udaya, Founder and Managing Director of the U-Tech Group. Directors Mr.Raghupathi and Mr. Santosh will support in manufacturing / assembly and complete the core team.
FARO Introduces BuildIT 2019 Software Platform FARO has announced the release of the advanced BuildIT 2019 software suite. BuildIT 2019 represents the logical evolution of the industry-proven BuildIT platform, which has provided exceptional value across a variety of industries. It offers three individual products, each specifically designed for the most challenging quality inspection, manufacturing and assembly or construction applications. Each product includes the most flexible and intuitive user interface in the industry. While the BuildIT 2019 solution suite is tightly integrated with FARO® hardware products to enable a 26
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best-in-class FARO® solution experience, it also enables consistent, high-quality outcomes for non-FARO hardware products. BuildIT Metrology 2019 elevates the standard for workflow optimization and productivity for alignment, inspection, and build applications by incorporating key customer learnings from the previous generation that include: Point cloud alignment and registration up to
MARCH 2019
10 times faster and file size reduction for analyses by up to 70%; Improved robustness of GD&T evaluation using feature-specific extraction settings for analysis; Dynamic reporting that automatically pre-populates analysis reports and reduces report preparation time and advanced automation capabilities for creating repeatable, guided, automated workflows Included standard in
the first generation were groundbreaking features as In-Process Verification, Feature-Based Alignment, and Foreign Object & Debris Detection. BuildIT Projector 2019 enhances these features to create a completely new, operator-friendly paradigm. The previous generation version of BuildIT was the first consolidated software and hardware solution designed from the ground up as an end-to-end, fully integrated Building Lifecycle Quality Assurance (QA) and Quality Control (QC) management tool. BuildIT 2019 offers a unique set of value added enhancements. www.mtwmag.com
BUSINESS NEWS
Renishaw announces introduction of the QuickLoad rail system Renishaw is pleased to announce the introduction of the QuickLoad™ rail system to its range of metrology fixturing. The QuickLoad rail system has been developed for use on co-ordinate measuring machines and provides a secure workholding position when used in conjunction with QuickLoad base plates, which locate to the rail on either side using quick release magnets and location pins. The interchangable design of the rail and plates aims to maximise the machine operator’s ability to inspect and release parts swiftly. The QuickLoad rail system joins a family of existing QuickLoad products, including the QuickLoad corner (QLC)
product range for vision applications, designed to simplify, increase speed and error proof fixturing. The QuickLoad plates use Renishaw’s industry leading hard-coat anodised, alpha-numerically labelled aluminum base plates available in M6 with M4, M8 and ¼-20 thread sizes available
upon request. When used with the company’s extensive selection of labelled modular components and FixtureBuilder software, the alphanumeric plates enable the user to set up parts the same way every time. The QuickLoad rail system offers a fast, easy and repeatable method which allows the user to set up parts for inspection on multiple plates, and load them to the rail efficiently to maximise throughput.
For more information Web: www.renishaw.com
HAAS offers limited time discount on Y Axis Turn mill centers and Large VMCs After the record-breaking sales of VF-I series and DT-I series, HAAS Factory Outlet – Phillips in India is all geared up to extend its market share by introducing a limited 40% discount on 2 additional product lines: Y axis turn mill centers and large frame VMCs. HAAS Automation Inc. is the largest machine tool builder in the western world and delivers more standard features, high-tech innovations and rock-solid engineering
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than perhaps any other CNC manufacturer in the world and at better prices. Post the excellent response at IMTEX 2019, the company has received a number of enquiries for Y axis Turn mill centers and large frame 40 and 50 taper VMCs. Talking about HAAS’ success in the India market in 2018: the company successfully delivered over 1000 machines to different companies in the last year alone. The response for the VF-I series and DT-I series has been outstanding to say the least. The VF-I Series offer the best-value, high-performance VMCs in the market:
MARCH 2019
outstanding features at an excellent price with a wide range of available options to customize the machine as per the customer’s exact needs. All Haas machines are designed and built in Oxnard, California, USA. The ST-Y series from HAAS are high-performance Y axis turn mill centers designed to provide setup flexibility, extreme rigidity, and high thermal stability. The addition of Y-axis, Caxis and live tooling allows milling, drilling, and tapping for increased machine capabilities reducing setups and improving productivity and accuracy. This machine offers the best performance
for the money invested– the best value – in its class. The models from the ST-Y series include ST-10Y, ST-15Y, ST-20Y, ST-25Y, ST-30Y, DS30Y and ST-35Y. The large vertical mills, 40-Taper & 50-Taper VF mills are the perfect solution for Large-Part machining: die and mould and production machining. These machines are also priced at a discount of up to 40% for Indian customers. www.mtwmag.com
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BUSINESS NEWS
FIBRO India inaugurates its second phase of operations FIBRO, known for high precision Standard Parts (Used in Die & mould) and Rotary Tables, inaugurated its second phase of Indian operations near Pune on 28th Feb. 2019 in the hands of Mr. Klemens Schmeiderer- Speaker of the board of LÄPPLE group and Mr. Jürgen Gurt- Managing Director of FIBRO GmbH, the part of LÄPPLE group. On the 50th Anniversary year of FIBRO GmbH, Germany i.e. in 2008 FIBRO India was established in a rented place and subsequently it moved to its own current place in Chakan, Pune during 2013. It started primarily to manufacture standard parts for Indian customers as well as for FIBRO Germany and other group companies abroad. The basic concept was ‘German Precision Crafted in India’. In the whole LÄPPLE group, this has been the first manufacturing unit outside Germany. Having tested the success for standard
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parts in India, the FIBRO management decided to delegate the Rotary Table business also to FIBRO India in 2015. However, FIBRO management realized that the Rotary table business also should follow ‘Standard Parts’ business model i.e. local manufacturing. As a result, FIBRO India acquired the neighboring plot and constructed plant primarily for Rotary Tables which was inaugurated on 28th Feb. 2019. Incidentally, the LÄPPLE group is completing 100 years in 2019. The LÄPPLE is primarily in automotive stamping like skin panels and critical sub-assemblies for reputed European auto giants like Mercedes Benz,
MARCH 2019
Audi, BMW, VolksWagen and Porsche etc. FIBRO are the pioneers in Rotary Tables for Automation and Metal cutting in a very wide range. The largest table manufactured by FIBRO is of 6-meter diameter and capable of carrying 400Tons work load. During the inauguration, Mr. Klemens Schmeiderer said that FIBRO India has been the major milestone for the whole LÄPPLE group as a part of its Globalization strategy and he is happy with the results. Mr. Jürgen Gurt said that they are planning to invest more for localization of additional products for Standard parts and Rotary Tables. He also added that the products
manufactured by FIBRO India are for Global market as such they ensure the strict quality standards are maintained at FIBRO India. During the inauguration FIBRO India launched its 100% Made in India Rotary Table for Automation, FIBROTOR ER 13. Also, its Website and Webshop was launched during the function for the convenience of its customers. While proposing the Vote of Thank, the Executive Director of FIBRO India Mr. Vivek Nanivadekar thanked the customers for the support and the FIBRO/ LÄPPLE management for the encouragement and believing the growth story of FIBRO India. www.mtwmag.com
The New Benchmark in Economical Shaving Made in India
200SVP Plunge Shaving Machine for medium and high-volume gear production raises shaving economy to new levels. It features a rigid shaving head and tailstock design, a modern Siemens control with Gleason Software for easy learning and manual or automated loading options. Support is guaranteed by Gleason’s knowledge in process technology, shaving cutters and workholding. All packaged on less than 6 m². www.gleason.com/shaving
IN FOCUS
At the Imtex 2019 trade fair (from L to R): Mr. Axel Schneider, Chief Technology Officer, Schmersal Group
SCHMERSAL : Protecting human & machine assets for safer workplaces Interview with Ramji Singh, VP Sales & Marketing, Schmersal India Q. Please brief us overall outlook SCHMERSAL as global company & its Indian infrastructure? The Schmersal Group is a global market leader in the field of functional machine safety. As a group we have had a very successful business year 2018 with continued growth rates. And we are convinced that this upward trend will continue. One reason is that we are currently experiencing a time of accelerated technological innovations, e.g. Industry 4.0, Artificial Intelligence, robotics etc. This has a positive impact on the global machine building industry, which is our major customer segment. The machine building sector is worldwide on a continued growth path. And Schmersal is growing with
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its international customers. This applies also to Schmersal India. In the Indian industry we see a growing awareness for the benefits of machine safety, especially since India is increasingly exporting its products and supplying multinational companies. But Schmersal’s success is not only due to a positive business environment. We do a lot to keep pace with the technological change and invest continuously in our R&D capabilities. That’s why we can always offer our customers stateof-the-art safety solutions. In India, we have an own R&D team to develop solutions that are adapted to the specific requirements of the Indian market – and which are produced locally true to the motto “Make in India”
Mr. Ramji Singh, Vice President – Sales & Marketing, Schmersal India Mr. Michael Ambros, Managing Director, Schmersal Group
Q. Please also highlight the latest initiatives of safety solutions for machine tools industry? A perfect example of a safety solution, that Schmersal has developed for the specific requirements of the machine tools industry is our solenoid interlock AZM400. The development was based on a survey which Schmersal conducted among its machine tool customers. They expressed a desire for a solenoid interlock especially for large safety doors that can also be locked and unlocked reliably under unfavorable conditions and thereby ensure a high level of machine availability. With this in mind, we have developed a solenoid interlock whose design combines compact dimensions, an unmatched strong holding force of 10,000 N, a bistable principle of
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IN FOCUS operation, an electric-motor-powered locking bolt and integrated RFID technology. In this way, the product not only fulfils the desires of the users but also the requirements of new safety standards. In addition, the AZM400 has various features that help to prevent machine downtimes and increase plant availability. Meanwhile, this innovative safety interlock has been very well received by our customers. But it is also a good example on how we always strive to find the best solution for the specific needs of our customers Q. What are the market opportunities for your company’s products in machine tools industry? The safety of machine tools is a major issue. Complex machinery, high speeds, and high power levels can be a dangerous mixture for the operator. Nevertheless, machine tools are very safe products. This high level of safety has been achieved not least due to the European Machinery Directive and other international regulations, that have established worldwide very high safety standards to which the industry has to comply. Therefore, the machine tool builder must consider safety concepts right at the beginning of the design phase. At this point, Schmersal can support its customers with its expertise in both, the machine tool sector and in the field of functional machine safety. We can help our customers to identify possible hazards, to design customized safety concepts and find the best solutions – in terms of safety and also in terms of economic efficiency. In addition, Schmersal has the world’s largest portfolio of safety components and a global presence. Therefore, we see tremendous market opportunities since few other suppliers can offer such holistic safety solutions for the machine tools industry.
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Q. What is future prospect for cloud solutions for machine tools industry? The machine tools industry like any other industry has to continuously improve its competitiveness in order to be successful in the market. Industry 4.0 concepts can help to achieve this goal. A major principle of Industry 4.0 is the collection and analyzing of data to monitor and control production processes. For example, predictive maintenance is based on a system of permanent status monitoring of technical processes and components directly on the machine. Sensors measure indicators including vibration, temperature and moisture. This data is recorded and evaluated so that potential component failure can be identified before it happens. The cloud is a key technology in this, allowing, amongst other things, comprehensive data analysis. The evaluation of monitoring information in the cloud is currently carried out with great success. The inclusion of safety technology in concepts of this nature has been an uncommon occurrence. The benefits, however, are obvious: components used to comply with safety standards can also provide data to contribute to increasing productivity. Schmersal has therefore developed a solution, that allows to transmit data from its safety sensors to the cloud: All
safety interlocks and safety sensors as well as some safety light barriers from Schmersal fitted with an SD interface can transfer cyclical data to any cloud service via the PSC1 safety controller, an SD gateway or a separate edge gateway. A connection to this cyclical SD data within the cloud offers users comprehensive diagnostics options, including information on switching cycles, safety statuses, limit warnings, distance warnings and much more. The benefit is improved transparency. Machine and plant operators get a whole range of data that is collected during cyclical diagnostics of the safety systems, which they can then use to optimise their machine as part of predictive maintenance. Q. Is there any plans for expansion & new investment in terms of product development or new technology adoption to cater the demand of the industry? Embracing the ‘Make in India’ initiative, the manufacturing facility of Schmersal India is enhancing its product range by designing and manufacturing customised safety products as per the needs of the customer specific applications in India. Also, Schmersal plans on adding
“The upward trend will continue”, says Mr. Ramji Singh, Vice President – Sales & Marketing, Schmersal India
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IN FOCUS more skilled manpower to enhance their local R&D centre and Product Management to focus on developing even more products for the Indian market. To date, Schmersal is the only company producing safety switches directly in India, meaning that we are very close to our customers and the market. Also, companies in India are showing an increasing readiness to adopt advanced technologies. An example is robotics: In 2017 robot installations in India increased by 30% to a new peak. Hence, it is of utmost importance for companies to address safety issues with robots. They need to make sure that robots and humans are working together without endangering the human life and the process. With regard to robotics, Schmersal offers a comprehensive range of products to safeguard robot workstations, such as optoelectronic protective devices, safety mats, RFID based interlocks etc.
Q. What is the top line product range & Is there any plans to launch new products? The latest innovation that Schmersal presented in autumn last year was a safety controller with OPC UA connection. Many experts believe that OPC UA will establish itself as the new communications standard for digitalised production. The latest generation of safety controllers from Schmersal is therefore fitted with an OPC UA server. This type of communication via the OPC UA server offers additional options and benefits. Comprehensive data records from all safety sensors in the Schmersal range can now be accessed in machine-readable format, with semantic descriptions via the M2M communications protocol. This includes, for example, status data of safety outputs, safety keywords, information on sensor lifecycle, order information, datasheets or CAD data
and images. The use of the global OPC UA standard ensures interoperability between products from different manufacturers and offers real added value for users of machines and equipment. They have access to additional information in order to, for example, establish the prerequisites for improved production control or more efficient maintenance planning. In addition, the key indices for products can be viewed and their documentation or operating instructions uploaded.
Q. What is your vision for your company? Our vision is to be the world’s leading provider of systems and solutions for machine safety. As a reliable partner, we assist our customers in all matters relating to functional machine safety and occupational safety and act as onestop-shop for turnkey solutions. Our customers can confidentially entrust us with the provision of efficient safety technology so that they can concentrate on their core competencies. We consider our efforts to be successful once the expectations of our customers have been met or even exceeded and when we have contributed towards the safe, sustainable and future-orientated improvement of their production processes.
Schmersal India, production facility and headquarter, Ranjangaon, Pune, India
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An Anexhibition exhibitionon ontechnologies technologiesfor forautomotive automotivemanufacturing manufacturing 44– –66July July2019 2019 Hall no.no. 1, 1, Chennai Trade Centre, Chennai Hall Chennai Trade Centre, Chennai www.aes-show.com www.aes-show.com
Display Displayexhibits exhibitsfrom fromthese theseprofiles: profiles: • •Automotive Automotivedesign designand andR&D R&D • •Automotive Automotiveinspection inspectionand andquality qualitycontrol control • •Automotive Automotivepaint paintand andfinishing finishing • •Automotive Automotiveplant plantequipment equipmentand andsystem system For Forbookings, bookings,please pleasecontact: contact: Rahul RahulGanjapure Ganjapure Tel: Tel:+91 +9122226103 61038424 8424M:M:+91 +919820796183 9820796183 rahul.ganjapure@india.messefrankfurt.com rahul.ganjapure@india.messefrankfurt.com Supporting associations Supporting associations
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INFOCUS
Our emphasis is on Quality, rather than cost: Ashok Gupta
Ashok Km Gupta, Chairman Crane-Bel International Pvt. Ltd.
Q. Your Company is known for its quality products. How do you churn out ‘Zero Defect Products’? We have a comprehensive Quality policy. Following are the steps we follow to ensure zero defect in our manufacture: a. We understand the importance of quality and the essence of our quality policy is hidden in the phrase; “The cost is long forgotten but the Quality is remembered for ever”. b. The philosophy of our company is to become a partner and not only the supplier of our customer. Each supply we make to our customer is the beginning of a long-term relationship, which contributes to the growth of each company. c. We are a team of qualified Engineers having specialized experience in Hydraulics, Machine Tools & Automation; including Designing, Development and Manufacturing to offer the best possible quality products. d. We work together with our customers in all fields to make their Plant, Machines and Systems more productive and reliable. e. We do not permit any defect. Whether it is raw material, manufacturing processes or the bought-outs. f. We concentrate our full efforts and
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Crane-Bel International was founded in 1980 at Ghaziabad by Er. Ashok Kumar Gupta, a Graduate Mechanical Engineer, having more than half a century of practical experience in the fields of design, development, manufacture, maintenance and rejuvenation of hydraulic machines, systems, equipment. Mr. Gupta’s unique and unrivaled experience helped Crane-Bel earn its spurs and name nationally and internationally as a reliable, customer-oriented company. In this interview, P.K. Balasubbramaniian delves deep and discovers the quality obsession and operating philosophy of the company which is pro-active to the needs of the customer. Excerpts:
expertise in the most important aspects like Design, Manufacture of Critical Components, Assembly, Quality Control and Testing. g. We have the quality certification of ISO 9001 for Design, Manufacture & Supply of Machine Tools, Hydraulic Machines, and Equipment, Automation Systems, Hydraulic Cylinders, Accumulators, Oil Filtration Systems, Power-Packs and Related Parts & Accessories. h. We manufacture our products under stringent tolerances and standards and we work together with our customers. As a result, we have been awarded by the National Award - 2006 of Quality products for the manufacturing of Outstanding Quality Machine Tools”, instituted by Government of India. Q. How do you give a competitive edge to your products? We use the latest and the best available technology in our products. Following are some of the major factors which contribute to our success: a. Our company philosophy, of
Sarvesh D Gupta, Managing Director puts in relentless efforts to take care of all aspects of design, development, manufacturing and automation in order to offer high-tech products of outstanding quality to customers.
becoming a partner and not remaining only the supplier of our customer, is the main factor of the success of our company. Each supply we make to our customer is the beginning of a long-term relationship, which contributes to the growth of each company. b. Full dedication and Adaptation of High technology products &
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INFOCUS
Crane-Bel Horizontal Broaching Machine
c.
d.
e.
f.
g.
choosing the best solutions for every customer. Regular R & D and Innovations for having an edge over the competitors’ products. We believe that there is no substitute for quality and there is no excuse for the product which does not meet the customer’s requirement. Our main consideration has always been to deliver high quality Machine Tools in time bound environment at a competitive price. We support the needs of Design Engineers and the Maintenance Engineers with the products that meet the specification requirements, in accordance with the functional needs of the customers. With the theme of winning ideas and products for the industry, Crane-Bel promotes the Pro-Active Maintenance concept which increases the life of machines and equipment and Automation for increasing the productivity of the plant and machines of the customers.
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h. We have a policy of considering the customer as our business partner and help customer at all the stages for increasing the productivity and maximizing the efficiency through innovation, to allow them grow faster. i. We use latest technology in the products for the benefit of our customers and we manufacture Machines, Equipment and Systems as per the ones requirements. j. We strictly follow the honest business practices and our customers are fully satisfied with our aftersales services. k. We provide the total systems, from concept through design, manufacturing, testing, supply, installation, commissioning and proudly stand behind our product.
Presses. Broaching is our Core Competence perfected over a period of about four decades of our strenuous efforts in providing the best solutions to our customers. Over the years, we have embraced a culture of Excellence and we have been able to innovate and develop the following unique products: • High performance Table-Up Broaching machines. • Automatic Broaching Machine with Winged Automation. • CNC Broaching Machine with Servo Drive. • Heavy-Duty Horizontal Broaching Machines
Q. Which are other Crane-Bel products that have made a mark in the market? Apart from the Hydraulic Machines, Systems & Equipment, we manufacture a wide range of Automatic & CNC Broaching Machines and Hydraulic
Oil Filtration System
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INFOCUS • Surface Broaching Machines and • Custom-Built/Special Purpose Broaching Machines Q. What are your growth plans? We have an Expansion and Growth Plan with a target to achieve more than double our Turnover during next three years, mainly by the following plans: • Adding new features in our products • Further improving the Quality and productivity of our Machine Tools • Increasing Production in the existing factory • Putting up an additional plant • Appointing marketing agents • Exporting our Products in the Global Market Q. What is your contribution towards National Self Reliance with Technological Innovation? We understand that Machine Tools Industry is mother industry and is a labour-intensive industry. We believe our industry has quite important and significant contribution to the National Self Reliance by directly providing the employment and further providing the machine tools to the automobile industries, auto-parts industries, Cycle parts industries and general engineering industries, which in turn provide employment to the skilled & unskilled workers and staff at the different levels thereby providing employment alongwith the self-sufficiency to the families of rural and urban masses collectively. To do this with meagre infrastructure is a big Contribution towards National Self Reliance. Since inception of the industry, we are regularly doing R&D and technological innovation as a regular feature of our industry: • In the very first phase of our industry, we innovated & promoted
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Table-up Broaching Machine
a unique & most simple Broaching as a common, affordable, accurate & highly productive machine tool which are used in Hand tools, Bicycle parts, Automobile & Auto-parts industries and General Engineering industries. • We have been regularly doing various R & D and innovations for energy conservation, system protection, simplification of the processes and enhancement of
productivity. • We have been promoting the ProActive Maintenance concept in Indian Industries for a long time and had been doing R&D for the same. Our Innovated fluid power products and machine tools have been mile stones on the way to promotion of Pro-Active Life Extension Maintenance concept and simultaneously have been increasing the productivity,
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INFOCUS improving the quality of products & repeatability with eliminating or minimizing the maintenance of Indian Industries. • We also developed a unique Oil management machine Systemguard® for the Contamination Monitoring and control, being an indispensable tool for the Pro-Active maintenance, Conservation of Oil, Environmental Protection and conservation of energy. • Another major Innovation we have done is innovating and successfully developing a unique, CNC Broaching machine which is fully computerized, without any Hydraulic system & Power-pack. Q. What are your initiatives for Environmental Protection? We have been working for the environmental protection and safety consistently. We have been regularly doing a lot of R & D and have developed the Unique Innovative systems & Machine tools, as already mentioned, including Oil management machine Systemguard® for protecting and conservation of oil and CNC Table-Up® Broaching machine without any Hydraulics and Hydraulic oil; to save the environment. As the discarding, replacing and disposal of used oil harms and damages the environment, as described under: • Waste oil is generally not handled properly and hence it pollutes the ground water, land, air, and environment. Water and soil contamination occur when any used oil is spilled, dumped or leaked on the ground. • Spilled oil can seep through soil to pollute groundwater, and some used oil will “run off” into surface lakes & streams. Water pollution can damage marine habitats. • Just one misplaced gallon of used
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•
•
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oil on the amount from a single small auto engine, has the potential to contaminate up-to one million gallons of fresh water. The discarded oil is very dangerous because of the contaminants present in used oil. These contaminants have been linked to bronchitis; adverse effects on human body development; lethal toxicity to plants and animals; and causes cancers of the skin, lungs, liver, bladder, kidney, and gastrointestinal tract. Used oil that is dumped on the ground or is put in storm drains contaminates ground water which is certainly very difficult to clean up. Used oil from earth moving equipment, cars, trucks, motorcycles, tractors and other engines, gear boxes and other industrial plants and machinery; contains traces of heavy metals, arsenic and other chemicals which are very harmful for plants, humans or other animals, when these chemicals are absorbed by plants and passed up the food chain. Because of these problems, it is criminal offense to dispose of used oil by dumping it on the ground or in water. When plants are grown in the oil contaminated soil or irrigated by the water contaminated by discarded oil, they absorb (bioaccumulate) high concentrations of heavy metals. One of the indirect risks of such environmental dangers is the poisoning of the food chain, which ultimately affects human health.
towards controlling inflation for achieving a sustained growth in GDP. To what extent the goal has been achieved is debatable, but the Govt. has agenda for big economic reforms since it took over, but it has not been able to get a ten out of ten for all the work done in the past four years. We feel that the political constraints of the Govt. has been an obstacle to the decision making process for big time economic reforms. Q. What is your definition for success? Success, according to me, is the result of setting a proper goal, being responsible for it, having strong will power, self-confidence & faith, acquiring the necessary knowledge & skill, properly planning for it, and then consistently working hard for achieving the goal. Q. We understand you have won a number of wards in recognition of your contribution? Yes, we have been honoured by the Govt. of India with the following National Awards: • National Award-2006 for Quality Products - Outstanding Quality Machine Tools • National Award-2007 for Research & Development Efforts • National Award-2008 for Outstanding Entrepreneurship • UdyogPatra Award, and National Integrity Award • Honour by Delhi Technological University as Achiever of 70 years (Celebrating Excellence).
Q. How conducive are the Government policies for the economic growth? In our view the Economic policies of the present Govt. are more inclined
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INDUSTRY INSIGHT
Why Indian Technology Market Remains an Enigma for Global Hightech!
Mr. A.P. Jayanthram, Ex MD, Heidenhain India
Some interesting revelations • India is considered as a huge IT hub. But Microsoft makes only 1.5% of their revenue from India! It is no different for global majors like Caterpillar, Toyota,Daimler ... you add the big names. • In the 73 billion Euro global Machine Tool market, India is the 10 th biggest consumer, with just 2.3% of the consumption pie . China consumes 30% and Germany 8.5%. Since 40% of consumption is local machines,for imports, the share is only 1.4%. • Why is it so? » It appears that most global companies try to implement a scaled down version of their global/European strategy for India, without worrying about the local compulsions. » India is not what it often appears to be. It is a flat pyramid with 700 million people living on 2$ per day. The top is unbelievably thin and that explains the minuscule high end market.
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Ground realities Indian customers who operate in an atmosphere of shortages and compromises, almost always expect 70% value at 50% cost. This is particularly true for Machinery and measuring/ testing equipment.
because every global competitor with a philosophy of token competition is targeting the same 1%! Most MNCs are happy here as they put a low bar. Most fully owned subsidiaries contribute just 1% of global revenues.
So, what is the way out? You need an India specific strategy and this does not mean slashing prices. When John Deere came to India, they had tractors too heavy for India’s fragmented land ownerships. They developed 35 HP tractors exclusively for India. Hyundai and Suzuki are successful in India, because they made India a global hub for small cars. A lot of successful European companies take India as a necessary compulsory addition in their coverage map, without a mindset to invest in this future market. They are used to an affluent client base that buy on impulse, reputation and comfort level. Many are reluctant about the very idea of customising markets. When an Indian customer imports a Machine, he is looking at a Swiss Army knife which can do everything under the sun. Matching his needs with the options and budgets is a highly technical, professional job that needs dedicated sales talent. Offering him a lot of expensive unwanted features by a feature sales specialist is of no use. India can be a fantastic laboratory for testing new business models provided there is enough analysis and dialogue. Smart global companies start here by selling global products at global prices to the top 1%. That is easy. But the eventual success depends on whether they can crack the middle market,
Questions one should ponder over Can a Mercedes really crack the Indian commercial vehicle market, 95% of which is shared by Tata, Ashok Leyland and now Volvo? A fascinating Marketing project, it would make. Though buying up the market by slashing prices is never a winner, there has to be some flexibility with the Indian MDs of MNCs who must not be going out of the country for a 3% discount. ‘Skimming the top’ model has huge limitations when it comes to marketing technology in a poor but potentially big country. Finding money for capital investment is a huge challenge for entrepreneurs in a high interest economy. Is the MNC willing to create his own global financing networks here? Can they practise real value selling by specially trained manpower that can effectively convince a buyer on what value he gets by spending a bit more initially and how it adds to his eventual profits? Can they invest in excellent hand holding support system in advance? Can they offer things like a 36 month warrantee as a standard confident statement of reliability? India is a sleeping giant and only those who are patient and willing to customise market inputs with deep study and interactive conversations can succeed here.
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COMPANY PROFILE
Shavo’s tailor-made technology solutions
Mr. Rushil Shah, Managing Director, Shavo Technologies Pvt. Ltd.
F
rom static elimination solutions to precision air moving products to instrumentation fittings and high purity gas delivery systems, Shavo is dealing in a wide spectrum of products and technologies. “Our endeavour has always been to work in niche high technology areas across industries where we can offer significant value for a variety of problems. Our products and their applications find solutions in a diverse range of industries such as Semiconductor, Aerospace and Defense, Converting, Automotive, Chemical and many more,” says Rushil Shah, Managing Director. The company’s core selling concept is its deep application knowledge and command over the technologies it sells.
Applied gas delivery systems
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Shavo Technologies Pvt. Ltd., a part of the Shavo Group with a standing and reputation spanning over five decades, is in the frontiers of niche high technologies cutting across diverse disciplines. The company represents some of the world leaders in their respective fields for technology solutions like static elimination, precision air movement, high quality instrumentation, high purity gas delivery, corrosive gas handling, energy absorption and so on. With a vast product portfolio, the company serves over a thousand customers from diverse key sectors including semiconductor, aerospace, defence, chemical, oil & gas, automobile and so on. The company has gone from selling component to systems and solutions and turnkey capability in an effort to keep offering better value by leveraging the technologies it provides. Cutting edge technologies All Shavo’s Principals have specific technologies that would be classified ‘cutting edge’ considering that almost all its principals are world leaders in their fields. For Static Elimination, it has integrated power supply ionising bars with full feedback control for Gas Delivery. Shavo has some of the most sophisticated fully automated systems capable of dealing with the most dangerous gases. It offers from HORIBA a multi gas, multi range Mass Flow controller - a first in the industry.
Static measurement for effective static neutralization
The company’s journey of working with High Technology Industries has started with Gast which today remains one of the world leaders in Air Motors and Fractional horsepower. Over the years, it has released many new pumps that have extended typical service life to new frontiers especially with the new rocking piston technology pioneered by Gast. Its latest 87 R series offers industry leading pressure performance at lowest noise levels. Corrosive gases are used in a wide range of industries from Chemical, Tooling and the new areas of Nanotechnology, Photovoltaics, etc. Handling corrosive gases requires deep application knowledge, understanding of the materials to be used especially soft goods. Many corrosive gases are
High quality instrumentation valves
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COMPANY PROFILE
Rocking piston compressor
also liquefied which need special considerations, from heating to weight measurement, etc. The awareness on the causes and cures for static electricity are low in industry but steadily growing. A lot of problems of contamination, material misbehavior, etc., are often attributed to other causes when they really are static related issues. Shavo continues to publish articles and bring awareness to the industry by working with a number of industrial associations. The valves and regulators it supplies to the Chemical Industry in general have a wide range of certifications. For valves, it has course type approvals from various third parties like Llyod’s, TUV, DNV, etc. and the products meet all industrial standards wherever required such as ASTM F-1387, for Oil &Gas , ECR 110 for Automotive NACE, for Sour Service and many more. Tescom vaporizing regulators, in addition to having ATEX Approval, is the first such unit to have PESO / CCOE Approval from Nagpur. Generally of course ‘Energy Absorption’ has applications wherever we need to decelerate motion, in the Industrial space. Factory Automation especially with Pneumatics is the key application, but Shavo also finds safety applications such as end stops for large cranes like those found in steel and ports as an important area. Lately the company’s focus has been vibration isolation with special attention to strategic electronics in the
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Shock absorption products
Defense Sector which has some of the most stringent requirements for G force transmissibility. The company’s Fluid Control products once again find applications in a very diverse range of industries, but the main end-users are Oil & Gas, Chemical, Analytical and general manufacturing. The growth areas in the Fluid Control Industry lie in Semiconductor manufacturing and Photovoltaics which demand ultra high purity gas delivery systems. Equipment to service these industries is typically made to the exacting specifications of the SEMI code which controls all processes from raw material to manufacturing, testing and even packaging. The surface finish and cleanliness requirements for these industries are extremely demanding often requiring products to be assembled in Class 100 environments. The company’s supplies to the Automotive Industry almost cover the entire range of its product lines e.g. all engine testing for the new EURO IV and Euro VI norms use Shavo’s Tescom Central Gas Supply Systems for calibration of gases. It supplies Gast Air Motors almost extensively to all automotive paint kitchens. You will also find Enidine shock absorbers at the end of travel on many assembly lines. The Meech Jet Stream Ionizing Systems, on the other hand, clean & neutralize car bodies and plastic parts prior to painting. Other Fluid Control
High pressure regulators
products find extensive applications in the CNG space and the automotive testing area such as car air bag testing for instance. Shavo is currently working with some of India’s Top Companies such as Reliance, Tata’s, Biocon, GE, Department of Space, Ministry of Defense and many more. The company has over 1000 live accounts as of today. Eminent service set-up Shavo’s service set-up / service team has been growing from strength to strength. It has full service capability at the Pune office and is in the process of building a world class center in its Bangalore Factory. “Our service support is a key pillar of the value we provide,” underlines Mr. Shah. When asked about addition of new agency lines, Mr. Shah says: “We have generally been extremely selective and have refrained from having a long line card, preferring a deeper involvement with our current partners to fully exploit their potential, but we have recently signed with Horiba to introduce flow control solutions and we would probably close with 2 more agencies in the Fluid Control area over the course of the next year.”
- P.K. Balasubbramaniian
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AMT SECTION
TECH TRENDS
AMT SECTION LEARN MORE ABOUT AMT’S CHENNAI TECHNOLOGY CENTRE AMT’s Chennai Tech Centre (CTC) is located in the MEPZ duty free zone just 7 km from the Chennai airport. It encompasses an area of 1,500 sq.m., including a 650 sq.m. technology demonstration area. Operational since May 2011, CTC has successfully served as a bridge between the Indian manufacturing sector and American advanced manufacturing technology. To learn more, please contact or visit CTC: AMT - Chennai Technology & Service Centre A 44 - Phase 1, MEPZ, SEZ Unit Tambaran, NH 45, Chennai - 600 045 Tamilnadu, India Phone: (+91) 44-22622690-92 Fax: (+91) 44-22622693 Arun Mahajan General Manager AMahajan@amtonline.org Cell Phone: (+91) 9790887032
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AMT SECTION
TECH TRENDS
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AMT SECTION
TECH TRENDS
This photo illustration is an example of a digital twin, showing a blend of real life and a virtual simulation of a main shaft being machined on a 5-axis machine.
ESPRIT® delivers solutions for Industry 4.0 smart manufacturing DP Technology is helping factories of the future prepare for the digital transformation in manufacturing, with solutions including digital twin, digital threads, machine-aware manufacturing, knowledge-based machining and cloud-enabled databases.
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o prepare factories for an increasingly digital future, and to better support Industry 4.0 and smart manufacturing initiatives, DP Technology is focusing on a range of solutions to drive automation in manufacturing. The ESPRIT® CAM System enables manufacturers to streamline their workflows, prevent silos from forming during the manufacturing process, increase tool life and machine utilization, and create
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greater access to practical knowledge for process improvement. • Digital twin: ESPRIT allows users to create a digital twin of their machine tools for programming, optimization and simulation. This virtual machine ensures that whatever happens on screen will also occur on the shop floor. Workpieces and cutting tools are set up virtually, resulting in exacting simulations, greater productivity and better toolpaths
for higher quality parts. • Digital thread: With ESPRIT, a digital thread ties together each step of the workflow from CAD design to finished part, ensuring that none of the manufacturing process is siloed. ESPRIT reads part data from CAD software and creates machine-optimized G-code and setup sheets, which it then passes on to shop floor management, tool data
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AMT SECTION
TECH TRENDS
ESPRIT®, DP Technology’s flagship product, is a powerful, high-performance, full-spectrum programming system for milling, turning, wire EDM, multi-tasking machine tools and metal additive manufacturing. ESPRIT and its support personnel embody DP Technology’s passion for excellence and vision of technology’s potential. management and enterprise resource planning software. • Machine-aware solutions: ESPRIT provides machine-aware CAM programming to increase tool life and reduce cycle times. The CAM system’s ProfitMilling® and ProfitTurning™ apps represent a fundamental change in the way toolpath in created: most CAM software works from the shape of the part first and considers the machine last, if at all. ESPRIT machine-aware solutions first consider the machine tool – its axes positions and their limits, acceleration, and attainable and requested cutting speeds, allowing users to run machines faster, get a better surface finish on their parts and significantly increase their tool life. As a result, with machineaware CAM, programmers make better choices regarding toolpath, without asking the machine tool or cutting tool to exceed their own abilities. • Knowledge-based machining: Knowledge-based machining, the term for artificial intelligence built directly into a CAM system, makes it possible to significantly cut programming time by capturing best practices, including machining processes and cutting conditions — leaving more time
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to focus on strategic process improvements and reducing time spent on repetitive tasks. ESPRIT’s KnowledgeBase™ solution streamlines part programming by automatically selecting the optimum processes — machining cycles, tools and conditions — for part features based on proven best practices. Recording practical knowledge via KnowledgeBase™ is more reliable than leaving it to memory and allows for higher levels of automation through repeatable steps. Because programming is more predictable and consistent, programmers encounter fewer problems and produce higher quality parts. • Cloud-enabled databases: As shops move to data-driven manufacturing, integration with cloud-based databases, such as MachiningCloud Inc., further facilitates access to knowledge, product data, resources and process controls for machines, cutting tools and work holding. These cloud-enabled databases suggest factory-recommended feeds and speeds for a given cut, let users quickly find the tools they need, and provide continuously updated manufacturer product data, including drawings and models of tools and cutting tool
assemblies for simulation. Because information is stored in the cloud, it is always up to date, available on demand and can be accessed anywhere. About DP Technology Corp. DP Technology Corp. is a leading developer and supplier of computeraided manufacturing (CAM) software. ESPRIT®, DP Technology’s flagship product, is a powerful, high-performance, full-spectrum programming system for milling, turning, wire EDM, multi-tasking machine tools and metal additive manufacturing. ESPRIT and its support personnel embody DP Technology’s passion for excellence and vision of technology’s potential. DP Technology reinforces its commitment to technical excellence by dedicating nearly 20 percent of its annual revenue to ongoing research and product development. This longterm focus has produced powerful technological innovations that have placed ESPRIT in an industryleading position since its market launch in 1985.
For more information, DP Technology and ESPRIT Call +1 805 388 6000, Email: esprit@dptechnology.com, Website: www.espritcam.com.
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AMT SECTION
TECH TRENDS
High-Performance Manufacturing With Hangsterfer’s 5080 (S-787)
SOARING NEW
HEIGHTS WITH
H
angsterfer’s Laboratories, Inc. researches, develops, and manufactures the Next Generation® of advanced metalworking fluids and lubricants in an ISO 9001 approved facility in the USA. Hangsterfer’s prides itself on its non-hazardous, bio-based technologies. Located on an active farm, the company’s connection with nature runs deep. As COO and 3rd-generation of this family-run business Edward Jones says, “we only formulate products that we’d be comfortable with our friends and family using”. The development of 5080 was no different. This high-performance coolant is free of formaldehyde, boron, and secondary amines. 5080’s unique bio-renewable formulation means that it is REACH-compliant and free of hazardous pictograms under GHS labeling requirements. Despite the lack of harsh chemicals, Hangsterfer’s 5080 eliminates common machining problems such as foam, residue and staining. It also
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lasts longer in the sump, leading to greater efficiency and cost savings over time. 5080 is a chlorine-free vegetable based semi-synthetic that was designed to perform in the toughest, high-pressure applications. It works
especially well on aluminum, composites, nickel, stainless steel, titanium, molybdenum, and their alloys. This makes it an excellent choice for medical and aerospace machining. Using Hangsterfer’s 5080 leads to a cleaner, safer, and happier work environment. Low consumption and reduced down time due to rust, residue, and machine cleaning will lead to cost savings over time. It’s time to switch to an advanced coolant like Hangsterfer’s 5080. For more information, Website : www.hangsterfers.com National Distributors
Sanjay Tools & Adhesives X20, MIDC Ambad, Nashik 422010 Suhas Belapurkar Mobile : +91 9892516810 Email: sbelapurkar@sanjaytoolsnsk.com Mr. Mandar Gokarn Mobile: +91 9822028518 Email: mandar@sanjaytoolsnsk.com
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TECH TRENDS
KELLENBERGER 100 - The perfect universal CNC grinding machine programming • Integrated automatic calculation technology Workhead 100
B
y the use of most modern manufacturing means next generation technology is being created, which can meet the customers technical and economical requirements today and tomorrow. Wherever highly accurate grinding is required, Kellenberger precision grinding machines are in use. The Kellenberger® 100 is a new high-performance, economical grinder for any of your universal grinding requirements. It delivers the most diverse of configuration options for the widest range of grinding operations. KELLENBERGER 100 offering the widest possible range of configuration options. The global innovation of a new grinding wheelhead with choice of 10 wheelhead versions to optimize design of the machine; Higher power of the grinding wheel help to increased productivity; redesigned Z-guideways provides greater profile accuracy. In the past IMTEX show, Kellenberger 100 was first displayed in India and attract broad attention. Base • FEM-optimized cast bed
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• Optimized slideway on Z-axis • Linear guide on X-axis Modular wheelhead with highprecision B-axis • 10 compact wheelhead versions for optimal machine design based on the parts to be processed • Diagonal configuration and new collision-free universal design with 500mm grinding wheel diameter. • Constant speed 80 mis with 0400 Possible Workhead and tailstock • Standard design with 100 kg workpiece weight • Strengthened version with 150 kg • High torque for non-circular grinding • Synchronous tailstock including automatic fine adjustment for production applications CNC control system with Fanuc 31i with 19” touchscreen • Comprehensive user support with revamped intuitive touchscreen control • Redesigned cycle programming • Workpiece-based graphic
• Infinite adjustable rotating speed 1-1000 rpm • Morse taper MT5 / size 5 outer short taper Roundness< 0.4 μ m (Option< 0 0002mm) • Micro adjustment ± 0.01° Tailstock 100
• Sleeve stroke 48 mm • Micro adjustment ± 60 μm/0 • MT 4 holding taper
For more information, Hardinge Asia call : 86 21 38108686 Fax : 86 21 38108680/38108681 Website: www.hardinge.com
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AMT SECTION
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TECH TRENDS
MARCH 2019
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TECH TRENDS
Kinefac Corporation : Global leadership in precision metal turning & forming machinery
K
inefac Corporation is recognized as a world leader in precision metal turning and metal forming machinery and processing technology for the manufacture of a variety of components such as high-precision double-end turned alternator and starter shafts for the automotive industry. Since 1962 Kinefac has continued to build its reputation for technical leadership in the equipment it provides to meet worldwide needs. Kinefac machines can be found on all continents of the globe, including Antarctica. These machines produce an extremely diverse set of precision parts for many different industries and products. Kinefac has expanded its footprint internationally as market opportunities have arisen. We have an office in Chennai, India to serve the automotive,
power generation sectors and other industries. Kinefac also has a sales office in Shanghai, China, where it has achieved considerable success by identifying distinct market niches for its products in the aerospace, automotive, power generation and transportation sectors. Kinefac Corporation now occupies nearly 60,000 square feet of manufacturing space where it houses six corporate divisions: • KINEFAC® Division – providing the most advanced metal forming / turning machines in the world today • KINE-FORM® Division – providing innovative, ultra-precision cylindrical die manufacturing • KINECOIL Division – produces highprecision, high-speed advanced CNC medical device coiling systems • KINESPIN Division – produces highperformance industrial centrifuge
machinery • KINEPOWER Division – the leading choice for fluid power technology • KINEPRO Division – develops and produces prototypes and unique metal form components Since 1972 Kinefac® has been recognized as a worldwide leader in manufacturing of high precision CNC center drive turning machines. The Kine-Turn® machine was first designed for the automotive industry where precision axial and radial dimensional tolerances including part concentricity are essential. These machines initially were of a mechanical cam design and have evolved presently to include Fanuc four axis CNC controls. Kinefac now offers a full line of Kine-Turn machines including the single end TS-21 model and the TD series double end turning models TD-11, TD-21, TD-41, TD-61 and TD-81. The TD series of Kine-Turn machines perform simultaneous double end turning of parts ranging from 4mm to 150mm in diameter and 15mm to over 750mm in lengths and provide unsurpassed shaft turning capabilities. Furthermore, these machines can be provided with an integrated part load and unload system to maximize your production requirements.
For more information, Kinefac Corporation Mobile: +91 9003075035 Email : Kinefac@amtindia.org Website: www.kinefac.com
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AMT SECTION
TECH TRENDS
KSPT : Innovative & specialized tooling solutions for the industry
K
YOCERA SGS Precision Tools (KSPT) is focused on providing innovative and specialized tooling solutions. Through testing and development, the KSPT team focuses on the latest technical competence and machining techniques to bring a continuous stream of new products and advancements to market. Our engineering team is committed to continuous improvement and optimizing machining parameters. KSPT has a dedicated technical team with a heightened aptitude for materials, applications and customer centered solutions within the highperformance machining industry. We test materials, tools, applications and coatings and engineer designs for improvements and operational advancements. The portfolio of KSPT products and services offer an unparalleled track record in performance, cost savings, quality and VALUE AT THE SPINDLEÂŽ. Stainless steels, like 17-4Ph are one of the most commonly used materials in all the manufacturing
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industry. Its applications include aerospace, automotive and even the nuclear industry. In an annealed state, 17-4 stainless steel can be one of the nastiest materials to work with. It can get gummy and warp or twist if it has not been heat treated. Titanium is also a very popular material that is widely used in Aerospace, Automobile and Biomedical part manufacturing industries, but it is not without its challenges. Titanium is very chemically reactive and therefore, tends to weld to the cutting tool during machining, thus leading to chipping and premature tool failure. Its low thermal conductivity increases the temperature at the tool/workpiece interface, which affects the tool life adversely. With these challenges in mind, the KSPT technical team designed the Z-Carb High Performance Rougher. The Z-Carb HPR Five Flute Roughing End Mills are ideal for achieving high metal removal rates (MRR) and a finish of 80 RMS or better. The specialized five flute design is engineered for increased productivity over three, four and even other flute end mills. The variable indexing geometry allows for improved chatter suppression over symmetrical designs. Radial Rake specially designed for balance between positive
cutting action and edge strength. Through coolant option delivers coolant effective to the cutting zone to enhance chip removal when pocketing or slotting. Variable flute pattern provides excellent chatter suppression over a range of spindle speeds. Manufactured exclusively with Ti-NAMITE-M coating for high wear resistance, reduced friction, prevention of edge build up and extended tool life, specifically with titanium applications. It is also available with Ti-Namite-A coating, providing excellent thermal and chemical resistance, allowing for dry cutting and improvements in carbide performance. This coating has a high hardness giving great protection against abrasive wear and erosion, allowing for supreme performance in stainless steel. Introduced in 2015, this outstanding tool continues to take the cutting tool industry by storm. Ideally suited for a wide variety of material groups, it is difficult to find an application in which this tool cannot excel. Often eliminating the need for multiple different tools needed to complete the job, this tool continues to save customers both time and money. In 2018 alone, sales engineers, with use of this tool, have saved customers over 1.2 million dollars.
For more information, KYOCERA SGS Precision Tools Tel: (800) 447-4017 Email: webmaster@kyocera-sgstool.com Website: www.kyocera-sgstool.com
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TECH TRENDS
Take Mastercam 2019 for a Test Drive
D
id you know that there is a way to try Mastercam for free? Mastercam® Demo/ Home Learning Edition (HLE) is available for home use to anyone that wants to learn how to use CAD/ CAM software, brush up on their Mastercam skills, or check out the latest features and functionality of both Mastercam and Mastercam for SOLIDWORKS®. Despite the word Demo, Mastercam Demo/HLE provides you with much more than a trial version of Mastercam. You’ll have access to the full potential of the software, from designing a part to generating highspeed toolpaths to machine it, with one exception. The only limitation is that the software will not send G-code to a CNC machine. Ultimately, Mastercam Demo/ HLE gives you the ability to learn Mastercam — every step of the way
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up to actually machining a part. Mastercam Demo/HLE is also available if you are looking for a student version of Mastercam, for personal use. The software is not to be used in a school or industrial setting, but anyone — teachers and students — can use it to learn CAD/ CAM from the comfort of their own home and prepare for a future in manufacturing. Since more shops use Mastercam than any other CAM software, learning at your own pace with Mastercam Demo/ HLE is a smart way to prepare for a manufacturing career. You can download Mastercam Demo/HLE to get familiar with the latest advances in CAD/CAM and brush up on your skills using the software. Start your journey in CAD/CAM on the right track with Mastercam! Go to https://signup. mastercam.com/demo-hle to request
your download. If your needs are beyond learning, and you are looking for CAD/ CAM software to boost your production speeds and capabilities for your manufacturing business, then a conversation with your local Mastercam Reseller is your best option. Contact Mastercam India to learn more. Schools and educators interested in teaching Mastercam should also contact Mastercam India. Ask about Mastercam® Educational Suite and options to enhance your curriculum and help prepare your students with practical skills for careers in manufacturing.
For more information: Mastercam Phone: +91 7378 55 2000 (India) Email: marketing@mastercam.com Website: www.mastercam.com
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AMT SECTION
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TECH TRENDS
MARCH 2019
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TECH TRENDS
Let Your Dies Live: 5 Wear Problems Die Casters Face and How Rocklinizing Solves Them
O
ur participation in Die Casting Congress & Exposition in Indianapolis, it was clear that the Rocklinizer Carbide Application Equipment delivers wear protection solutions to some of the biggest problems facing die casters. But what are those problems, and how does the Rocklinizer solve them? First, we’ll delve into the top 5 issues die casters face and how the Rocklinizer alleviates them. Then, we’ll list the top 5 advantages of the Rocklinizer for die casters. 1. Heat Checking: This is probably the most frequent cause of failure of a die casting die, i.e. thermal fatigue caused by the alternating heating and cooling of the die surface. Small cracks eventually form a closed network, and become so large that the casting metal will flow into the steel surface below. Then you’re stuck resinking or remaking the die entirely - an expensive proposition. But, you can solve this issue by applying tungsten carbide with the Rocklinizer to the areas most prone to heat checking on a preventative maintenance basis. If you’re already facing large heat checks on your die, you can first use a sanding drum to remove them. Then, simply apply tungsten carbide using our rotary applicator from .0001” to approximately .005”, controllable within .0001” by machine setting. 2. Wear on Gates, Vents & Runners: These wear areas stay much cleaner when they’ve received tungsten carbide. Minor cracks in a die can be covered as long as they haven’t
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been allowed to progress to a width greater than approximately .002”. 3. Soldering: Soldering of the zinc or aluminium casting material to the die surface is also a cause for rejection of many castings. Treatment prior to a production run has eliminated soldering at gates, vents, parting lines, and the die cavity where molten metal has a tendency to solder to the cavity. 4. Ejector Pin Flashing: This can be eliminated if the die is in fair condition before treatment. Tungsten carbide applied to the ejector pin about one inch back from the face of the cavity has had good success. 5. Galling or Seizing of Cores: The thermal expansion of zinc and aluminium die cast metals is much greater than that of the steel core. The metal shrinks onto the cores, thus resulting in extreme pressure at the core section. The cores with the carbide surface make the lubricant or die releasing agent adhere
better to the steel, thereby providing a nice finish on the cast parts. Now that we’ve addressed the biggest problems, what are the biggest benefits of “Rocklinizing” in a die casting facility? Our customers realize: 1. LESS Machine Downtime 2. LESS Operator Idle Time 3. LESS Die Removal and Reinsertion Time 4. LESS Die Maintenance 5. MORE Die life, Productivity, and Cost Savings
To learn more about using the Rocklinizer in die casting or for a wide range of other wear reducing and gripping applications, please contact us. For more information Rocklinizer, USA www.rocklinmanufacturing.com National Distributors
Sanjay Tools & Adhesives X20, MIDC Ambad, Nashik 422010 Suhas Belapurkar Mobile : +91 9892516810 Email: sbelapurkar@sanjaytoolsnsk.com Mr. Mandar Gokarn Mobile: +91 9822028518 Email: mandar@sanjaytoolsnsk.com
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TECH TRENDS
Use of TIP-TIG Technology in Process Equipment Plants by Rakesh Choudhary, Head WAPS, Ador Welding Ltd. (with inputs from Plasch, TiP-TiG, Austria)
T
IP-TIG welding is a new advanced innovation of the common GTAW Process. This process uses new, patent-pending technology (TiPTiG), that delivers the highest possible weld energy with the lowest possible weld heat, all while still being user-friendly. What is TIP-TIG welding? TiPTiG new welding with a hot wire process can be used in every industry. It is very simple to learn, use and simple to teach. This process is so unique that higher travel speed, lower heat input, reduced cycle time, and an overall better-quality welding advantage can easily be achieved. The Process The TIG weld receptivity for higher weld deposition rates is done by decreasing the speeds for the weld solidification process and increasing the fluid weld area. This allows for a 100%-400% increase in TIG wire feed rates, increasing the overall weld deposits. All these attributes like faster speeds and higher than normal weld energy, increase the resulting TIG weld quality and overall process productivity. The process is also slag-free and
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uses the lowest possible heat input of any welding process, producing a Heat Affected Zone (HAZ), all of which help to reduce distortion and weld stress. It produces some of the highest quality products with the best metallurgical and mechanical properties on all alloys, but also increases production up to four times the normal speed. There is also no inter- pass cleaning, creating availability for an increased Arc on time and weld quality. The TIP TIG process is available in manual and automated capability to attain weld and clad quality levels way beyond the conventional TIG – Hot – Cold Wire TIG – Pulsed MIG and the Flux-Cored process.
Fig.3
How it Works A TIP TIG welding system uses a wire fed GTAW system just like a typical TIG system, but it’s distinctive for the vibratory effect on wire at weld pool which is achieved by a linear forward and backward mechanical motion created by the customised wire feeder system. The forward and backward motion of the filler wire creates an oscillation that is then transferred to the weld, agitating the molten weld pool and ultimately disrupting the surface tension. In addition to this vibratory
Fig.1
Fig.2
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TECH TRENDS effect on the wire, a hotwire current (powered by a secondary power source) is also applied to the filler metal, prior to entering the weld puddle. The two pictures (fig. 1 & 2) describe the weld finish with Manual GTAW & Manual TIP-TIG process. ChampTig 400P Power source from Ador Welding with the TipTig wire feeder. Benefits of the TIG-TIP process • Increased fluidity of the weld pool • Greater tolerance to joint fit-up • Significantly reduced joint sensitivity • Greater ability to accept more wire into the weld pool, results in a higher deposition • 4-6 times increased travel times • Reduced cycle time and heat input • Cleaner welds with agitated weld pool • Reduced weld stress with the reduced heat input Approved Alloys TiPTiG welding can work on a wide range of alloys such as carbon steel, stainless steel, duplex and super duplex stainless steels, inconel, titanium, aluminium, copper, nickel, and many other critical materials like P-91, which are used in process plant production. Heat Exchangers Heat Exchangers are commonly constructed from low Carbon Steel, Copper, Copper-Nickel, Stainless Steel, Hastelloy, Inconel, or
Fig.4
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Titanium. There are certainly some unique applications and challenges associated with the welding of heat exchangers, such as the position and access for the popular circumferential welding of Tube to sheet welds or the half tube shell welding. A trained TIP-TIG welder can typically weld a 50mm tube in 30 seconds… or less with the highest quality and lowest heat input. Our typical travel speed for fillet welds will be between 300 to 500 mm/min on most applications. Compared with 80 to 150 mm/ min with conventional GTAW. TiPTiG manual system is a low cost semi-automatic solution to tackle any job by selecting a wide variety of torches for different applications, with modified 180 deg torch it allows a complete tube sheet welds without repositioning the wire or stopping, allowing for defect free welds. The typical customers in the manufacturing and repair of various sized heat exchangers are in power plants, chemical plants, petrochemical plants, petroleum refineries, natural gas processing, and sewage treatment.
Fig.5
pipe and make the welds look simple, that’s a process that should be given consideration. With TIP-TIG, no brushing, no grinding, no spatter, no weld rework, no feeding of wire, no foot control, less skills. Note weld smoke prep machining lubricants. (*Incoloy refers to a range of superalloys produced by the Special Metals Corporation group of companies. They are mostly nickelbased, and designed for excellent corrosion resistance as well as strength at high temperatures; there are specific alloys for resistance to chemical attacks)
INCONEL CLADDING Normally, when you manually clad the end of a pipe ID with Inconelusing Pulsed MIG as shown in the picture and result is often not so good. However when we use TIPTIG, the results are visible as shown on the mentioned pictures. In the pictureTIP-TIG cladded Job, TIP -TIG Inconel 800 pipe was welded with Inconel 82 wire on 10 inch pipe 3/4 Wall. The TIP TIG weld cycle time for the Inconel pipe was 40 – 50 minutes, whereas the customer used to take around 4 hrs with regular TIG. When your weld process can weld a complex incoloy*
Fig.6
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TECH TRENDS Duplex Steel Welding Applications Application The picture (fig.5) is of a very thin Gage Duplex Boiler. Traditional automated TIG process with cold wire may result in sluggish duplex welds. The customer typically attained a maximum Hot Wire TIG weld travel speeds from 12 – 15 inch/min. Then the customer switched over from Hot Wire TIG to the TIP-TIG process. The TIP TIG weld parameters and speeds were achieved using an 0.035 (1mm) 2205 Duplex wire, with TIP-TIG travel speed of 35 inch/min was achieved providing 200% increase in weld travel. The welds had a superior, less sluggish weld bead appearance and the parts had a dramatic reduction in weld distortion, (note the much smaller HAZ). Also the TIP-TIG process was much more stable and consistent. TIP-TIG produces the cleanest welds from lowest possible oxidation. The welds will have the lowest possible weld pores and inclusions and the smallest possible weld HAZ. Welding of P-91 Material Welding of Grade 91 (9Cr-1Mo-V) chromium-molybdenum steel has presented numerous challenges since its introduction inthe 1970s. The gas tungsten-arc (GTAW) process can produce welds of high quality;
however, manual welding can be expensive and labour intensive, requiring skilled welders with extreme hand-eye coordination and dexterity. Grade 91 productivity can beincreased in either shop or field fabrication by introducing a semiautomatic high deposition metal transfer (HDMT) GTAWwelding process that combines controlled excitation of wire with a hot wire addition. This technique is costeffective and can beused for the entire weld from root to cap while producing high quality welds that industry expects from the GTAW process. With TiP-TiG weld study, it indicates that semiautomatic HDMT GTAW welding process is capable of producing toughness valuescomparable to or exceeding manual GTAW and that the process provides an attractive alternative for welding P91 root and hotpasses or the entire weld from root to cap.Results of this study indicates that semiautomatic HDMT GTAW welding process is capable of producing impact valuescomparable to or exceeding manual GTAWT. The process also provides an attractive alternative for welding P91 root and hotpasses or the entire weld from root to cap. The semiautomatic HDMT GTAW welding process permits an increase in energy(heat input), larger weld puddle and increased deposition rate while still
Fig.7
Fig.8
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providing tempering of the previously deposited weldbeads or layers. TIP-TIG HDMT (HIGH DYNAMIC METAL TRANSFER) FOCUS TIP-TIG HDMT FOCUS is a unique TIP-TIG welding process. Its precision and reliability make the TIPTIG HDMT FOCUS welding process particularly suitable for automatedapplications in combination with linear axles, robots and other guiding systems. Nearly all steels, non-ferrousmetals or galvanized sheets can be welded in one layer with filler material; e.g. CrNi-steels with a material thickness of up to 10 to 12 mm can be welded in single pass without any Joint preparation. Some of the welded examples are listed below. it has resulted in elimination of backing gas in austenitic stainless steel welds using high deposition metal transfer gas tungsten-arc welding(HDMTGTAW) TIP-TIG HDMT FOCUS PROCESS Example • Material: CrNi 8+8mm • Weld current: 500A • Weld speed: 46 cm/min • Wire feed speed: 2,0m/min Details of Welded Samples • Material: CrNi 10+10mm • Weld current: 500A • Weld speed: 32 cm/min • Wire feed speed: 1,8m/min TIP-TIG REDUCED COSTS BY OVER 60%, WHEN COMPARED WITH CONVENTIONAL TIG PROCESS TIP-TIG Cost Comparison The following comparison shows the actual savings calculated on a real stainless-steel welding application comparing conventional TIG and TIP-TIG on a pipe application (2” Sch 80 Stainless) in the 5G position.
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TECH TRENDS
Variable / Results
Units
Conventional TIG
TIP TIG Process
Welding process
GTAW
GTAW
Wire type
ER308L
ER308L
Wire size
mm
2.4
0.9
Wire deposition speed
mm/min
100
1900
Melt off rate
g/h
200
580(3 times)
Deposition efficiency
%
100.00%
100.00%
Deposition rate
g/h
200
580(3 times)
Duty cycle
%
100.00%
100.00%
Final deposition rate
g/h
200
580(3 times)
Argon
Argon
Gas type Flow rate
cfh
30
30
Gas/Wire ratio
cf/g
63.05
23.62(60% Reduction in gas per gm of wire)
The above data shows, the deposition rates approx. 3 times to standard TIG process which reduces the production costs by 60%. Conclusion TIP-TIG is an innovative TIG process and good alternative to standard gas tungsten-arc (GTAW) process. Its versatility and simplicity makes the manual welder to give higher output. The Automated High Deposition Metal Transfer (HDMT) GTAW welding process that combines controlled excitation of wire with a hot wire addition and gives very
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promising results to challenging applications. Plant equipment manufacturing, wherever GTAW is applicable, is possible to be replaced by TIG-TIG process which gives very high output without compromising on quality. The success in P91 welding with TIP-TIG, also increases the application possibility in that area.
References: 1. Paper on ‘ACHIEVING TOUGHNESS IN P91 WELDS FROM ROOT TO CAP USING SEMIAUTOMATIC HIGH DEPOSITION METAL TRANSFER (HDMT) GTAW WELDING PROCESS ‘ by Charles W. “Pat” Patrick 2. Information from TiPTiG USA 3. Information from TiPTiG International AG .
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Faccin integrated solutions for your onshore & offshore projects.
Wind Energy providers look East Mr. Giordano Toninelli, Area Sales Manager – Faccin SPA
W
ind energy business has an historical background in Europe due to the high number of wind farms around Europe, but in the last years, the focus of offshore wind investments is starting to move from Europe to Asia. Wind energy business in Asia has historically been led by China with 35% share of the cumulative MW capacity worldwide (according to the last Global Wind Energy Council - GWEC report) but other emergent markets like Taiwan are becoming new powerful players in the offshore wind sector. The Taiwanese government set the objective to source 20% of electricity from renewables by 2025 and offshore wind is the backbone for delivering the government’s objective of phasing out nuclear power by 2025. The official target set by the Taiwanese government for offshore wind is 5.5GW offshore wind by 2025 target; of
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the initial 3.5GW of capacity, 500MW must be commissioned by 2020, and the remaining 3GW ought to be operational between 2020 and 2025. Thirty-six new offshore locations have been identified for the future planning. The combination of a clear target set by the Taiwanese government combined with the good offshore wind seabed conditions, have convinced the offshore wind industry to look at Taiwan as another GW size market in Asia. Driven by this scenario, leading Taiwanese wind tower manufacturers have trusted Faccin’s experience and successful track record of installed wind tower automation systems for their most exigent wind tower projects. Faccin’s highly technological machines are designed to maximize productivity, thus the profitability of the wind tower cans manufacturer. All this is achieved by a precise and
fast rolling machine with an oversized reliable structure, which helps reduce time in the following steps of the wind tower like assembly and welding and a user-friendly CNC capable of handling automatically not only the machine but also the handling system. A high level of supply availability and the lowest possible processing time is our priority. Installation and training are always provided in order to develop our customers’ skills. It allows them to operate confidently and independently in their day-to-day business. Learn more about us and discover our latest developments by visiting our website www.faccin.com
Watch the video to see it in action!
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ENDLESS POSSIBILITIES
MARPOSS FLEXIBLE SOLUTIONS OPTOQUICK is the latest generation Marposs flexible solution, for high precision gauging controls on shafts, as for instance cam, crank or gear shafts, gear shafts or electric motor shafts. Optoquick helps operators with fast and precise quality controls while located directly at the side of the manufacturing machines. The combination of optical and tactile sensing technologies - complete MARPOSS design - allows the Optoquick to deliver extended gauging capabilities and flexibility, at the highest level of its category. OPTOQUICK, NO MATTER WHAT THE GAUGING CHALLANGE IS.
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TECH TRENDS
Renishaw XM-600 system enables faster and easier CMM error mapping Renishawâ&#x20AC;&#x2122;s newly launched XM-600 laser measurement system offers enhanced capability to connect directly with Renishawâ&#x20AC;&#x2122;s range of UCC CMM controllers
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sing technology developed for the XM-60 multi-axis calibrator, this enables faster and easier error mapping, measuring all six degrees of freedom from a single set-up, in any orientation for
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linear axes. XM-600 communicates easily with Renishaw UCC software during the calibration routine to quickly build a complete error map of the CMM. This functionality is supported from
within UCCsuite V5.4.1 and onwards, enabling the complete error map of a CMM within half a day. For more information, Website: www.renishaw.com
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TECH TRENDS
Machine Safety in the Age of Digitisation Digitisation in industrial production imposes new requirements on machine safety. It also lays the foundations for new solutions. This article looks at the effects of Industry 4.0 on functional machine safety. Keywords: machine safety, digitisation, internet of things, platform economy, Industry 4.0.
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he Schmersal Group develops and produces some 25,000 switchgear units, making it one of the largest providers anywhere in the world. Motivated by a vision of a safe world of work, the company’s development engineers are constantly working on new devices and systems for all conceivable application situations. Development focuses on three areas — lift technology, automation technology and safety technology — and has produced a range of mechanical and non-contact switchgear devices, a portfolio of safety switchgear and safety switching systems for protection of man and machine. Digitisation, the internet of things, platform economy, Industry 4.0. Behind all of these buzzwords is a real
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‘mega trend’ that is sweeping through industry. Virtually every company has been touched by this mega trend, and we’re likely to see significant changes in every stage of industrial production as a result. This also affects machine safety, and in a multitude of ways. In the first instance, new machines and production concepts impact the design of safety systems. If components are manufactured in highly-automated one-size production batches, machines need to offer much greater flexibility, as too must the safety equipment. The most striking example of this are collaborating robots, which operate alongside workers without safety fences to separate them. Secondly, the unbroken networked
communication systems of Production 4.0 offer new opportunities for machine safety. Infrastructure like the cloud and edge computing and, at product level, virtual machine and system twins, help to enhance the transparency and flexibility of safety equipment. We will outline some examples of both trends below. Increasing productivity as a goal It is a principle that machine safety should not be allowed to impair the productivity of a machine. This is far from a new requirement, but in the age of Industry 4.0, it has become far more pressing. In response to this, increasing numbers of machine builders are seeking cooperation from machine safety experts early on in
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TECH TRENDS the design of new series, with the aim of integrating safety functions into machine functions in such a way that productivity is maximised alongside high levels of safety. New tools such as multi-discipline Systems Engineering are available to assist with this challenge. When it comes to machine safety, qualified services are available and offered by Schmersal under the tec.nicum brand. Services include design support, encompassing machine safety aspects and customer-specific programming of safety control units. Both help to ensure that safety functions can be integrated into or coordinated with operational machine functions as seamlessly as possible, so as not to impair productivity. Systems and solutions for machine safety In today’s world, machine builders can benefit greatly by procuring safety systems from a single source. As a systems and solutions provider for machine safety, Schmersal of-
fers safety components and systems for signal evaluation alongside consultancy, project planning and engineering services. In view of the increasing complexity of machines, machine control units and safety systems, it is vital that we offer complete solutions packages. Individual components such as RFID-based security sensors have already been developed, like the RSS260, which can also transmit diagnostics information such as error messages, e.g. ‘Fault or short circuit at a safety output’ or ‘Faulty actuator’, to enable rapid elimination of errors. In addition, these advanced diagnostics functions also enable predictive maintenance and the avoidance of machine downtime by transmitting non-safety-related status information to operating control units, such as a notification to adjust the safety door in the event of a door offset. The extended features of these RFID sensors, such as the RSS260, also include individual encoding for enhanced manipulation protection. Data exchange beyond the machine Things become even more complex when you go beyond component level to control unit level. The goal here is to collate and evaluate the data generated by safety switchgear, a task accomplished with help of safety-oriented bus systems such as ASi Safety at Work. If necessary, decentralised concepts can also be realised, such as on machines built as modular systems. In that case, field boxes and safety installation systems from Schmersal may be used to help create the conditions for quick and easy series connec-
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tion of safety switchgear units and for the integration of different and mixed switch types, such as safety interlocks and safety systems. This also allows non safety-related diagnostics signals to be transmitted to a standard PLC via common field bus interfaces, such as ProfiNet or Ethernet IP. From the safety door to the cloud The new Smart Safety Solution even allows diagnostics information to be transmitted to the cloud via the Protect PSC1 safety control unit or the SD gateway and an edge gateway for the capture of data such as limit and distance warnings and operating status information from safety equipment. There is, therefore, unbroken communication over the entire automation pyramid. Diagnostics information can then be displayed on screens and retrieved on devices such as tablets and smartphones, allowing for remote monitoring of production processes and predictive maintenance. Common cloud platforms, such as Microsoft Azure, are used to allow data to be displayed via dashboards. In this case too, new-generation safety control units take on management of increasing complexity in the safety circuit, with the modular PSC1 safety control unit capable of evaluating data from various production cells. As such, multiple robot cells are able to communicate with one another and exchange safety-related data and error messages. With this capability, machine builders can now determine which data to transmit. In the medium term, products produced on the machines will also be integrated into the data stream as they carry with them the relevant data like ‘virtual twins’ — a fundamental element of Industry 4.0. With the cloud-based Smart Safety Solution, Schmersal has already created the conditions for this and other similar concepts.
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Good communication skills required These examples demonstrate how the ability of components to communicate is central to the exchange of data over different levels. Flexibility is equally important. As such, the PSC1 allows the safety functions of machines to be modified to different applications within each modular principle. Core components are freely programmable compact control units (PSC1-C-10/100) with I/O expansion modules available for secure signal processing from different safety switches. A universal communication interface allows the user to make simple software-based selections and adjustments of different field bus protocols. The same hardware also allows connection to all common field bus systems (PROFINET, PROFINET PROFIsafe, EtherCAT, EtherCATFSOE, Profibus, Profibus ProfiSafe and Ethernet IP). The new opportunities offered by digitisation are also changing the way in which designers, who are responsible for selecting the safety systems, work. At Motek 2018, Schmersal will be unveiling an online planning tool that has been designed to enable quick and easy configuration of the modular PSC1 safety control unit. The PSC1 configurator is an online tool with 24/7 availability. It is both intuitive
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and easy to operate and offers designers a robust planning foundation in just a few minutes. The planning tool automatically selects the optimal PSC1 safety control unit based on a selection of safety sensors and safety outputs and indicates the space that will be occupied by the assembly configuration on the profile rail. At the same time, the PSC1 configurator also generates a bill of materials including item names, material numbers and details of devices. This bill of materials is linked to Schmersalâ&#x20AC;&#x2122;s online catalogue, allowing the user to look up device information as required. The bill of materials can be exported in Excel or PDF format for direct e-mail attachment and subsequent quotation. Interplay between man and robot And finally a look at the supreme discipline of machine safety â&#x20AC;&#x201D; the interplay between man and robot in a shared workspace, with no safety fences to
separate them. Something that can only be achieved with a safety-related control unit that has been configured to ensure that robots never leaves their work zones and never exceed defined axle speeds. The Schmersal Group offers robot manufacturers the functionality of a safety-related control unit for human/robot cooperation in the form of its Safety Controller product. Sensor systems are essential whenever there is direct contact between man and robot, so that collisions can be detected, and robot movements stopped promptly. Work is being conducted in close cooperation with the Bonn-RheinSieg University of Applied Sciences to develop a technically feasible and economically efficient safety solution to address precisely this problem. This and the other examples outlined above demonstrate that machine safety can help to realise Industry 4.0 concepts while also harmonising occupational safety and productivity in innovative and complex integrated systems.
Author: Christian Heller, Head of Sales for Central Germany, Schmersal Group www.schmersal.com
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TECH TRENDS
High Precision Gap Monitoring in Plant & Machinery
With the eddyNCDT 3060, Micro-Epsilon has developed a powerful displacement measuring system based on the eddy current principle, which combines precision, speed and temperature stability in a unique way. These characteristics are complemented with maximum ease of use and an excellent price/performance ratio. The system shows its strengths primarily with gap measurements in harsh ambient conditions.
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he eddyNCDT 3060 system is designed for displacement and distance measurements. Due to its robust design and high measurement accuracy, the system is used to monitor the lubricating gap and thermal expansion, as well as to determine shaft movement and radial run out of machine parts and drive components. Factorycalibrated for either ferromagnetic or non-ferromagnetic materials, the inductive displacement measuring system consists of a compact
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controller, a sensor and a cable. With more than 400 compatible sensor models, high speed and smart signal processing, the eddyNCDT 3060 product series from MicroEpsilon defines a new performance class in inductive displacement measurement. The powerful eddyNCDT 3060 eddy current displacement measuring system is ideal for fast, non-contact displacement measurements onto metallic targets. As sensor and controller are actively
temperature-compensated, very high measurement accuracies down to the micrometer range can be achieved even in fluctuating temperatures. The sensors are designed for ambient temperatures up to a maximum of +200°C and an ambient pressure up to 20bar. The measurements are performed at a frequency response up to 20kHz. The compact controller design as well as the fieldbus connection enable easy integration into machines and systems.
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More Precision Inductive sensors (eddy current) for displacement, distance & position
eddyNCDT High precision inductive sensors (eddy current) for non-contact displacement, distance and position measurements Robust and industrial-grade sensors for harsh, industrial environments: dirt, vibrations, pressure, temperature High resolution and temperature stability High frequency response for high-speed measurements Customer-specific sensors and controllers Extensive product range for versatile application possibilities
+91 20 2674 1009 | info@micro-epsilon.in | www.micro-epsilon.in
TECH TRENDS The eddyNCDT 3060 system is designed for displacement and distance measurements. With more than 400 compatible sensor models, high speed and smart signal processing, the eddyNCDT 3060 product series from Micro-Epsilon defines a new performance class in inductive displacement measurement.
Individual adaption possibilities Another particularity feature of note is the distance-independent multi-point calibration which enables the customer to carry out field linearization in addition to the factory-calibration. The measurement accuracy can even be increased using the DT3061 controller model for a 5-point linearization. Furthermore, the DT3061 offers switching outputs and temperature outputs and allows the storage of multiple characteristic curves. Parameter set up is performed via a modern, user-friendly web interface that is accessed via an Ethernet interface. Gap analysis in axial piston pumps The eddyNCDT 3060 eddy current measuring system also shows its strengths when analyzing the gaps in axial piston pumps, where sensors monitor the gasket gaps in very limited space while being exposed to high rotational speeds and harsh ambient conditions. Axial piston pumps convert mechanically generated kinetic energy into hydraulic energy. This means they
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are often used in slow-moving machines that simultaneously perform, in addition to their motion, hydraulic movements such as lifting, turning or gripping, for example via blades or crane booms. Inside the pump, a cylinder with a piston rotates between two fixed plates in order to build up hydraulic pressure. These plates can be used to control the desired pressure by regulating the flow opening. To ensure that the connected mechanical parts can rotate optimally and for as long as possible, friction should be minimal. Therefore, narrow gaps between the components ensure the best sliding properties. Most of these gaps are under 20 microns wide, sometimes even less than 10 microns. In addition to reducing friction, these so-called sealing gaps also have the task of keeping the hydraulic oil in circulation and thus significantly influence the mode of operation of the machines. Changes in the gap can lead to pressure loss or a pump failure. The behavior of the gap is therefore measured on the test rig in
order to optimize the design of the pump. So far, gap measurements inside the pumps were not possible because of the extreme requirements. The sensors used deliver precise results even when exposed to high rotational speeds, high pressures and temperatures above 100°C. Furthermore, the pumps are extremely compact, which significantly limits the space available for integration of sensors. Thanks to the extremely small sensor designs and their high pressure and temperature stability, the eddyNCDT inductive miniature sensors are ideal for this application. The eddyNCDT 3060 eddy current measuring system is therefore used on the test rig for evaluating the pumps. As a result, micrometer gap measurements can be achieved from which ultimately analyses can be made in order to optimize the efficiency of axial piston pumps. Monitoring oil gaps in hydrostatic bearings Monitoring the oil gap in hydrostatic bearings is also a task for the eddyNCDT 3060 measuring system. Hydrostatic bearings are used in large plant and machinery such as stone mills and telescopic installations. Monitoring the gap size in these bearings is a critical factor, as any disturbances in the hydraulics can cause pressure drops, which in extreme cases, can cause the gap to close, resulting in damage to the bearings and ultimately system failure. In order to be able to retrofit older plants, the measuring system used which is fixed on the bearing shoe must be easy to install. Due to the long service life and the worldwide use of these plants, the sensor should be easy to replace. For this reason, non-contact eddy
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TECH TRENDS current displacement sensors of the eddyNCDT 3060 series are used. Decisive factors for the measurement task are good repeatability and high temperature stability. These sensors have a robust, compact design. The plant is operated outdoors where splash oil and water is present. Measuring the bearing gap in wind turbines Wind turbines typically have two main bearings in which the rotor shaft runs. Due to safety and cost reasons, wind turbines require 24/7 monitoring. Monitoring the bearing gap between the bearing surface and the drive shaft is one of the primary objectives. An oil film in the lubricating gap prevents direct contact between the bearing surface and the shaft. Improved sliding properties of the bearing increase the turbineâ&#x20AC;&#x2122;s effectiveness while prolonging its service life. The sliding properties mainly depend on the width of the bearing gap. Based on the size of the bearing gap, conclusions can be drawn about the wear. This is because when the gap width is reduced, less oil covers the bearing surface and the component
To date, bearing gaps were measured during standstill. Inductive sensors based on eddy currents from Micro-Epsilon acquire the measurement values during plant operation, thereby enabling reliable, cost-saving real-time analysis.
wear increases. This would lead to high temperatures, rapid wear and to bearing damage. In the worst case, the plant comes to a standstill which results in high service costs. To date, bearing gaps were measured during standstill based on a tactile principle. Inductive sensors based on eddy currents from MicroEpsilon acquire the measurement values during plant operation, thereby enabling reliable, cost-saving real-time analysis. The sensors can be used in the test bench and in high volume applications. Serial use is ideal as the sensor technology can
Monitoring the oil gap in hydrostatic bearings is also a task for the eddyNCDT 3060 measuring system. Decisive factors for the measurement task are good repeatability and high temperature stability. These sensors have a robust, compact design.
already be aligned and precisely adjusted during installation and initial operation. High robustness for industrial environments In contrast to conventional inductive sensors, displacement sensors based on eddy currents from Micro-Epsilon stand out due to their high accuracy, frequency response and temperature stability. The sensors are suitable for use at ambient temperatures of up to 200°C. Furthermore, the sensor and the controller are actively temperature-compensated at the factory while providing reliable measurement results even with fluctuating temperatures. The sensors are insensitive to dirt, pressure and oil which is why they provide highly accurate results in ambient pressure up to 20 bar.
For more information, Website: www.micro-epsilon.in
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TECH TRENDS
Achieving Flame-Retardant Properties Without Red Phosphorus
LANXESS offers alternatives to polyamide 66 compounds containing red phosphorus Polyamide 6 and 66 compounds with halogen-free flameretardant packages 88
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ed phosphorus is an established flame-retardant additive for polyamide 66. Even small amounts of it are enough to provide thermoplastics with good fire-resistant characteristics with scarcely any impact on the mechanical properties. However, such compounds have recently undergone significant
price increases, as both polyamide 66 base resin and red phosphorus have become more expensive. Consequently, specialty chemicals company LANXESS is noticing growing demand for high-performance alternative materials based on polyamide 6 and 66 that feature flameretardant characteristics in other ways,
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TECH TRENDS ratio,â&#x20AC;? explains Alexander Radeck, application developer in the High Performance Materials (HPM) business unit. Through its HiAnt service, LANXESS helps customers to meet the standards defined, for example, in requirement specifications and delivery specifications when they switch materials.
particularly in the electrical/electronic and IT industries. â&#x20AC;&#x153;Our range includes suitable compounds with halogen-free flame-retardant packages that exhibit similarly effective flame-retardant properties and in some cases are even better. The polyamide 6 compounds in particular boast an excellent price-performance
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Potential for light colors, no contact corrosion Unlike their counterparts containing red phosphorus, the compounds from LANXESS can be given any color, including light shades. This is a point in their favor as color is an important element in design and is used in many applications as a feature of component safety markings. A further strength of the compounds is that metals are much less prone to corrosion when they come into contact with their flame retardant additives in warm, moist environments. Moreover, the compounds are also easier to handle in terms of occupational hygiene. Improved tracking resistance Polyamide 66 compounds with flame-retardant mechanisms based on red phosphorus are usually available with glass fiber content of between 20 and 40 percent. Alternative materials to compounds with glass fiber content of 25 percent include Durethan AKV25FN04 polyamide 66 and especially Durethan BKV25FN04 polyamide 6. Both exhibit similar tensile moduli, strength at break and elongation at break, Charpy impact strength and densities. At 600 volts, their tracking resistance (comparative tracking index CTI A, IEC 60112) is somewhat higher. Durethan AKV25FN04 is particularly suited to applications that call for high heat distortion temperatures or V-0 classification at a specimen thickness of 0.4 millimeters in the UL 94 flammability test from US testing organization Underwriters
Laboratories Inc. (UL). Durethan BKV25FN04 is classified under V-0 at a specimen thickness of 0.75 millimeters. Both compounds are f1-listed by UL (starting at 0.75 millimeters). This means that they are also suitable for components that will be outdoors and subject to the effects of water and UV radiation, such as connectors for photovoltaic systems. Better flame-retardant properties Durethan AKV30FN04 polyamide 66 and the Durethan BKV30FN04 and BKV45FN04 polyamide 6 compounds make excellent substitutes for polyamide 66 compounds containing added red phosphorus and glass fiber contents around 35 percent. All three materials attain better classifications in UL 94 testing, achieving V-0 standard (0.4 millimeters). Their thermal endurance (relative temperature index, or RTI) as per UL 746B is also higher. With 45 percent glass fiber reinforcement, Durethan BKV45FN04 meets stringent requirements for strength and rigidity. With its outstanding flameretardant properties, it passes the tests required by European standard DIN EN 45545 for fire protection on railway vehicles with the top grade of Hazard Level 3. This applies to components listed in requirement sets R22 and R23, such as choke coils. Some halogenated compounds from LANXESS also constitute suitable and cost-effective alternatives to polyamide 66 types with red-phosphorus-based flame-retardant packages. Two such examples are Durethan AKV25F30 polyamide 66 and Durethan BKV25F30 polyamide 6. Their assets include better flame-retardant properties, which are evident in glow-wire testing on end products in line with IEC 606952-1 (glow-wire end product test, or GWEPT), for example. For more information Website: www.lanxess.in
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FARO Introduces FARO RevEng for Design Professionals RevEng tools and functionality are tightly integrated to assure a seamless handoff of project information, which dramatically streamlines end-to-end workflows
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ARO has announced the immediate availability of FARO RevEng™. This advanced software platform provides FARO Design ScanArm and FARO 8-Axis FaroArm® system users with a powerful tool that enables a comprehensive digital design experience. RevEng™ addresses a variety of reverse engineering and design challenges across a range of industries including Automotive Aftermarket, Research & Development, Heritage Preservation, Industrial Machinery, Engineering Services and Computer Graphics. RevEng tools and functionality are tightly integrated to assure a seamless handoff of project information, which dramatically streamlines end-to-end workflows. For design professionals who need to capture high quality color point cloud scans to generate high quality mesh models, RevEng™ displays a clear, true to life color representation of the source items. As a result, users have absolute confidence that exceptionally high-quality information can be edited in RevEng™ or exported to 3rd party software for editing and final model generation. For users who need to refine mesh models and extract sketch geometry for 3D design activities or 3D printing, RevEng™ delivers a full set of tools to edit and optimize the mesh model. This enables production of the most accurate and efficient digital representation of the scanned object possible. Final output can be a watertight mesh model, mesh shell optimized for 3D
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printing, or a collection of 2D and 3D curves to feed into the CAD modeling stage of the design workflow. Additionally, RevEng™ includes advanced algorithms that significantly reduce processing time. “As a solutions-driven enterprise, FARO is focused on our customers’ optimizing their investment,” stated Thorsten Brecht, Senior Director, 3D Design. “FARO RevEng™ is modeled with this as the core development sensibility. We appreciate that time to market and design flexibility are critical to the success of any design project.” About FARO FARO is the world’s most trusted source for 3D measurement, imaging and realization technology. The Company develops and markets
computer-aided measurement and imaging devices and software for the following vertical markets: • 3D Manufacturing - High-precision 3D measurement, imaging and comparison of parts and complex structures within production and quality assurance processes • Construction BIM - 3D capture of as-built construction projects and factories to document complex structures and perform quality control, planning and preservation • Public Safety Forensics - Capture and analysis of on-site real world data to investigate crash, crime and fire, plan security activities and provide virtual reality training for public safety personnel For more information, Website: www.faro.com/in
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Shavo Technologies Pvt. Ltd. 29/2 Kharadi, Off Pune Nagar Road, Old Kharadi Mundhwa Road, Pune: 411 014 Tel. No.: +(91) (0) 7030938211, 7410004817, Fax No.: +(91) (080) 28395963 Email: shavogroup@vsnl.com | Website : www.shavogroup.com
TECH TRENDS
Induction Heating With Shorter Cycle Times & Higher Process Reliability For more than 30 years, EMAG eldec has been developing highquality and robust generators for induction heating. The specialists are currently expanding their portfolio with low-frequency technology (LF). Concrete application examples make this very clear: The entire process benefits from shorter cycle times and higher reproducibility
Mr. Dirk Schlesselmann, Deputy Head of Application Technology Research and Development at eldec.
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elding and joining processes are particularly challenging for car manufacturing, since tremendous unit volumes must be machined within a minimal cycle time and without any unacceptable changes to the material structure—this is why induction heating often is an indispensable component of the interlinked overall process. Technology helps to quickly bring the component to the temperature required for the process. The main process starts immediately thereafter. However, this must not lead to any overheating of the component, which would result in loss of hardness, oxidation or unacceptable deformation. LF technology wins in trials The advantages that EMAG eldec LF generators (low frequency) provide in this context are illustrated by a current application example from the eldec technology center: The goal here was to heat up a simple corona
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(similar to a gear) to a temperature of at least 200 and no more than 370 degrees Celsius—and this with the shortest possible cycle time and highest possible process reliability. To achieve this, the experts used a numerical calculation to comparatively analyze the induction heating with a low frequency as well as with a typical medium frequency.
higher maximum temperature is not admissible. As an alternative, the process time can also be increased when medium frequencies are used. This will nevertheless require a heating time of 8.5 seconds to achieve the desired temperature distribution (without exceeding the maximum temperature).
The results are clear: When using a low frequency of 2 kHz and a process time of five seconds, the desired heating pattern of at least 200 degrees Celsius appears throughout the corona. If a medium frequency of 12.5 kHz is used, the admissible maximum temperature must be increased to 420 degrees Celsius. Otherwise, the minimum temperature of 200 degrees will not be reached throughout the corona within the targeted five seconds. However, the
Faster heating within the volume “We use numerical calculations to design processes faster and more accurately as would be possible when proceeding by trial and error— in other words, start by building an inductor, testing it, redesigning it and so on. The results also translate very well into practice from a qualitative standpoint and in this respect they make the advantages that the LF technology provides very clear,” explains Mr. Dirk Schlesselmann, Deputy Head of
A typical application for the induction technology from eldec: The corona must be heated to a temperature of at least 200 but no more than 370 degrees Celsius.
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TECH TRENDS Application Technology Research and Development at eldec. “The lower frequencies heat up the inside of the volume faster because the magnetic field penetrates into the component. This is why we can significantly reduce the cycle time compared to when using medium frequencies. Moreover, it’s easier to remain within the desired temperature process window and the risk of overheating recedes. Not least, the occurring temperature gradients are smaller. And, in the end, this means that the risk of cracks forming on the component is smaller.” With that in mind, the induction specialists at EMAG eldec already offer a wide range of generators with LF technology (power output: 50 to 500 kW, frequency range: 2 to 8 kHz). Their potential areas of application are tremendous: The technology offers great benefits to applications, such as preheating prior to welding gear wheels, joining of stators in electric motor housings, impregnating stators or annealing after hardening, for instance. “In principle, it can make sense
When using a low frequency of 2 kHz (left), the magnetic field penetrates deeper into the component (right image: use of a medium frequency of 12.5 kHz).
wherever heating within the volume should be performed at low cycle times. However, our LF generators not only ensure faster processes, but also operate with higher process reliability. The devices also score points with their cutting-edge technology. They use the robust and well-established IGBT transistor technology, have an efficiency of more than 90 percent and their energy is precisely measured out. We also want to bring these benefits to the LF segment of the market in a targeted manner as of today.”
Two temperature distributions—each one after a processing time of five seconds. When using 2 kHz (left image), the desired temperature of 200 degrees Celsius appears within the corona—red means: target temperature reached. The authorized maximum temperature of 370 degrees Celsius is not exceeded. When using 12.5 kHz (right image), the maximum temperature must be increased to 420 degrees—gray means: maximum temperature exceeded.
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A typical application for the induction technology from eldec: The corona must be heated to a temperature of at least 200 but no more than 370 degrees Celsius. Two temperature distributions— each one after a processing time of five seconds. When using 2 kHz, the desired temperature of 200 degrees Celsius appears within the corona— red means: target temperature reached. The authorized maximum temperature of 370 degrees Celsius is not exceeded. When using 12.5 kHz, the maximum temperature must be increased to 420 degrees— gray means: maximum temperature exceeded. When using a low frequency of 2 kHz (left), the magnetic field penetrates deeper into the component.
For more information, Website:: www.emag.com
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Telescopic Rails & Industrial Automation: How to Increase Performance in Production Systems
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n the field of industrial automation, it is extremely important to choose a telescopic rail that can always ensure maximum performance , and guarantee that production systems function correctly. This prevents malfunctions and problems that slow the system down. The Rollon Group, with one of the most complete ranges of mechanical solutions available on the market, based on integrated and highly customizable products,
confirms its position as the ideal technological partner for anyone working in this rapidly expanding sector. Industrial automation applications: which telescopic rail is needed? In industrial situations, telescopic rails are often used for automated cantilever extractions of mobile parts of machinery. They are often operated in critical conditions, for example, with heavy loads,
demanding cycles or in dirty environments. For this reason, these systems must be reliable and guarantee optimal sliding properties for long periods of time. The use of unsuitable products can cause problems, such as reduced efficiency of the entire system or slowed production rates. Therefore, which aspects are the most important to consider to make sure we choose the right telescopic rail? The designer must carefully evaluate a few characteristics: â&#x20AC;˘ Type of movement that the rail would be making: horizontal or vertical, with a constant or variable stroke. Telescopic rails with caged ball bearings, for example, show their limits with variable strokes or vertical uses, due to the way the cage operates. Telescopic rails with rollers can guarantee in both cases good sliding movement and long working life.
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Linear solutions global provider.
Linear Line
Actuator Line
Telescopic Line
Actuator System Line
ROLLON India Pvt. Ltd. - INDIA 1st ďŹ&#x201A;oor Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA www.rollonindia.in - info@rollonindia.in
Rollon is a global provider of linear motion solutions for several industrial sectors, such as: industrial machines, railway, automation, packaging and logistics, aerospace.
TECH TRENDS
• Expected working life and load capacity: in automated applications, the rail must often operate for long periods (a few million cycles) with long maintenance intervals and carrying heavy loads. With this in mind, the characteristics of the materials become extremely important: a process of hardening the raceways, such as induction tempering or deep nitriding, can confer the hardness necessary to manage these situations in the best possible way. • Maintenance intervals: selflubricated systems, slow release grease tanks and raceway cleaners are elements that considerably prolong maintenance intervals on telescopic rails, and sometimes even manage to eliminate them. Needless to say, this quickly develops into a huge advantage in terms of cost and performance. • Speed and acceleration: a telescopic rail system is typically made up of a fixed part, a mobile part and an intermediate element. For high dynamics applications, the latter element often does not slide with optimal performance due to high stress. Accessories like synchronization systems and bumpers help increase efficiency in applications like these.
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• Misalignment: the alignment between the fixed and mobile parts of an extraction is not always precise. Often, misalignments of several millimeters are found and these reduce the life span of the rails considerably. In these cases, it is possible to undertake costly surface adjustment processes, which double assembly times, or opt for a rail that can absorb these misalignments. • Reliability in difficult environments: telescopic rails in industrial environments are almost always in contact with production residue, debris or dust. A large rolling component allows the rail to slide optimally even with impurities. • Anti-corrosion: water, liquids, acid or base solutions. A wide range of materials or anti-corrosion treatments allow the rail to be used efficiently in every environment. Telerace telescopic guides by Rollon: maximum efficiency for automation. The range of Rollon products has recently been expanded with the introduction of the Telerace family: telescopic guides with ball bearings, with double ball bearings and nitrided raceways, able to easily manage variable strokes, high speeds and stressful cycles, also in vertical
applications. These rails have large rolling components (the maximum diameter of the bearings is 31.5 mm) with internal sliders fitted with raceway cleaners and lubrication systems. The nitriding treatment ensures maximum efficiency up to 2 million cycles thanks to a raceway surface hardness of 60-62 HRC. Double ball bearings allow the system to manage heavy loads, up to around 780 kg per pair for the best performing rails (TLR 43). Lastly, Telerace rails are designed with a slight rotation of the rail elements with respect to the intermediate element, and this allows them to manage misalignments up to 2° and flatness problems up to 3 mm. Available in several different models in carbon steel or stainless steel AISI 304, these rails can be treated with the “Rollon e-coating” for greater resistance to corrosion (up to 700 hours in saline mist). For more information: ROLLON INDIA Pvt. Ltd. 1st floor, Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA Tel: +91 80 67027066 Fax: +91 80 67027004 Email: info@rollonindia.in Website: www.rollonindia.in
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TECH TRENDS
Seco Double Quattromill 14 Maximizes Low-Horsepower Machine Performance The new Seco Tools Double Quattromill® 14 cutter allows shops with lower horsepower machines to maximize their face milling operations
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he face milling cutter uses double sided inserts with 8 cutting edges for cost-effectiveness as well as for increased in depths of cut in roughing, semi finishing and finishing operations. Seco designed the Double Quattromill® 14 as a smaller version of the company’s Double Quattromill® 22, which is ideal for large machines with higher horsepower and torque capabilities. The Double Quattromill® 14 comes in 45° and 68° lead angle versions for depths of cut up to 6mm (0.236”) and 8mm (0.315”), respectively. The 45° angle, which excels in weak or unstable fixturing, provides better chip thinning and higher feed rates. The 68° angle reaches high depths of
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cut with the same size inscribed circle (I.C.) on the insert as the 45° angle, but with better clearance to avoid sidewalls or part fixturing. Unlike the inserts on standard tangential-type face mills, the Double Quattromill® 14 offers extremely free cutting to lower cutting forces and machine power consumption while it extends tool life.Double Quattromill® 14 cutter bodies come in fixed-pocket and cassette styles, with standard or close pitch along with metric or inch versions. Seco also applied its new surface texture technology to the Double Quattromill® 14’s cutter body flute surfaces for enhanced chip control and evacuation as well as durability.
The Double Quattromill® 14 offers three insert ranges with various edges and grade options. The ME10 geometry works with sticky materials such as titanium and stainless steel. The M10 geometry includes sharper edges and smaller T lands for reduced cutting force that excels at lower horsepower levels, working with sticky materials, some tool steels and super alloys. The M16 provides the best edge protection of the three insert geometries when machining abrasive materials such as steels, tool steels and cast irons.
For more information, Website: www.secotools.com
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TECH TRENDS
ESPRIT is the Formula for Success for Metri-Tech
CMM inspection of finished part programmed in ESPRIT
In its 30,000-square-foot facility, Metri-Tech manufactures ultra-precision, high-volume critical components for the aerospace, medical, defense and commercial industries
Hans L. Gratzer, Chief Operating Officer / Chief Technical Officer
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etri-Tech Engineering, Inc., in Huntington Beach, CA, isn’t your typical job shop —that much is evident from the company’s shop filled with automated production equipment, including a wall-mounted Live Scheduler, which resembles a six-foot tall iPad. Hans
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Gratzer, Jr., COO / CTO of Metri-Tech and son of company founders Hans Sr. and Katharina Gratzer, developed the scheduling program to help his 38 employees better visualize what is going on in the shop at any given time and plan for their next jobs. It’s part of the company’s forward-thinking approach to automation. “Most job scheduling systems are number-driven. But people like pictures,” Gratzer says. “With this system, what you see is what you get — kind of like ESPRIT.” Metri-Tech has used ESPRIT almost since the CAM software’s inception — Gratzer estimates they first installed it in 1988. “My dad bought the software, and he was very happy with it because we were mainly in the fitting business at that time; he liked that it could program families of parts very well — because they’re similar geometries,
they can be adjusted very easily with ESPRIT. It was a huge time savings.” But just as crucial to Metri-Tech were ESPRIT’s accurate, full-color simulations — the first in the industry. “That allowed us to give more visibility to our programming and reduce mistakes in our setup the first time around. Most of our machinists do both the setup and the machine operation, they know what they’re doing. Now they do not have to worry during the setup process and first piece run; they know the program will be right due to the precise nature of ESPRIT simulation, setup sheets and posts.” Thirty years later, ESPRIT keeps Metri-Tech at the top of its game, thanks to its ease of use and quick support. The company uses the software for full 5-axis, contour composite milling, swarf milling and multi-axis multi-spindle turning. “ESPRIT is very
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TECH TRENDS progressive in the 5-axis and multi-axis realms,” Gratzer notes. “ESPRIT is just easier, faster, stronger and more accurate than other CAM programs we have tested or demoed over the years.” In its 30,000-square-foot facility, Metri-Tech manufactures ultra-precision, high-volume critical components for the aerospace, medical, defense and commercial industries in all types of materials, including more exotic materials like Inconel, Titanium, Nitronic, Invar, Kovar, Ferrium, Polyurethane, Teflon, PEEK and Ultem to name a few. “Customers use us as a solution: they have problems and we fix them,” Gratzer says. “We’re experts in most manufacturing processes, and our customers come to us for the precision and quality of the parts we produce.” The company started out making fittings, which provided them an understanding of how they fit into the larger assemblies. This allowed them to gradually move into more complicated parts. “Doing fittings evolved into us going in the opposite direction: manufacturing the parts the fittings fit into, which were housings and manifolds. Then obviously when you get into the more complex and assembly side of medical and aerospace, you get into the critical finishes and close tolerances of the internal workings of the manifolds and housings like spool and sleeve as-
An ESPRIT simulation, for validation of a mill/ turn part prior to moving into production
semblies and shaft work. It was a very interesting and methodical transition.” The company operates 42 machines in total with a number of 3-axis Mori Seiki lathes and Nakamura-Tome lathes with up to 13 axes, which allow the company to be more creative with small parts. Metri-Tech also runs 3 and 4-axis vertical mills and several Matsuura full 5-axis vertical trunnion machines with up to 42 pallets and 520 tools. Combined, Metri-Tech’s arsenal of machines provide programmers with hundreds of pallets and thousands of different tool options. Many of the shop’s palletized machines are robotic, and the company is working to bring in mobile robots to transfer parts from machine to machine and virtual augmentation to help programmers easily view their custom manufacturing software
Metri-Tech programming ESPRIT
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and scheduler on the shop floor. Metri-Tech, which boasts an ISO AS9100D certification, offers polishing and ultra-critical finishes, as well as a high-end quality control facility in-house. “What sets Metri-Tech apart from the competition is quality on larger volumes. Anybody can make a few good parts, but consistency and repeatability over larger volumes is the key to our success. Most customers say that quality is a given nowadays; it’s truly not,” Gratzer says. “We take so many steps in assuring a quality part gets to the customer. We have a group of very dedicated employees, and everybody’s looking out for the quality of the product. The main reason why customers come to us is 100% quality, all the time. If they need a job done fast and they need it done right the first time, they come to us.” Metri-Tech’s performance has been strong since its inception in 1978, but shortly after Gratzer came to work for the company in 1998, and with his vision for technology, automation and reinvestment, they have experienced significant growth. Forecasts show it may double its business within short order and “I give credit to our passion for this industry, striving for automation and all the products we use, including ESPRIT,” Gratzer says. “I feel our next 40 years are going to be stronger than the last 40.”
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TECH TRENDS
igus introduces wide range of new products The firm will showcase Control cables with Heavy Duty connectors ready-to-connect from the catalogue
igus Readychains
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achine tool industry is booming rapidly in India with global ranking 10th in production and 8th in consumption as per Gardner World Machine Tool Output survey 2018. India’s economy may improve which is expected to strengthen government of India’s aim of manufacturing sector contributing to around 25% of country’s GDP. With 20 years of existence in India and steady growth over the year. 2018- 2019 has been one of the strongest in terms of sales with an excess of 30% over previous year achievement of 108 crore. igus India has 160+ employees with sales engineers in over 20 locations PAN India. Expansion of factory space by adding 20,000 sqft to satisfy customers need faster and with best services. Every year igus introduces new products, this time igus will showcase Control cables with Heavy Duty connectors ready-to-connect from the catalogue. Top quality and Costeffective. igus offers products from express catalogue, just select right product and in no time it’s on your machines. Harnessed chainflex® control & Power cables with Heavy
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duty industrial connectors as a premium product for your machine. 112 harnessed control cables from our catalogue from batch size 1, to your desired length and additional customised, harnessed cables on request. For every application, the most inexpensive cable that is guaranteed to do the job: 8 cable qualities. iglidur G1, the new lubrication and maintenance-free plastic bearing. igus has announced development of its improved version of iglidur G – the iglidur G1. The new material promises to reduce wear rates at low loads (up to 5 MPa) down to levels up to a quarter of what they were before.
With this new material, customers can reduce costs by around 40 per cent, the service life under heavy loads has almost been doubled, depending on the application parameters. At the same time, the all-rounder can now be used continuously at temperatures up to 180degC (iglidur G: 130degC). In conjunction with the more than 50 per cent reduction of moisture absorption, this means that the material is suitable for an even wider range of ambient conditions. Initially, iglidur G1 will be made available in 113 standard dimensions in the form of cylindrical bearings and flange bearings. More to add we have Motor control system dryve D1, for all igus® motors ST, DC, EC/BLDC. This is wide range of automation tasks by simple parameterization in which no programming is necessary with no software installation or app needed. It is controlled by means of a PC, tablet or smart phone. This can be used for single axes, line, flat linear and room linear robots and delta robots. Stepper
Wear results compared PA 12 with igus I3-PL.
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TECH TRENDS In Industry, selective (ST), DC and EC/BLDC laser sintering is currently motors with up to 21A peak one of the most widespread currents and 48V. Digital manufacturing methods in inputs/outputs, analogue additive manufacturing. inputs, CANopen, Modbus igus is now expanding its TCP for connection to 3D printing service with master control systems such this method, so that wearas Siemens or Beckhoff. resistant prototypes or small The advantages of the batches of components for drylin® delta robots are moving applications can be it is Lubrication-free and Motor control system ® made quickly, easily and maintenance-free drylin dryve D1, for all W toothed belt axis with igus® motors ST, DC, delivered in a short time (at EC/BLDC least 2 weeks). igus offers pick rate of 60/min due to selective laser sintering lightweight components (SLS) with wear resistant highmade of plastic and aluminum. Its performance plastics I3-PL in addition Workspace is up to Ø 360 mm. This to the FDM method. Small batches of can be used for pick-and-place tasks, up to 500 parts made of iglidur I3-PL such as belt transfer stations, Sorting can now be printed. Components that systems, Assembly systems, Joining has complex geometries but now can processes, Handling of small parts be made quickly and at low cost. and for fast positioning tasks
Bus cable (PUR), chainflex CFROBOT8.PLUS are world premier + 360 degree on robots. They have 10 million double strokes guaranteed, 10Xd bend radius, e-chain with 3D movements as its travel distance. This is best for torsion applications with PUR jacket, shielded with advantages of oil resistance and coolant resistance, flame retardant, notch resistance and most important hydrolysis and microbe resistant. igus ibow adapter (MAT904104175) is suitable for 923 power connectors, size 1 can be retrofitted for an angle of 90 degree or supplied ready-made as a harnessed igus readychain. This is secure, flexible, cost effective and customized. For more information, Website: www.igus.in
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TECH TRENDS
Threadmills achieve around 20 to 40% increase in tool life compared to other threading processes ANCA’s LaserPlus in process measurement enables lights out manufacturing of large volumes of Threadmills
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hread milling is a versatile, cost-effective process for cutting a variety of threads, parts and workpiece materials on the same machine. This process produces an internal or an external thread by doing a helical interpolation on a CNC-machine which can make helical paths. Thomson Mathew, ANCA Product Manager said: “Threadmills generate superior burr-free surface finishes and reduce tool inventory costs. Shops can use the same tool for both left and right-hand threads as well as for different thread tolerances. A broad range of materials and hole diameters can also be thread milled with the same tool. Unlike tapping, threads produced through milling can be machined to full depth at high accuracy, even in hardened materials. Some of the other advantages are faster cycle times and less tool breakage – basically these are a really
effective tool.” Advantages of the Threadmill • Provides a 20-40% increase in tool life compared to other threading process • Increased strength and rigidity specially on hard material when cutting forces are applied. • Reduces inventory costs of tooling. • Threadmill Inserts allow for small to larger cutter diameters. Thomson continued “Our Tool and Cutter grinders can effectively manufacture a range of Thread Milling cutters. Customers wanting to manufacture this cutters in large volume or for lights out manufacturing can make use of the Blum laser for measurement and compensation inside the machine.” “There are so many great applications available that people are not familiar with. For example
– Thrilling. This is the process of threading and drilling (accomplished in the reverse order). The cutting tool tip is shaped like a drill while the body has a thread-shaped form with a countersink cutter form near the shank. The cutter first plunges to drill the hole and then the thread is circularly interpolated while the chamfer is also formed. The advantage is this process eliminates a tool, tool-holder, and tool change.” Blum laser support measurement and compensation The Blum laser inside the machine can measure and compensate the tool diameter and crest width as shown above. There is option in software to control the upper and lower tolerance for the diameter compensation. The software has two different operations for thread grinding and cresting. This allows you to choose roughing and finishing wheels for threading and to use number of passes if required. The Laser measurement is done after the cresting for diameter and width compensation.
For more information, Website: www.anca.com
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Taming power quality is now child's play
When you use DigiVolt Stabilizers, Tranquil Ultra Isolation Transformers and Powercon Power Conditioners from Unity Controls, power quality is under total control and would no more hamper your production and product quality. These silent sentinels protect your sophisticated, high precision production equipment from the ill-effects of voltage, spikes, surges, transients, sags, noise and harmonics affecting AC power lines. Thus ensuring continuous uptime and enhanced productivity and consistent quality.
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CASE STUDY
Renishaw & Hartford combine to deliver intelligent, ‘Smart Factory’ solutions
In the face of global skills shortages and rapidly emerging Industry 4.0 trends, Taiwanese CNC machine manufacturer Hartford undertook to develop an innovative, easier-to-use human machine interface (HMI) for its CNC machines. At the same time the company strived to ensure process measurement and inspection at its CNC machine manufacturing operations could keep pace with ever-improving product quality goals
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stablished in 1965, Hartford is Taiwan’s biggest exporter of CNC machining centres as well as being the country’s largest machining centre manufacturer. It is recognised as one of the CNC machining industry’s leading global brands with a reputation for technological advancement. Hartford’s comprehensive range of machine tools is used extensively by major manufacturers including Airbus, Boeing, CRRC Corporation, Ferrari, Ford, Foxconn, LG, Pratt & Witney, Samsung, Siemens and Volkswagen. Developments in Industry 4.0 technology and world shortages in skilled labour have meant that
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forward-thinking CNC machine manufacturers like Hartford are placing greater emphasis on automation, connectivity, data transparency and ease-of-use. However, achieving Industry 4.0’s goals of ‘intelligent manufacturing’ and the ‘smart factory’ still relies on accurate and effective process control systems. They need to be easy-to-use and provide sufficient immediate data to enable self-correction and adaptation to any sources of process variation. Achieving the goal of ‘intelligent manufacturing’ For Hartford, a global company that has exported 46,000 machines to
65 countries across Europe, North America and Asia Pacific regions, maintaining the very high quality of its product in the face of rapid technological and economic change and fierce international competition is a key consideration. At its manufacturing facility in Taiwan, the company produces a complete range of medium to large-sized three-axis and five-axis CNC machines for use in major industry sectors including aerospace, automotive, electronics and energy. Its product range comprises vertical machining centres, precision boring machines and gantry-type machines. With more than 95% of Hartford’s cast components being manufactured
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HIGH QUALITY FOR YOUR HIGH QUALITY FOR YOUR MACHINERY MACHINERY
MGM brake motor main features • TEFC 3-ph asynchronous brake motor (0.09kW-130kW)
MGM motor main orfeatures • ACbrake 3-ph brake (no rectifier) DC brake on request
• TEFC 3-ph asynchronous brake motor (0.09kW-130kW) • Oversized brake disc for higher brake torque, longer life and • AC reduced 3-ph brake (no rectifier) or DC brake on request maintenance • Oversized brake fortorque higher adjustment brake torque, life and • Fine and easydisc brake (aslonger standard) reduced maintenance • Very quick brake reaction time • Fine and easySTART/STOP brake torquecycle adjustment (as standard) • Frequent applications • Very quick brake timestandard) • Manual brake reaction release (as • Frequent START/STOP cycle applications • Hexagonal hole on non drive end of the shaft for manual rotation • Manual brake release (asspeeds standard) • Single speed or two motors • Hexagonal holedesigned on non drive end of the shaft for manual rotation • All motors for inverter duty • Single speed or two speeds motors • All motors designed for inverter duty
VARVEL production lines • RS-RT worm gearboxes: 28 to 150 mm centres.
VARVEL production lines and double worm. One stage worm, helical/worm
• RS-RT mmNm. centres. • RD worm helicalgearboxes: gearboxes:2850toto150 2300 Two and three stages. One stage worm, and double • RN parallel shafthelical/worm gearboxes: 180 to 3300 Nm.worm. Two and three stages. • RD helical gearboxes: to 2300 Nm. andNm. three stages. • RO-RV bevel/helical50 gearboxes: 180 Two to 3300 Three stages. • RN shaft gearboxes: to 3300 Nm. and three • parallel RG precision planetary180 gearboxes: 10Two to 230 Nm. stages. • RO-RV gearboxes: 180 to 3300 Nm. Three stages. Onebevel/helical and two stages. • RG precision planetary 10 to 230 Nm. • VR dry friction speedgearboxes: variators: IEC63 to IEC90 One1and stages. to 5two stepless speed range, 300 to 1500 rpm. • VR• dry friction speed variators: IEC63 to to IEC90 VS planetary speed variators: IEC71 IEC112 1 to15tostepless speed range, 300200 to 1500 rpm.rpm. 5 stepless speed range, to 1000 • VS planetary speed variators: IEC71 to IEC112 1 to 5 stepless speed range, 200 to 1000 rpm.
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CASE STUDY and machined in-house, a continuous and progressive approach towards quality inspection is essential for achieving the precision required for a wide range of machine components, including machine heads, spindles and automatic tool changers. Helping customers cope with the widespread shortages of skilled labour presents Hartford with a further vital challenge to address, as Mr Bruce Lin, Manager of Hartford’s R&D Intelligent Technology Department explained: “Our customers are needing to process work pieces of increasing complexity, however a lack of skilled labour means they are having to insist on machining centres that are even simpler to use.” Intelligent HMI with Renishaw app Hartford has invested significant resources into the research and development of intelligent CNC controllers in recent years and developed Hartrol Plus. The Hartrol Plus intelligent controller is as simple to use as a smartphone. The HMI provided by the Hartrol Plus CNC controller follows key design principles promoted by
Hartford uses the Renishaw QC20-W ballbar to check machine positioning performance
Set and Inspect on-machine app integrated with the Hartrol Plus CNC controller
Industry 4.0 ideals and helps address skills shortages. It provides machine operators with all the information they need to make the right decisions. The way in which it visualises data helps operators to make more informed decisions and solve problems more quickly. Renishaw’s Set and Inspect onmachine app has been integrated with Hartford’s new controller, enabling users to exploit advances in automated measurement and
data collection, making machine tool operation and human-machine interactions simpler and more intuitive. Set and Inspect is a highly visual graphical user interface (GUI) which leads the operator through every step of on-machine probing processes including workpiece set-up, tool setting and other measurement tasks. Operators no longer need to commit machine code instructions to memory, reducing data entry errors and programming times, as well as increasing processing efficiency by as much as 20%. Hartrol Plus has been well received by customers, with more than 1,000 units sold to date. Precision measurement for high quality CNC manufacturing Hartford began using Renishaw products more than 20 years ago. In order to meet its stringent highquality objectives, the company has introduced a variety of Renishaw high-precision measurement systems. The precision of all CNC machined components it manufactures is verified using Renishaw PH20 5-axis
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CASE STUDY
Hartford produces a complete range of medium to large-sized threeaxis and five-axis CNC machines
probes on co-ordinate measuring machines (CMMs). This happens before components enter the assembly line, to ensure that they are ready to be assembled. Precise assembly and positioning of machine tools is also critically important, with five-axis machine tools needing to be positioned with a deviation of less than ±6 µm. A Renishaw XL-80 laser interferometer is used to measure machine position and both linear and angular errors. The XL-80 generates an extremely stable laser beam with a wavelength that conforms to international standards. Linear measurement accuracy of ±0.5 ppm can be guaranteed, thanks to a precision stabilised laser source and accurate environmental compensation. Hartford uses the Renishaw QC20-W ballbar measurement system to perform cross-validation at different operating speeds to ensure that X- and Y-axes of the machine tool are correctly matched, and errors are kept down to less than 5 µm. Every Hartford CNC machine not only undergoes 100% laser
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verification and ballbar testing before dispatch, it can also use the customer’s own workpiece for processing verification, with Renishaw OMP40, OMP60 and RMP60 machine tool measurement probes used to measure the precision of the processed work piece. AxiSet™ Check-Up for rotation centre compensation Hartford also uses Renishaw AxiSet Check-Up to analyse the performance of machine rotary axes. Compatible with common 5-axis and multi-axis machines, it provides CNC machine users with a fast and accurate way to check the location of rotary axis pivot points and automatically compensate if necessary. Importantly, AxiSet Check-Up does not need to rely on operator experience, as the operator can simply call up the relevant program and press ‘Cycle Start’ to complete the test process in just a few minutes. Data is automatically recorded into parameters for use in analysis, further guaranteeing the standardisation of every machine tool produced.
Mr Lin said, “We also recommend that users use AxiSet Check-Up to test the machines’ rotary axes after they are installed, as factory conditions may differ significantly from Hartford’s manufacturing conditions, in terms of foundations and how level surfaces are. Shipping and installation can also cause precision errors, so AxiSet CheckUp’s automatic compensation allows machine tools to maintain high levels of precision and quality.” He continued, “All machine tools can suffer from wear and drift after a certain period of usage, with the level of precision of their positioning declining over time and causing a correspondingly poor level of machining precision. We therefore recommend that users perform scheduled checks on machine tools using AxiSet Check-Up every 6 to 12 months, in order to ensure that the level of machining precision remains consistent and productivity remains high.” In the manufacture of its worldleading brand of CNC machines, Hartford’s on-going commitment to stringent quality inspection has seen the company continuously embrace the latest thinking in process measurement techniques. Its imaginative use of leading-edge Renishaw measurement solutions over time has helped sustain its global competitive edge and reflects Hartford’s bold corporate philosophy: “We are here to make the best machines to the highest standards.”
For more information, Website: www.renishaw.com
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Woodworking Machine OEM goes 100% Mitsubishi Electric With the success of the VFDs, Unique Machine has evolved to a 100% Mitsubishi Electric solution, incorporating servo motors, PLCs, cables, and, most recently, HMIs
A
leading manufacturer of woodworking machinery is leveraging the benefits of the latest automation technology from Mitsubishi Electric.Fed up with the disadvantages of using automation products from a mix of different suppliers, Phoenix, USA-based Unique Machine & Tool Company wanted to find a reliable singlesource supply partner. The OEM eventually settled on Mitsubishi Electric and, after initial success with VFDs, soon adopted servo motors, PLCs, cables and HMIs from the same supplier. Reliability and brand reputation have subsequently improved immensely, with Unique Machine today making ‘100% Mitsubishi Electric’ a major part of its sales presentations.
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Established in 1969, Unique Machine manufactures high-quality automated woodworking machines, used mostly by cabinet shops and door manufacturers in the design of custom kitchens and similar applications. Products include shapers and sanders, raised panel door machines, CNC machining centres, mitring machines, and dedicated cope and stick stations. Back in the mid-1990s, Unique Machine began the transition from manufacturing mostly manual machines, to producing highly automated, extremely user-friendly systems, pushing the limits of thenavailable technologies. “We had a ‘plug and play’ vision that was relatively new at the time,”
explains company President Jeremy Lutringer. “To bring it to fruition, we had to use an eclectic mix of products from different automation manufacturers, and that caused a lot of problems. Whenever there was an issue, the different manufacturers would point fingers at each other and not take responsibility. It was very frustrating.” In addition to lacking a single point of responsibility, the need to depend on a multitude of manufacturers for different components was adding complexities and driving up costs. “We had to continually write new drivers to make the different components talk to each other, and we also had to have custom cables designed,” explains Software & Controls Engineer Jon Mattson. The way to rectify the situation seemed clear: find and partner with an automation company that could offer a complete product line. Unique Machine came across a major automation supplier that seemed to fit the bill. However, the company soon discovered that the service and attitude of its new partner left a lot to be desired. “Their business model was to lock you into software service and upgrade agreements, as well as licensing fees, which had to be paid on an ongoing basis,” says Mattson. “That may be acceptable or even advantageous in some industries, but in the woodworking sector our customers are accustomed to paying for a machine once and having it run for 30 years. Demands for ongoing technical
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CASE STUDY fees just don’t fly.” But, Mattson notes, the real damage to Unique’s reputation was yet to come. “Our supplier was not providing very good support; if we had a problem with one of their products they would either put a band aid on it, or not respond at all. Furthermore, they suddenly dropped a couple of products we were using and stopped all support service for them. That made us look really bad to our customers.” Frustrated, Unique Machine decided to find another supplier, but was committed to proceeding conservatively. “Mitsubishi Electric had been calling on us and we decided to give them a try, but we had been burnt and didn’t want to jump from frying pan to frying pan,” explains Lutringer. “We decided to trial their VFDs in the first instance. They’re relatively simple components, and since we had used about 10 different brands of VFDs before, we would be able to weigh the relative quality right away.” Almost immediately, the Mitsubishi Electric VFDs showed themselves to be far superior to any brand the company had used previously. “The reliability of Mitsubishi Electric VFDs was far better than anything we had ever experienced, both out of the box and out in the field,” confirms Mattson. “With our previous supplier, we might experience five or six VFD failures out of 15 machines. However, with Mitsubishi Electric I can’t think of a single failure, and we’ve used many, many more Mitsubishi Electric VFDs.” Lutringer adds: “Other drives would throw up errors and stop working at the first hint of heat. Woodworking shops can run hot and that was a big problem, but the
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Mitsubishi Electric drives stand up to the harshest conditions and just keep working.” In addition to huge improvements in reliability, the Mitsubishi Electric VFDs are providing a number of other benefits to Unique Machine and its customers. “Mitsubishi Electric drives are very easy to program,” states Mattson, by way of example. “The interface on the front of the drive and an autotune feature that lets you simply plug in the characteristics of a new motor, save a lot of time. And, with other brands, we would have to put in separate braking resistors to stop the motor quickly in an emergency. In contrast, the Mitsubishi Electric VFDs do it on their own, in less than 10 seconds, and without any risk of overheating that can plague resistors. This integrated safety is a big plus as it helps us optimise the safety of our equipment while saving on cost and providing a much neater, clutter-free cabinet that really projects ‘troublefree’ to our customers.” With the success of the VFDs, Unique Machine has since evolved to a 100% Mitsubishi Electric solution, incorporating servo motors, PLCs, cables, and, most recently, HMIs. “We had been using Windows PCs for many years because we liked the flexibility and functionality they allowed for creating full-featured interface screens and, for a long time, industrial HMIs just couldn’t compare,” says Lutringer. “This has all changed with Mitsubishi Electric HMIs, which offer a lot of flexibility as well as feature-rich functionality. There was a smooth learning curve and we are very happy with the graphic capabilities, object actions, image sharpness and quality, even compared with full-featured PCs.” Now offering 100% Mitsubishi Electric components in most of
its machines, Lutringer feels that the partnership has given Unique Machine a big advantage. “100% Mitsubishi Electric is definitely something that we highlight in sales presentations,” he says. “Most customers know that having a single, high-quality brand of components on-board makes for easier troubleshooting. Also, I think that the Mitsubishi Electric brand name carries a connotation of quality that no other can match in this space.” That quality, Lutringer notes, is something that Mitsubishi Electric has worked hard to maintain for the company over the years: “We’ve been very happy with the level of support that we get. Access to engineers, customer service, sales – whatever we need – it’s always there. It’s in stark contrast to what we’ve experienced with other automation suppliers.” With Mitsubishi Electric by its side for several years now, Unique Machine has enjoyed some of its greatest successes in nearly half a century of trading. “If we hadn’t found a stable automation partner we probably wouldn’t have had some of these results,” concludes Lutringer. “Bottom line; I think Mitsubishi Electric adds confidence for us when we ship a machine out the door, while our customers also have confidence in the products because of the automation technology they feature.”
For more information, Website: www.MitsubishiElectric.com
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PRODUCTS SHOWCASE
PRODUCT SHOWCASE The new Gast 86/87R Series of oil-less rocking piston compressors & 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 :
For Product Enquiry Contact 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 Phoned: 020-2615 9641 Email: shavogroup@vsnl.com
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“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.
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PRODUCTS SHOWCASE
“Torpedo” High Performance Range Tools: Indian Tool Manufacturers “ITM” – (A division of Birla Precision Technologies Ltd.) has newly launched Torpedo Taps and Drills & End Mills. ITM focuses on its R&D department to continuously develop exceptional quality products for its customers. As a result of this extensive study and continuous efforts, we proudly introduce ITM “TORPEDO” advanced new range of products to compete with international standards to ensure Superior Performance, Extra Tool Life and Guaranteed Results. I) Torpedo Series Taps are made out of the highest quality of Powder Metallurgy HSS materials. These High Performance Taps are manufactured on our latest CNC Machines, with specific geometries to suit different machining applications, based on work materials. ITM Torpedo series Taps consists of Spiral Flute, Spiral Point, Roll Form, and Straight Flute-Cast Iron. To enhance the performance of taps, we can supply these taps with surface treatment like TiN, TiAlN, TiCN etc. 1. Spiral Flute Taps are best Suited for Blind Hole applications and are specially designed to eliminate chip clogging, they are available in size range of (Size Range: M3 to M16). 2. Spiral Point Taps are specially designed for Through-Hole application and are suitable for higher cutting speed for higher productivity. (Size range is from M3 to M16). 3. Roll Form Taps is best suitable for both Blind and Through-Hole application. Roll forming operation is chip-less operation, forming a thread by displacement of materials and not by cutting, hence these taps are best suitable for soft materials like Aluminum, Brass, Bronze etc., (The size range is from M6 to M16.) 4. Straight Flute - Cast Iron Taps are best suitable for Cast Iron material and size range is from M3 to M16. II) Torpedo Series of Drills are also made out of the advanced grades of HSS PM materials. These Drills are produced on our latest CNC Machines, with unique geometries to give better accuracy holes and excellent performance. These drills are developed to machine hardened steel materials like Stainless Steel, Nickel Chromium Steel and Forged Steel etc. These Torpedo High Performance Drills are designed having Special point geometry to reduce thrust forces while drilling. Size range in metric as per IS 5101 Metric Size 3.0mm to 13.0 mm Inch size as per BS 328 Inch Series: 1/8”to ½.”
For Product Enquiry Contact Birla Precision Technologies Limited Email: itmth@indiantool.com
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III) Torpedo Series of End Mills are made out of best quality of HSS grade of Materials. These High Performance End Mills are manufactured from our latest CNC Machines, with special geometry to give better performance with higher productivity. These End Mills best suitable for materials like Stainless Steels, Nickel Chromium steels and tougher machining applications. These new series of our “Torpedo” range of Products are new generation tools which will work at higher cutting parameters on latest CNC Machines and we are very confident that these products are best solutions for your higher productivity.
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PRODUCTS SHOWCASE
Precision Ball Screw Spline-PBSA Series The Precision Ball Screw Spline contains Ball Screw grooves and Ball Spline grooves that cross each other on a single shaft. The Precision Ball Screw Spline nut has a special designed support bearing directly set up on the outer ring of the nuts. The Precision Ball Screw Spline is capable of performing three modes of motion (rotational, linear and spiral) with a single shaft by rotating or stopping the spline nut.
For Product Enquiry Contact Superslides & Ballscrews Co. India Pvt Ltd SUPERSLIDES HOUSE, A-774 T.T.C Industrial Estate, MIDC, Firebrigade Road, Off Thane- Belapur Road, Koparkhairne, Navimumbai-400 701 (INDIA) Tel.: 022-4935 5555 (40 Lines), Fax: 022-4935 5556 E-mail: sales@superslides.in / info@superslides.in Website: www.superslides.in
Features 1. High Positioning Accuracy: The Ball Spline groove preload is designed Gothic arch. By applied preload, the backlash in the rotational direction is eliminated therefore having higher positioning accuracy. 2. Lightweight and Compact: Spline nut and the support bearing is integration structure. The Spline nut is designed lightweight. Therefore, the highly accurate and compact design is achieved. 3. Simple Installation: The balls recirculation in ball holder, prevent balls falling from the spline nut while assembling. 4. Support Bearing: The support bearing of the Ball Screw is designed a contact angle of 45°, thus it has higher axial rigidity, while Ball Spline has a contact angle of 45°, thus it has the average force of axial and radial direction. 5. Smooth Motion and Lower Noise: As the Ball Screw is adapting end cap recirculation structure, thus can be smooth motion with lower noise. Application SCARA robot, Assembly robot, Automatic loader, and Machining center’s, ATC equipment.
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 and 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.
For Product Enquiry Contact Ador Welding Limited Akurdi Chowk, Chinchwad, Pune 411 019 Tel.: 020- 4070 6000 Email: cmo@adorians.com Web: www.adorwelding.com
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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, and • 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, & Electrical grounded cable L= 5 m with plug.
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PRODUCTS SHOWCASE
Diamond cut knurled control knobs with collar or flange
For Product Enquiry Contact Elesa and Ganter India Pvt. Ltd. A-54, Sector - 83, Noida 201 305 (U.P.) INDIA Tel. +91 120 472 6666 Fax +91 120 472 6600 Email: info@elesaganter-india.com Web: www.elesa-ganter.in
Control knobs are suitable to perform adjustment or precise alignment of machine parts and precision instruments. This kind of activities require high reliability and the best grip as essential features. New MBR. diamond cut knurled control knobs are available with collar or flange with laser-engraved precision graduations or triangular index. Marks help to identify visually the current position of the instrument’s body. The fine pitch knurling on the rim of the knob improves the grip providing more comfort for the operator’s hand during rapid rotations – no unpleasant angular work for the hand and wrist – and greater sensitivity for fine adjustments. MBR. control knobs are also available with rear compartment for potentiometer housing. Compact shape and modern design together with coloured centre cap, available in the seven ELECOLORS® - Pure Orange, Light Grey, Colza Yellow, Flame Red, Pastel Blue, Jet Black and the newly introduced May Green - allow the perfect aesthetic compatibility with the machine they are destined for. Moreover, the possibility to have different colour options help in identifying different machine functions, improving safety. In addition to the wide standard range (combinations of dimensions, collar, flange and coloured caps), MBR. control knobs can be customised with caps in other colours, graphic symbols, marks or writings and with flange with special graduations. Product technical data sheets, along with drawings and tables with codes and dimensions are available on our website elesa-ganter.in.
Steady Volt Servo Voltage Stabilizers Frequent voltage variations are a menace that can damage electronic components like power supplies, drives, PLCs, controllers, etc. Their effects are widely felt in CNC, printing and textile machines as well as laboratory, data processing, medical & telecommunication equipment. Frequent breakdowns of such machines are costly to repair. This apart, the downtime and frequent interruptions in operation brings substantial loss of revenue. Steady Volt from Unity Controls is a state-of-the-art Voltage Stabilizer designed to protect such equipment from voltage variations and its ill-effects.
For Product Enquiry Contact Unity Controls Pvt. Ltd 405, Sapphire Arcade, 42 M.G. Road, Ghatkopar (E), Mumbai 400 077 Phone: 022- 2501 3832 / 33 E-mail: sales@unitycontrols.in Web: www.unitycontrols.in
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Following are some of its unique features: • Intelligent microprocessor-based system(available in new digital models) • Digital interface with large LCD display and keypad • Auto re-start, adjustable output voltage, trip bypass, fault list • No hunting, oscillation and noise generation • Innovative transformer design to minimize power loss • Constant output voltage across a wide input voltage range • Single phasing prevention, surge suppressor and EMI / RFI filter With the best-in-class response time and correction rates, Steady Volt offers improved power quality and greater energy efficiency, thereby saving the cost of breakdowns and energy utilization. Apart from protecting your equipment from damage, Steady Volt also saves energy during continuous operations.
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PRODUCTS SHOWCASE
Super compact safety module More safety in a space-saving 17.5 mm
For Product Enquiry Contact DOLD Electric India Pvt Ltd (100% Subsidiary of E.DOLD & Sohne Kg - Germany)
B – 3 Vishranti Heritage, Gotri Road, Vadodara – 390 021 Call: +91 990 9001585 Website: www.dold.in
The 17.5 mm wide e-stop module UF 6925 of the SAFEMASTER series offers the highest safety in the narrowest spaces. The device is well-suited to monitor emergency stop buttons and safety gates in almost any application. Its broad voltage range from DC 8 to 36 V makes it impervious to voltage fluctuations, such as those that occur when activating battery-fed devices. This predestines the safety module for a great variety of applications in machine and plant engineering and in mobile applications. The emergency stop module fulfils the highest safety requirements, up to PL e / Cat. 4 or SIL 3. In comparison to other safety modules available on the market, the device saves over 20% of space in the switch cabinet. Besides its low space requirements, the safety module also stands out for its time-saving wiring, which requires no tools. The push-in cage clamp terminals on the front side ensure fast and easy device connections. Switches on the back of the device provide a temper-proof setting. This allows the operator to select the start type and cross fault detection. LED displays facilitate fast diagnostics. It can be used in battery-operated systems, driverless transportation systems, construction vehicles, and crane equipment. In addition, the safety module is permitted for use in furnaces pursuant to EN 50156-1 and for safety related systems for the process industry pursuant to IEC/EN 61511.
Nexgen Refrigerated Air Dryers
For Product Enquiry Contact GEM Equipments (P) Ltd. SF No.103, Avinashi Road, Arasur, Coimbatore 641 407 Phone: 0422-2363800 / Email: sales@gemindia.com
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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, and larger heat transfer area for higher efficiency. The rugged electronic panels display both inlet and dew point temperatures. They incorporate a Tripper module 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.
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ADVERTISERS INDEX COMPANY NAME
PG. NO.
A ACE MICROMATIC GROUP
BACK PAGE
ADOR WELDING LIMITED
85
ANCA MACHINE TOOLS PRIVATE LTD APEX PRECISION MECHATRONIX PVT. LTD. AUTOMOTIVE ENGINEERING SHOW - 2019
COMPANY NAME
FIBRO INDIA PRECISION PRODUCTS PVT. LTD.
65
P
FLIR SYSTEMS INDIA PVT. LTD.
33
PARAGON MACHINERY CO. LTD.
25
PRECIHOLE MACHINE TOOLS PVT. LTD.
103
PRECISION MOTION INDUSTRIES, INC. ( PMI )
23
G GEDEE WEILER PRIVATE LIMITED
11
101
GEM EQUIPMENTS (P) LTD.
31
GLEASON WORKS (INDIA) PRIVATE LIMITED
35
GLOBE-TECH ENGINEERING EXPO - 2019
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GP PETROLEUMS LTD.
39
41
51
CNC SOFTWARE, INC.
INSIDE BACK COVER
CRANE-BEL INTERNATIONAL PVT. LTD.
83
D
ELGI EQUIPMENTS LTD. ENGIMACH - 2019 EPPINGER TOOLING ASIA PVT. LTD. ERWIN JUNKER MASCHINENFABRIK GMBH
63
R RENISHAW INDIA (PUNE)
49
IMTOS - 2019
111
ROLLON INDIA PVT. LTD. - INDIA
95
INTEC - 2019
29
RR KABEL LIMITED
99
J
S
JERGENS INDIA PVT. LTD.
59
JYOTI CNC AUTOMATION LTD.
17
75 21
15 27 109 86 - 87
9
F FACCIN S. P. A.
19
FATTY TUNA INDIA PVT. LTD.
43
SHAVO TECHNOLOGIES PVT. LTD.
91
T
MARPOSS INDIA PVT. LTD.
73
MEERA CASTING
79
MGM-VARVEL POWER TRANSMISSION PVT LTD
107
MICRO-EPSILON INDIA PRIVATE LIMITED
81
MILLENIA TECHNOLOGIES
70 - 71
E ELECTROTHERM (INDIA) LTD.
Q QVI INDIA PVT. LTD.
M DUTCH TECH TOOLS PVT. LTD
PG. NO.
I
C
DOWEL ENGINEERING WORKS
PG. NO.
7
B BIRLA PRECISION TECHNOLOGIES LIMITED
COMPANY NAME
THE ASSOCIATION FOR MANUFACTURING TECHNOLOGY
53
TRUCUT PRECISION TOOLS PVT. LTD.
FALSE COVER
U UNITY CONTROLS PVT. LTD.
105
W MITSUBISHI ELECTRIC INDIA PVT. LTD.
13
MMC HARDMETAL INDIA PVT. LTD.
INSIDE FRONT COVER
54
Y
O OERLIKON BALZERS COATING INDIA PVT. LTD.
WOHLHAUPTER / ALLIED MACHINE & ENGINEERING COMPANY
INNER INSIDE FRONT COVER
YG-1 INDUSTRIES INDIA PVT. LTD.
MARCH 2019
FRONT GATEFOLD
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Inside Story
Mr.
Ramji
Singh
Vice President â&#x20AC;&#x201C; Sales & Marketing, Schmersal Group
My Lifeâ&#x20AC;&#x2122;s Goals Vision: To manage a company of more than 100 crore turnover with a responsibility of Top management. Social Goal: To help poor children in their education and make them independent. Business Goal: Top Management role to handle entire company operation of more than 100 crore & more than 100 member team.
My Leisure Choices Favourite Tourist Spot: Northeast India. Music I Like: Guitar. Sports I Love: Volleyball & Cricket.
Ask my Taste Buds Favorite food: Choley Bature Favourite Drink: Orange Juice.
In Awe of I Admire: The Military, in this world of Villains & Heroes, They are my heroes. Their Dedication, their commitment, their Discipline, their code of Ethics is beyond comparison.
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WE HAD A GREAT SHOW !
YOU CAME TO SEE US. YOU SAW OUR SOLUTIONS. YOU INSPIRED US.
Thank you! Letâ&#x20AC;&#x2122;s stay connected ! Email us at :
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Call us at
+91 7378 55 2000
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Mastercam India 303 - Tower 1, World Trade Centre, Kharadi, Pune - 411014, Maharashtra, India
RNI No. MAHENG/2015/64267 Postal Reg. No. THC/173/2018-2020. Posted at Mumbai Patrika Channel Sorting Office G.P.O. Mumbai 400 001 on 15th of every month and Published on 10th of every month
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