Turning workplaces into safer places.
www.schmersal.in info-in@schmersal.com +91 2138 614 743
Patented Modular Safety Fence Solution along with Safety products for Robotics and other applications as per International Standards.
Visit us at: ACMEE Expo 2018, Hall A, Booth no. 51, 21 – 25 June 2018, Chennai, India
Volume 03 No. 12 | May 2018 | ` 150
Pages 112 | RNI No. MAHENG/2015/64267
QUALITY CUTTING TOOLS
Automotive
AerospAce
Die & moulD
GenerAl enGineerinG
CEO CORNER INNOVATION - The latest trend In decades past, the concepts of robotics and miniature technology we’re familiar with today fell outside the realm of what was possible, yet technological advances are catching up to and even surpassing these ideas. These new breakthroughs are having such an impact that manufacturing is experiencing what many consider to be a new industrial revolution. To achieve this Industry 4.0 goal will be challenging for manufacturers but within their grasp. Industry leaders are emerging who have broken away from the traditional factory structure and built companies spearheading the charge. Although there has been significant movement from larger companies, those established manufacturing leaders are still heavily encumbered by bureaucracy and face challenges in moving quickly with a unified vision. So, it’s not surprising that smaller, more agile companies are the ones rapidly innovating in the world of manufacturing. In addition to their lean operations and motivated teams of specialized professionals, startups in particular are being propelled in their competitive quest to gain market traction through significant funding from the VC community. Industry drivers are already riding this wave of “smart-factory” innovation, implementing advanced analytical software, automated services and short turnarounds, with high precision. The strides being made in the manufacturing industry through new technologies are nothing short of fascinating and it’s certain that even more advancements will be made. As technologies become faster, smaller and more sophisticated, they’ll be originating in factories and shops where these new procedures are being used. Both businesses and consumers will be benefiting from these innovations, as people’s health and longevity are improved, communication becomes easier and manufacturing is simplified for a variety of companies.
CEO
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MACHINE TOOLS WORLD MAY 2018
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 69911, E: indiainfo@anca.com, W: www.anca.com
www.mtwmag.com
Publisher & Printer Shirish Dongre
CEO
Contents
Vol 3 Issue 12 | MAY 2018
COVER STORY
Shekhar D.
Editor Shilpa Dongre
Assistant Editor Huned Contractor
Marketing Team Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, Vinod Surve, Kamlesh Balkrishna, Kavita Chaudhari
Designer & Layout Arun P. Shinde, Nandan S. Moghe, Dinesh S. Gawade
LMT Tools India : Recognition for performance with excellence
Online Division Ganesh Mahale
Circulation Executive Satish Kadam, Amol Ranshur Branch Offices (Zonal)
Mr. Ramakant Reddy Managing Director LMT Tools India Pvt. Ltd.
40
NORTH (Delhi & NCR regions) Sandesh Jain : 09810837877 / 09871602777
SOUTH (Chennai & Coimbatore) Y. V. Raghu : 09566141224 Bangalore Vaman : 09686721340
EAST (Kolkata & Other regions) Kamlesh B. - 09819464242
WEST (Maharashtra & Gujarat) Pune Shilpa K. - 09833373371 Gujarat Dinesh Shah - 09327344559 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 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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MACHINE TOOLS WORLD MAY 2018
BUSINESS NEWS
INDUSTRY SPEAK
20
Mitsubishi Materials introduces MVX Drills with new chip breakers and grades
20
Mastercam’s Wildest Parts Competition Gets a Boost
22
Die & Mould India International Exhibition concludes on a high note
22
EOS launches new EOS P 810 Polymer Industrial 3D Printing Platform
24
Schmersal India inaugurates its First global support IT centre in Pune
Green Manufacturing Practices at ELGi Green Manufacturing Practices at ELGi
32 IN FOCUS
In the right mould: Sridevi Tool Engineers
26
Prestigious award for Renishaw’s Indian software team
34
Most Authorized & Honorable Prize in European Machine Tool Market 2017 MM AWARD Grand Prize in MILLING Category
Machining Center for Impeller and Small-size Complex Shape Processing
Specifications
A-Axis
X-A
xis
xis
Z-A
B-Axis
Ram Type Moving (X/Z-Axis)
Ø200
mm Table Size
15
kg Workpiece Weight
40,000 (HSK-E40)
r/min Spindle Speed
20
EA No. of Tools
300/300/200
mm (X/Y/Z-Axis) Travel
50/50/50
m/min (X/Y/Z-Axis) Rapid Traverse
200/200
rpm (A/B-Axis) Rotary Table Speed
2G/2G/2G
G (X/Y/Z-Axis) Acc./Dec. Speed
SIEMENS 840D sl
CNC Controller
Rotary Tilting Table(A/B-Axis)
HYUNDAI WIA INDIA PVT. LTD. Address : #4/169 1st flr, LOTTE Bldg, Rajiv Gandhi Salai, (OMR), Kandanchavadi, Chennai - 600 096, Tamilnadu, India Office Tel. No. : (0)76049 03348, E-mail : sales@hyundai-wia.com
Contents
Vol 3 Issue 12 | MAY 2018
COMPANY PROFILE
44
42 We give strategic advantages to our customers from diverse industries
Grob-Werke: Thrives on new technologies
48 Gala Precision’s Forte: Precise Surface Engineering Solutions
TECH TRENDS
56 Shavo Technologies offers high-tech tailor made solutions
TECH PROFILE
70
Inter-stage Membrane Dryer: Lower Life Cycle Costs, Zero Maintenance
96
60
Optimising Cutting Tool Performance!
FACCIN’S PGS-ULTRA: CNC Control for Rolling Machines
PRODUCTS SHOWCASE
104
Elesa+Ganter tubular handles
82 80
Realtime communication with KUKA.PLC mxAutomation
Precisae 2D/3D measurement using laser profile scanners
105
Welding Fume Extractor, King Extractor-II-MU 3
107
New Extech Laser Distance Meters Measure up to Jobsite Challenges
12
86
88
92
Safely Hand in Hand
Collaborative Robots: A vision to create better skilled jobs
Hardened Solutions in Linear Motion
MACHINE TOOLS WORLD MAY 2018
107
MSR linear guideway
108
Gears, Gear Components & Assemblies
Editorial Board
Editorial Index A
K
Accusharp Cutting Tools 96 Ador Welding 72, 105 ANCA 76
KUKA
B
MAC Machine Tools Mastercam Micro-Epsilon Mitsubishi
Bettinelli Automation 42 Mr. Arun Mahajan General Manager
Mr. A.P. Jayanthram Consultant
AMT- The Association For Manufacturing Technology
Grob Machine Tools India Pvt. Ltd.
Mr. GK Pillai Managing Director & CEO Walchandnagar Industries Ltd
D
Die & Mould India DOLD Electric
22 108
E
Elesa & Ganter India 104 ELGi Equipments 32, 70 EOS 22 Eppinger Tooling Asia 108 F
Mr. Arjun Prakash Managing Director Effica Automation Ltd.
Ms.Samina Khalid Marketing Manager Renishaw Metrology Systems Ltd.
Mr. Rupesh Paparaju Director, Bettinelli Automation Components Pvt. Ltd.
FACCIN FLIR Systems
60 107
G
Gala Precision GEM Equipments GROB
48 106 44
H
HEIDENHAIN Hyundai Motor
68 24
L
LMT Tools India
Manjit Singh Matharoo General Secretary Association of Ludhiana Machine Tool Industries
Mr. Suhas Belapurkar Director - Sales & Marketing ( Industrial Products) Sanjay Tools & Adhesives
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 MAY 2018
Mr. Jayant Vaidyanathan VP - Sales & Application Tsugami Precision Engineering India Pvt. Ltd.
88 20 82 20
P
Pilz India Precision Motion Industries (PMI)
86 107
R
Renishaw Rollon India Rolls-Royce
26 92 26
S
Schmersal India Seco Tools Shavo Technologies
24 62 56, 105 Sridevi Tool Engineers 34 U
Unity Controls
MTW Overseas Associates USA Nancy TARTAGLIONE, Mepax USA n.tartaglione@mepax.com / usa@mepax.com
GERMANY Sebastian OLLIER Mepax Deutschland, Tel: +49 711 222 54 456, deutschland@mepax.com
FRANCE MEPAX SA, Romain CLASS Tel.: +33 1 39 02 77 78, FRANCE
SPAIN Sofiane JEDIDI Mepax España Tel : +34 963 255 886, spain@mepax.com
ITALY Valeria VILLANI Tel.: +39 339 8610117, Via Firenze, Milano, Italia
UK Liz Jones Tel: +44 (0)1227 276016 , l.jones@mepax.com
RUSSIA Garri ZALTS Mepax Russia Tel: +7 495 576-7666 / gizalec@yandex.ru
40
M
For editorial contribution contact E-mail: shweta@divyamediaonline.com
Mr. Dinesh Khambhayta President MTMA-RAJKOT
80
CHINA/South Korea/Taiwan Mepax - Konaxis Shanghai Julien PENARD Tel : (+86) 21 6252 2731/ china@mepax.com
106
BUSINESS NEWS
Mitsubishi Materials introduces MVX Drills with new chip breakers and grades Smart thinking has led to simple solutions for some old problems associated with indexable insert drilling. Difficulties such as chip clogging on deep holes, dissimilar rates of wear on inner and outer inserts due to differing peripheral speeds, plus flexing and wear of the drill body itself have all been resolved with a new and innovative design.
New UH breaker for hardened steels and UN breaker for aluminium The existing range of inserts for steels, stainless and cast iron has been complemented with 2 new chipbreakers and a new insert grade. The latest PVD coating technology has been applied to the new DP8020 grade to supplement its durable carbide substrate. This makes it the ideal grade to combine
with the new UH chipbreaker. The strengthened edge of this chipbreaker provides the properties for reliable drilling of harder materials up to 45HRC. For aluminium machining, the uncoated TF15 grade now comes equipped with the new UN chipbreaker. With a sharp ground edge, it provides outstanding chip disposal and helps to prevent chip welding for increased reliability.
Different grades for inner and outer inserts The outer insert in this type of drill naturally runs at a higher speed than the inner, thereby leading to higher levels of wear. Consequently the inner insert needs to have a higher level of stability and resistance to fracturing at lower
speeds. This anomaly has been negated by using a CVD coated outer insert that has higher abrasion resistance, in tandem with a PVD coated inner insert that can cope better with fracturing forces and resistance to welding. This combination means improved reliability and fewer changes of insert for increased levels of productivity.
Interchangeable inserts with 4 cutting edges The SOMX type inserts are interchangeable from inner to outer position, have 4 cutting edges and a unique wavy chipbreaker design for improved chip control. The peripheral edge also has a wiper type geometry for excellent hole
wall accuracy and surface finishes. The inserts are also positioned in such a way that when cutting, they are both equally in contact with the workpiece, thereby reducing drill body flex to provide a more consistent performance.
Tool body The tool body is designed with through coolant holes and an optimum sweep of the flutes that provides extra metal thickness behind the direction of the principal cutting force. This controls tool body deflection and helps to achieve reliable deep hole drilling up to 6 x D. Additionally the body surface is heat treated to prevent wear from chip evacuation. The sizes available are Ø17mm-Ø43mm in L/D=2, 3, 4, 5 and 6. And Ø17mm-Ø63mm in L/ D=2, 3, 4 and 5.
Mastercam’s Wildest Parts Competition Gets a Boost It’s that time of year again – time to think about entering Mastercam’s Wildest Parts competition. This year, Mastercam is offering two different competitions open to any current student, team of students, or instructor programming with Mastercam to participate in. Students worldwide can enter their “wildest” part made in school this year to Mastercam’s Wildest Parts Competition and get a chance to win $1000 and other prizes. The Wildest Parts Competition is an annual contest, sponsored by CNC Software, Inc. — developers of
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MACHINE TOOLS WORLD MAY 2018
Mastercam® —where students can submit any part they cut during the school year. Last year, the winning students were Grayson Weber from Capital High School in Helena, Montana who made a survival multitool and
Christian Ziruk from Washington State University in Pullman, Washington who made a deep sea AUV camera enclosure. “We look for high quality, original parts that haven’t been made before, or parts that are
familiar yet feature a unique, new design. We like eye-catching designs that would look nice on a display, because we do show them off at educational trade shows,” says Michelle Nemeth, Marketing Specialist at CNC Software. “We’re always impressive by how innovative students can be with Mastercam, and we encourage students to really think beyond the norm. They may create something specifically to enter into the competition — or have already made something in school that would qualify.”
BUSINESS NEWS
Die & Mould India International Exhibition concludes on a high note The 11th Biennial Die & Mould India International Exhibition came to an end on April 14, 2018. The four-day event organised by TAGMA India showcased the latest products and solutions for the die & mould industry. The 11th edition held at Goregaon, Mumbai saw 300 exhibitors from 19 countries presenting a variety of products and services for die & mould and other related industries. The number of visitors too increased two-fold as compared to the previous edition. With a 15% increase in exhibitors than the previous edition and 45% increase in this venue, DMI 2018 resulted in a huge success. TAGMA has been working towards the benefit of the Indian die & mould industry for more than two decades. The industry body has been successfully organising trade shows, events, seminars and other activities keeping in mind the interests of the tooling industry. One such event is the Die & Mould India International Exhibition. Suresh P Prabhu, Minister of Commerce &
Industry and Civil Aviation of India addressed the gathering through a video message during the inauguration ceremony. “We are happy to see such an event related to die & mould being organised in Mumbai. TAGMA is doing a great job by encouraging the industry. Design is very important for manufacturing; it is a critical area and requires expertise. The industry has our support and we hope the new standards will help the industry and further provide a boost to the economy.” Jamshyd N Godrej, Chairman of the Board of Godrej & Boyce Manufacturing Company
Limited and the Chief Guest for the inauguration added, “I have always propagated the idea of exhibitions. Exhibitions like DMI help people understand the kind of development that has happened in a particular industry.” Guest of Honour, Cabinet Minister, Maharashtra Legislative Assembly, Raj K Purohit said, “Die & mould, also known as the mother industry serves as the backbone of manufacturing. The same way TAGMA has the power to mould the future of the Indian die & mould industry. Exhibition of this stature will help the industry grow.
EOS launches new EOS P 810 Polymer Industrial 3D Printing Platform EOS is showcased its latest portfolio of industrial additive manufacturing (AM) solutions at RAPID + TCT 2018 in booth #1118, hosted in Fort Worth, Texas, April 23-26. EOS launched the new EOS P 810 polymer platform specifically designed to process the new high-performance, ALM material HT-23. Developed in close cooperation with Boeing, this world’s first economic, high-temperature polymer AM solution addresses industry requirements for demanding high-performance parts. As such, this technology package is particularly developed for the aerospace industry but can also be applied for other industries. Scott Killian, aerospace business development manager, EOS North America, emphasizes: “The aerospace industry has to meet challenging requirements when it comes to UV resistance, flame retardancy and meeting Federal Aviation Regulations (FAR) such as FAR 25.853, which sets standards for materials within compartment
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MACHINE TOOLS WORLD MAY 2018
interiors. Additive Manufacturing enables the design and manufacturing of complex geometries without expensive tooling. This allows aerospace OEM’s to replace composite parts which to date are being produced manually via carbon fiber laminating. They can also replace aluminum parts with HT-23 while still meeting the material strength properties required for the application. With the EOS P 810, our customers can produce
lightweight parts, reduce time for production and parts assembly, and cut overall costs-per-part.” The system builds on the well-established EOS P 800 and is specifically designed for the requirements of industries such as aerospace and processes exclusively the HT-23 material. HT-23 is the first carbon fiber-reinforced PEKK material that can be processed on EOS systems, as such offering isotropic part properties. Parts additively manufactured with this material offer high strength, low weight and are capable of withstanding high temperatures. It is the first high-performance material with a low refresh rate of 40 percent, as such also contributing substantially to reduced costs-per-part. “Our EOS P 810 polymer 3D printing platform and the ALM HT-23 material enabled us to help Boeing reach high demands for weight reduction, cost efficiency and reduced assembly time for components,” said Killian.
THE ALTERNATIVE TO TURNING
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BUSINESS NEWS
National Fire Service Day observed at Hyundai Motor India Hyundai Motor India (HMIL), the country’s largest exporter and second largest passenger car manufacture observed the National Fire Service Day, which falls on April 14th. Paying homage to the brave fire fighters for their exemplary courage and devotion, the Safety team conducted several activities and competitions amongst its employees, contractors and vendors, to increase awareness on preventing and managing fire and fire related emergencies. This year’s highlight was a demonstration on putting out fire in an enclosed area where highlyflammable material is stored in large volumes. In addition, other events like Hydrant Operation,
Bucket Brigade, Extinguisher Operation, Target Shooting, etc. which saw around 530 employees (both men & women) in participation, all aimed at improving the preparedness of employees in case of fire either at home or office. In a first, 120 employees from 31 vendor companies also participated in the event. ‘Safety is the way of life at Hyundai and our commitment towards creating a safe environment has helped us to be rated as the ‘Safest Plant for 2017’ amongst all overseas plants by Hyundai Motor Group,’ said Mr. Stephen Sudhakar J (Sr.
Vice President - Administration). Safety is also the first and the most important pillar in the employee-led ‘My Place, My Pride’ initiative, which began at HMI in 2016, by which 77 Safety Ambassadors have been deployed to instill the culture of safety in their respective work stations, all across the plant. HMI believes that A Safe Place is a Great Place to Work! The safety team regularly conducts mock drills and training for employees. Their two modern multi-purpose firefighting vehicles are always available, not just for HMI emergencies but also to help other companies and the local Fire & Rescue Station at Sriperumbudur, whenever they need it.
Schmersal India inaugurates its First global support IT centre in Pune Manufacturer of electromechanical safety and lift switchgear and systems, Schmersal India Private Ltd., a subsidiary of The Schmersal Group, Germany,inaugurated its first global support IT centre in Pune today. The Centre inaugurated by the Managing Director of K.A. Schmersal GmbH &Co. KG., Germany Mr. Michael Ambros, is spread across an area of 3305 square feet with a workforce of 15 Functional and Technical Consultants. At the launch of the Centre Mr.Ambros expressed, “This is the first global support activity that has been established outside Germany, and India has been recognized as one of the competence centres with skilled resources to provide support for SAP implementation and software development to the entire Schmersal Group. This activity has also led to increased employment opportunities for the Indians” With the motto,‘turning workplaces into safer places’ Schmersal
24
MACHINE TOOLS WORLD MAY 2018
Norbert von Poblotzki (left), Head of IT – Schmersal Group, Michael Ambros Managing Director of K.A. Schmersal GmbH &Co. KG., inaugurating the new office India started operations in 2007 as a sales organisation to participate in the growing India market for machine safety. In 2012, a cornerstone for the production factory in India was laid in Ranjangaon near Pune, Maharashtra, with a total investment of about 8 million Euros,by the Schmersal Group in the construction ofthe new factory which started production in July 2013 and today has a headcount of 86 employees. To further strengthen its India
presence, the Company plans on adding more skilled manpower to enhance their local R&D centre and Product Management to focus on developing more products for the Indian market. “Embracing the ‘Make in India’ initiative, the manufacturing facility in Schmersal India is enhancingits product range by designing and manufacturing customised safety products as per the needs of the customer specific application, for the local market as well as export to the Schmersal Group from their 100% export-oriented unit (EOU)
located within the current Indian factory. Also, we have set up a free trade and warehousing zone (FTWZ) near Mumbai, which is specifically for global Indian companies who are allowed to import goods at a special concessional duty,” proclaimed Mr. Sagar Bhosale, the Managing Director, Schmersal India Pvt. Ltd. By the end of 2017, the Indian Factory manufactured and supplied more than one million safety switches in India market. Current manufacturing capacity is five million safety switches per year.
Sagar Bhosale, Managing Director, Schmersal India, addressing the media
The Trusted Partner in Metal Forming Machines
PRODUCTIVITY AUTOMATION PRECISION
BUSINESS NEWS
Prestigious award for Renishaw’s Indian software team At the Maharashtra Information Technology (IT) Awards on February 19th, 2018, global engineering company, Renishaw, was presented with the award for IT Research and Development (R&D) Engineering Services Software. The award was presented in Mumbai by the Chief Minister, Devendra Fadnavis of Maharashtra during the Magnetic Maharashtra Convergence 2018 Global Investors Summit. The Maharashtra IT Awards promote entrepreneurship in the IT industry across the state, recognising outstanding performance and encouraging the use of IT in society. The event, which was inaugurated by Narendra Modi, the Indian Prime Minister, hosted industry leaders from around the world alongside policy makers from the Indian Government. Renishaw employs around 400 people in India, operating from five offices, including
a manufacturing facility and an Additive Manufacturing Solutions Centre. The company has a team of 140 Software Engineers in India to develop sophisticated and complex software products to complement the company’s metrology, Raman spectroscopy and additive manufacturing hardware offerings. Renishaw India has played a key role in the development of QuantAM build preparation software for use on Renishaw additive
manufacturing systems. The team also contributes to other company software including MODUS and APEX software for metrology applications, WiRE spectroscopy software and the CARTO calibration software suite. “A large amount of Renishaw’s software work takes place in India,” explained Vikas Saxena, Director and Head of Software at Renishaw India. “Since it was established, the team has gone from strength to strength. India has a very strong software industry, so it is a big achievement for a manufacturing company to win a software focussed award. “Renishaw produces industry-leading hardware and systems for metrology and additive manufacturing,” continued Vikas. “The team use simulation and abstractions to develop the tools needed to support the company’s product portfolio, an essential part of our operations.”
Rolls-Royce and Goa Shipyard Limited agree to manufacture MTU engines in India Rolls-Royce and Goa Shipyard Limited (GSL), a premier defence shipbuilding yard in India under the Ministry of Defence, have agreed to cooperate in the local manufacturing of technologically-advanced MTU Series 8000 engines in India. Under the agreement, which was signed today at India’s leading defense trade show Defexpo, the companies will assemble the 16-cylinder and 20-cylinder MTU Series 8000 engines at GSL’s new facility in Goa. The MTU brand is a worldwide leader in large diesel and gas engines and complete propulsion systems and part of Rolls-Royce Power Systems. The agreement includes transfer of MTU technology related to localising of engine components,
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MACHINE TOOLS WORLD MAY 2018
engine assembly, testing, painting and major overhauls. MTU Series 8000 engines are the largest and most powerful MTU diesel engines with a power output of up to 10 MW. They are fitted onboard all Offshore Patrol Vessels (OPV) recently constructed or currently under construction in India. This includes eleven Coast Guard OPVs by GSL (six completed and
five under construction), five Naval OPVs under construction at Reliance Defence Engineering and seven Coast Guard OPVs by L&T. RAdm (Retd) Shekhar Mital, NM, Chairman & Managing Director of GSL said: “Since main diesel engines constitute the heart of a ship and are among the major high value imported equipment items onboard ships, the collaboration
will aid to significantly increase the indigenous content onboard ships constructed in India.” It will also provide a strategic edge to Indian Defence Sector as know-how and infrastructure for such niche technology will now be available with a PSU Shipyard, which can be gainfully utilised by the Indian Navy and Indian Coast Guard. Praveen Mohan, Director & CEO, MTU India, said: “We have been working with the Indian defence sector for several decades and our well-proven MTU engines propel and power many vessels of both the Indian Coast Guard and Indian Navy. We are committed to collaborating with our stakeholders to help support the country’s vision of indigenisation and selfreliance.”
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www.nord.com NORD DRIVESYSTEMS Pvt.Ltd. 282/2, 283/2, plot no. 15, Village Mann, Taluka Mulshi Adj.Hinjewadi MIDC-II, Pune- 411057 Maharashtra INDIA Toll Free No. 1800 200 2042 India@nord.com, www.nord.com Member of the NORD DRIVESYSTEMS Group
DRIVESYSTEMS
INDUSTRY SPEAK
Green Manufacturing Practices at ELGi Optimizing energy usage in manufacturing, increasing the usage of renewable and alternate energy sources, and implementing a continuous energy savings improvement plan is the right approach for a greener tomorrow: Anvar Jay Varadaraj
I
n the manufacturing sector, implementation of green manufacturing practices is much more than compliance. It also brings about lasting benefits in terms of sustainability, profitability, and effectiveness in the businesses. Demanding the right seriousness, open-mindedness and leadership towards green manufacturing drives are among the top priorities among manufacturers worldwide, as every team works to consume less and producing more. It is the responsibility of manufacturers to reduce carbon emissions in all their processes, avoid wastage of any kind, and build a green enterprise that does more and more with less inputs, based on continuous learning and corrective actions. Such persistent focus has yielded positive results, including financial benefits, for many global manufacturers. Elgi has constantly endeavoured to do more with less, and its sustained efforts have resulted in reduction of its manufacturing carbon footprint from 1,600 kg of CO2 per million of sale (INR) to 1,200 kg of CO2 per million of sale (INR) from 2014 to 2018. At ELGi, windmills generate 15 percent of the total energy in the plant that adds up to 20 lakh units of electricity every year. The windmills are maintained by an in-house team with utmost care. Every resource counts, and cannot be wasted. Each concerted effort to save resources such as water, wood, fuel or electricity from being wasted has a profound impact on the overall
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MACHINE TOOLS WORLD MAY 2018
business efficiency of the organization, and makes it greener. ELGi recycles its waste in every form, into something of value that enriches other industries and communities. ELGi recycles its foundry wastes and by converting it to 40,000 solid construction bricks per year. About 2,000 litres of hydraulic oil used in ELGi’s CNC machines and about 1,000 kg of paint powder are recycled. 60,000 Litres of recycled water from ELGi’s manufacturing processes are used to water the gardens. The company also recycles its used batteries and puts them into use in school laboratories in the region. The company plants trees in its campuses, implemented paperless offices and has also put in place a comprehensive energy management system. Natural light illuminates most of its campuses, cutting power consumption further. Globally, 70 percent of all fossil fuels are used in industrial operations alone. This mindboggling number would make it obvious that it is critical for all industries to focus on using the maximum number of renewable energy sources and materials in their manufacturing processes. It is not just enough to go green during the manufacturing processes. The philosophy should extend well into the design and manufacture of highly energy efficient products. Therefore, it is crucial to roll out highly energy efficient products from the factories that consume lesser energy during their entire lifecycle. ELGi has obtained ISO 14024:1999 green label product certification for its EG and
Anvar Jay Varadaraj, Head – Marketing & Communications, ELGi Equipments Limited
EN series of compressors that are green in both their manufacturing, as well as performance. Measuring each and every energy and material input is important for a green enterprise. Implementing effective energy management systems will help bring visibility to every unit of power consumed, and help optimise it. Every appliance, be it motors, fans, lights, transformers or office air conditioners, should be monitored, and optimized to continuously reduce energy consumption. All of ELGi’s manufacturing processes are ISO 50001:2011 certified for its stringent energy management systems. ELGi has reduced its power to sale ratio from 1.15 percent to as little as 0.97 percent last year. The facilities have also begun to implement agile Internet of Things (IoT) projects to cut energy costs further. ELGi has set energy baseline and energy performance indicators at every level of its manufacturing processes. Plans are now on way to set up rooftop solar energy panels that produce up to 100 kW of power. Optimizing energy usage in manufacturing, increasing the usage of renewables and alternate energy sources, and implementing a continuous energy savings improvement plan is the right approach for a greener tomorrow. At ELGi, the leadership has constantly pushed for better, greener practices in all that the company does.
MANUFACTURING SYSTEM FOR GEARS WITH TRACKMOTION PRODUCTIVE
FAST
HIGHLIGHTS
+
Turning and gear hobbing machine with automation all from one source.
+
Process description: Soft turning the 1st side, soft turning the 2nd side, gear hobbing. Turnkey solutions for the complete line.
+ +
Modular machine integrated with automation. Machine concept perfect for line formation.
SIMPLE HANDLING
COMPACT
+ +
Less operators required and machine maintenance made easy.
+
The TrackMotion automation system performs the complete transport of the part, including rotation.
+
The use of stacker pallets allows autonomous operation for hours.
Short travel times for loading and machining, resulting in the shortest possible cycle times.
EMAG India Private Limited “Technology Centre” I No. 17/G/46-3 · Industrial Suburb I 2nd Stage · Yeshwanthpur I Bangalore · 560022 I Karnataka · India Phone: +91-80-42544400 I Fax: +91-80-42544440 I E-mail: sales.India@emag.com I Website: www.emag.com
IN FOCUS
In the right mould: Sridevi Tool Engineers “All our activities are oriented towards delighting our customer�, says Surendra C. Kalyanpur, Managing Director, Sridevi Tool Engineers Private Ltd.
Mumbai-based Sridevi Tool Engineers specializes in design, development and manufacture of plastic injection moulds for automobile, white goods, luggage and other engineering industries. Established in 1972, the company is one of the largest commercial tool rooms in India with a capacity to produce moulds up to 3000 T of locking pressure. The company, equipped with the best of production machines sourced from Europe and Japan, has an uncanny eye for quality and precision. With an enviable customer base built up over a span of four and a half decades, the company is thriving on import substitution, developing some of the most complex moulds which otherwise have to be sourced from Korea, China or Japan after a long wait and spending a colossal amount of foreign exchange. Mr. P.K. Balasubbramaniian speaks to Mr. Surendra Kalyanpur, Managing Director, Sridevi Tool to ascertain the capabilities and commitments of this technology driven company which is on a growth trajectory to make the most of the boom experienced in the automobile industry. Excerpts: 34
MACHINE TOOLS WORLD MAY 2018
Q. Sridevi Tools was started in 1972. How do you recount the beginnings of the company? I am a self-made entrepreneur. After my Intermediate Science, I picked up a job. I started my career with Lawkim Motors in Thane where I worked for long 10 years. Then I moved to Bharat Bijlee, also in Thane, wherein I had a stint of about 4 years. In both the places I was in the Machine Shop. The rich practical experience I gained helped me in my career. So my foray into the die & mould business, I would say, was by choice. I started my company, Sridevi Tools, in 1972. That was the time when no tool rooms were available in the country. Die & Mould making was a highly skilled job. CNC machines were not available then. We started our operations with a small drilling machine, a lathe and 5-6 people. We first made PVC fitting moulds and then moulds for making TVs and refrigerators. 1986 was a
IN FOCUS turning point in our business. That was the year when we first bought a 3-axis milling machine, Deckel from Germany. Since then there has been no looking back. We operated from Saki Naka for about 17 years. In 1986 we came to Vasai.
Q. Could you give more details of your present manufacturing facilities? We have a full-fledged manufacturing facility in Waliv in Vasai, Mumbai - a 60,000 sq. ft. area housing our factory and office. We have some 39 production equipment which include 27 CNC machines and 12 EDMs - all imported from Europe and Japan. We have a workforce of 400 people which include 200 engineers.
Q. What are the factors that contributed to your success? I would say dedication and hard work. Ours is a specialized line which needs focus and unwavering commitment to quality and precision. We have to give our 100% all the time.
Q. What’s your niche today? We specialize in making precision engineering moulds for manufacturing automobile parts and products. All
Sridevi put up an impressive show at the recently held Die & Mould India International Exhibition at BEC, Mumbai automobile majorsin India including Maruti, Mahindra & Mahindra, Hero, Honda, Yamaha and Tata Motors are our customers.
Q. What are the processes involved in executing an order? We are tied up with all 2-wheeler and 4-wheeler manufacturers and tier-I suppliers in India who refer their requirements to us. Our offers are considered based on the cost, capability and delivery. Once an order is placed on us, we design the mould, procure the raw materials, and get down
to machining, assembly, trials and tests. The raw materials used are tool steels and alloy steels and requisite hardware. Most of these raw materials are imported. And the tests are done on injection moulding machine. After the trials and tests, the moulds are dispatched.
Q. What’s your present manufacturing range? We make moulds of 250T to 3000T locking pressure. Our capacity utilization is 100%. A small percentage (5%) of our production is also exported to European countries like Italy, Spain and France, as well as to Russia. Export is not a thrust area for us since most of the MNCs are here and we serve them.
Q. What are your growth strategies?
Sridevi’s modern manufacturing facilities in Vasai, near Mumbai
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Our going is good. For the last 2-3 years we have registered a growth of 20% year on year. This year, we expect a 30% increase in our turnover. We are on an expansion mode. Land has already been acquired for starting one more production unit. We would also be investing in import of some more special machines. We are exploring newer market segments. Aerospace, for instance, is a potential market. Our thrust will be more on developing import substitutes for
IN FOCUS
Instrument panel moulds developed by Sridevi. The company has developed several import substitutes Japan. We have already developed these moulds. There is a huge demand for these moulds. Instrument panel moulds, as a product range, should enhance our turnover by another 10-15%.
invest heavily on plant and equipment to improve our quality and precision. This year itself we are investing Rs.28 crore and importing sophisticated manufacturing equipment.
Q. How customer-centric is Sridevi?
Q. So where will you be five years hence?
Well, all our activities are oriented towards delighting the customer. Our customers are quite happy to work with us because of our quality obsession, cost-competitiveness and prompt delivery schedules. This is evident from the fact that we have got several ‘Best Performance Awards’ from our clients like Honda. Sridevi has received a number of Awards in recognition of its outstanding performance OEMs. Every mould is different and customized, demanding stringent quality control requirements. Moulds for automobile lights are something very critical. Instrument panel moulds are mostly imported from Korea, China and
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Q. What’s the importance you give to technology upgradation, innovation and quality improvement? We always strive to keep ourselves abreast of the technological innovations in our field. Quality improvement is an on-going process at Sridevi. We
Five years hence we should be a Rs.250300 crore entity with a wider customer base.
Q. What are your comments on the industry scenario? The Die & Mould Industry in India is worth Rs.16,000 crore. Of this, 30-40% is still being imported. So one can imagine the growth potential of this industry. Tool-making is basic for the growth of the machine tool industry. At the same time, tool-room companies are all family run. They keep a low profile. The industry as a whole does need encouragement and support from the Government.
G-SERIES
Precision at the highest level GROB 5-axis universal machining centers stand out due to their absolute precision and reliability in the automotive, medical and mechanical engineering industries, in tool and mold making as well as in the aviation industry. The proven 5-axis simultaneous technology with horizontal spindle position enables you to machine parts of various sizes and materials in a flexible and failure-free way while offering maximum stability of the machine. Fast chip-to-chip times and the innovative further development of our spindle technology guarantee a high economic efficiency and productivity.
Contact: GROB MACHINE TOOLS INDIA Pvt. Ltd. I Hyderabad, INDIA Phone: +91 40 4202-3336 I E-mail: info@in.grobgroup.com
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www.grobgroup.com
15.02.2018 10:20:47
COVER STORY
LMT Tools India : Recognition for performance with excellence
Q. Please brief us about company’s Indian & global reach? LMT Tools belongs to LMT Group, a family managed holding company. The Group bundles several, leading technology companies with more than 1,200 employees at 13 locations worldwide. LMT Tools is based out of Oberkochen, Germany. As a group we have four principle brands LMT Fette, LMT Kieninger, LMT Onsrud & LMT Belin. Two of these brands come from
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Germany, one from France and one from the US. We have the manufacturing base in Chakan, Pune where we produce hobs and catering to the Indian automotive industry from motor-cycles and scooters all the way up to cars and have graduated including trucks and tractors. We are expanding the manufacturing programme to round tools and gradually we will be moving into other tools as well, as and when
we see the necessity. The reach and go to market approach has given us lot of confidence having established Centers of Competence for gear cutting, milling, tapping and thread rolling - here we have most of our engineers trained in Germany, thereby ensuring we offer performance solutions to the customers in sync with what they exactly want. LMT Tools India also caters to the export demand for Gear hobs & received Star Performer Award for Highest
COVER STORY www.mtwmag.com
Mr. Ramakant Reddy Managing Director LMT Tools India Pvt. Ltd.
Export for Year 2013-14 and 2015-16.
Q. Please also highlight the latest initiatives in cutting tools industry domain? Now everyone is talking about green machining and industry 4.0 and technology like IOT. We are working closely on Industry 4.0. Back home in Germany which is where most of these technologies are introduced, our team is working closely with the universities,
colleges and the leading companies and we are part of the group with which we try to ensure that as and when such progress is made it gets translated. So if and when a particular market is beginning to see and show demand for such things, we are one of the few, who will not be left behind. We are very much participating in most of these activities; for example, if you ask me one of the things which you see here whether it is part of Industry 4.0 or not, some of our thread rolling system we have 3D printed covers. So things like that have started coming in. So we are able to turn around pretty fast, when customer wants something which is highly customised. To sum it when the progress is made at the market end, we are certainly not caught unaware.
Q. What are the market opportunities for your company’s products in India? We are concentrating on niche and highly focused in specific areas. With the growing demand in Indian Automotive industry we maintain the No. 1 supplier position. Our LMT Kieninger range of products – Advanced Tools like Line Boring Bars, Motion Tools, Cylinder Boring Bars with auto compensation for wear correction, tools to produce spherical shapes are predominantly
used in production of automotive industry, we are easily among the top three suppliers of these tools and are working closely with most of the machine tools manufacturers and end users. We have unique Thread Rolling System where we certainly claim the pole position globally. Aerospace and Medical sector is growing in India and our round tools in the field of High feed milling and special Solid Carbide Endmills carving a name for itself. We see major opportunity in Die and Mould Industry for our products specially designed for roughing, semifinishing and finishing operations.
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? We plan to expand our manufacturing base in India adding the new products to our manufacturing program.
Q. What is your vision for your company? To achieve manufacturing excellence & become preferred supplier of all major Automotive, Aerospace & Die & Mould Industries in India. Expand manufacturing base for LMT Group products in India.
MAY 2018
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COMPANY PROFILE
We give strategic advantages to our customers from diverse industries
Rupesh Paparaju, Director, Bettinelli Automation Components, India
B
ettinelli S.p.A, established in 1953, specializes in the development and manufacturing of precision motion control components and systems. In 1996 a separate division named CDS Cam Driven Systems was created for engineering solutions in automation and motion technology. CDS produces the widest range of mechanical Cam Driven Units, commonly known as rotary / indexing tables for precision motion control applications, requiring rotary or linear transfer, positioning and handling. The products range includes, cam indexing and servodriven tables, ring positioning drives, intermittent and oscillating drives with parallel or right angle configuration, rotary & linear part handlers, precision link transfer systems, and epicycloidal servo reducers.
Wide ranging products
The broad product spectrum covers IP parallel shaft indexers, IT roller dial indexing tables, TR roller dial indexing tables, HP roller dial indexing tables, IG/ IGA roller gear indexer, TL precision link conveyors, MHP/LHP part handlers, FTHT open center ring tables and packages of rotary indexing tables. Bettinelli has a wide range of standard products. These are delivered in 3 weeks. When it comes to customized products, these are designed,
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manufactured and shipped in 6-8 weeks. The manufacturing takes place centrally in Italy. The regimen starts with design & engineering, CNC induction hardening, CNC milling, grinding, quality check and then assembly, painting and shipment. In order to ensure quality, all components are machined internally, including the cam hardening by a proprietary CNC controlled induction hardening equipment. For better finish, the products are also subjected to chemical nickel plating, blasting and painting. The manufacturing process is constantly controlled to conform to international standards. The company’s quality systems are ISO-9001-2008 certified.
are used in pallet transfer tables, assembly machines, painting applications and test rigs, just to mention a few. In machining industry, they are used with advantage in deburring, lapping and pressing machines and in transfer lines. In SPM & robotics, they find applications in transfer lines, station loading, sequential operations and so on. Inwelding, these indexers are inevitable in positioners, synchronous welding, robotic welding and component transfer. Packaging too is a major application area. Cam systems are used in box filling machines, wrapping machines, cartoning and capping machines. Indexers are also used in casting, printing and cosmetics industries.
Strategic advantages
Over the years, Bettinelli Group and CDS Indexers have become synonymous with high quality automation products and technologies. “Our design and manufacturing systems have furnished competitive and strategic advantages to numerous industries in pharmaceutical, automobile, manufacturing, packaging and a plethora of other sectors. And for automation functions, our solutions are invariably preferred by companies,” says Rupesh Paparaju, Director, Bettinelli Automation Components, India. The Indian subsidiary, headquartered in Pune, serves its customers in India by providing installation, commissioning, and after-sales support. It also offers technical consultation. In the pharmaceutical industry cam driven systems are used in filling, blister pack, tablet making and packaging machines. In automobile industry, they
Parallel Shaft Indexer
Rotary Indexing Tables, TR Series Closer to the customer
The Indian arm of Bettinelli, based in Pune, Bettinelli Automation Components Pvt. Ltd., is highly customer-centric. “Our presence in India means quite something in fostering a symbiotic relationship with our customers. It helps us to match our world-class products with our eminent customer support,” underlines Paparaju, Director, who has built up a team to improve Bettinelli’s response time. “CDS are high-tech products which lend themselves to enhance the operational efficiency and productivity at the customer’s end. We stay close to the customer to understand his needs and offer customized solutions within the shortest possible time to ensure peak uptime of his equipment and operations”, he adds. - P.K. Balasubbramaniian
COMPANY PROFILE
Grob-Werke: Thrives on new technologies
G
robe-Werke, with a standing of over 90 years, is one of the global players in the development and manufacturing of machines and production lines. Its customers include the world’s most prestigious car manufacturers, their suppliers and many other renowned companies from various industries. With production plants in Mindelheim (Germany), Bluffton, Ohio (USA), São Paulo (Brazil) and Dalian (China), and worldwide service and sales subsidiaries, the company is represented around the globe. The GROB Group, with a workforce of about 6,600 employees, generates worldwide revenue of over 1.3 billion euros. Its portfolio ranges from universal machining centers to highly-complex manufacturing systems with own automation function through to manual assembly stations and to fullyautomated assembly lines. Furthermore, production plants for electric motors and assembly lines for battery and fuel cell technology are part of its product range. GROB engineers are delivering solutions for the technology involved in spraying engine components, in cutting high-strength turbine housings and machining structural and chassis components. By developing GROBNET4Industry, its proprietary industrial software for the digitalization and networking of production systems, GROB is taking a giant leap into the digital future. Glorious past
The success story of GROB-WERKE began back in 1926 when the company was founded by Ernst Grob, who was
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producing folding boats, weaving machines and stationary combustion engines at that time. In 1952, Burkhart Grob, the son of the founder, assumed responsibility for the company almost completely destroyed during the war and was able to forge the link to the emerging automotive industry with high-quality and technologically-convincing production machines. In 1968, the Mindelheim plant was built and the company’s headquarters was relocated from Munich to Mindelheim. Besides the parent plant in Mindelheim, the plants in Bluffton (USA), São Paulo (Brazil) and Dalian (People’s Republic of China) are part of the production network of GROBWERKE. This production network is expanded through thirteen sales and service branches in South Korea, China, India, Russia, Great Britain, Hungary, Mexico, Italy, Poland, Switzerland, the Netherlands and the USA to guarantee the best service quality.
Even after Dr. Burkhart Grob passed away in May 2016, the future of the family company has been strictly set out. Christian Grob takes the company into the third generation as the new Supervisory Board Chairman. Even at this early stage, the next generation is being prepared for future tasks. By purchasing DMG meccanica in January 2017, GROB has acquired a strong partner in the field of electromobility. GROB now also acts as a developer of system concepts for electromobility, which is a future-facing step for expanding the existing product range of highly-efficient manufacturing and assembly plants. In January 2018, DMG meccanica was renamed GROB Italy S.r.l. Product and service spectrum
The product range of GROB-WERKE GmbH & Co. KG can be divided into the following areas: System solutions and special-purpose machines: Machining centers or flexible
NC4 non-contact tool setting system Non-contact tool measuring and broken tool detection on a variety of machining centres
Key benefits:
Specification:
• Reduce tool setting times by up to 90% and reduce scrap caused by setting errors
• ± 0.1 µm 2σ repeatability
• Improve setting accuracy
• Measures and detects tools of Ø0.03 mm or larger
• Broken tool detection cycles enable reliable unmanned machining
• Flexible systems – fixed or separate
• Increase productivity, improve quality and increase profits.
• Ultra-compact systems – just 30 mm wide and 35 mm high • Environmental protection – features patented MicroHole™ and PassiveSeal™ technology • Easy installation – ideal for retrofitting offering fast set-up
call +91
20 6674 6200 or visit www.renishaw.co.in/nc4
Renishaw India [Pune] S.No.282, Hissa No.3, Raisoni Industrial Estate, Village Mann, Tal:Mulshi, Pune 411057 T +91 20 6674 6200 F +91 20 6674 6211 E india@renishaw.com
www.renishaw.co.in
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COMPANY PROFILE manufacturing systems are designed specifically for the customer’s part. Offering so-called turn-key solutions, GROB provides the required planning, engineering, manufacturing and commissioning on site at customers’ facilities – everything from a single source. In most cases, these systems consist of modular machining centers and special-purpose machines that are interlinked with the latest automation solutions. Typical parts are for example cylinder heads, crankcases, transmission case and housings for auxiliary units of the engine. Universal machining centers: The machining centers are mainly operated as stand-alone machines but are also available with automation solutions. They are typically used in the aerospace, automotive and medical industries, in tool and mold industries and in case of felxible contract manufacturers. Assembly technology: All assembly stations and assembly lines for the
automotive industry are individually planned, designed and custombuilt according to specific customer requirements. The systems are used for semi-automatic or fully automatic assembly of assemblies equipped with a variety of robot cells and measuring and test stations. They are typically used for example for the assembly of engines or manual transmissions for passenger cars and trucks. Assembly systems for electromobility: As a general contractor, GROB offers machines, automation systems and purchase components for electromobility as well as the required management expertise. From stator and rotor assembly through to final assembly, we deliver a modular and reliable plant concept for high-output electric motor manufacture. Into the Future
At GROB-WERKE, the development
of new technologies has been a key element of the company’s success since the very beginning. New technologies that set benchmarks in the mechanical engineering sector are continuously emerging. The G550TS thermal spraying system developed by GROB thus expands the production chain for cylinder crankcases. GROB has also developed a motorized spindle with cross-feed – an outstanding concept for the complete machining of turbine housings on the machining center. The company is taking a giant leap into the digital future with the proprietary software GROB-NET4Industry, developed for the digitalization and networking of production processes.
For more information, Website: www.grobgroup.com
Grob’s Plant in Mindelheim
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More Precision High precision sensor systems
Compact laser triangulation displacement sensors Compact and lightweight High accuracy Small light spot for smallest objects Analog and digital output Integrated web interface with predefined presets
Laser-Line Scanner Up to 4,000 profiles/sec Up to 1,280 points/profile Very compact and extremely precise Fully integrated electronics Ethernet GigEVision/RS422 Direct connection to PLC Red laser / blue laser
+91 20 2674 1009 | info@micro-epsilon.in | www.micro-epsilon.in
COMPANY PROFILE
Gala Precision’s Forte: Precise Surface Engineering Solutions
G
ala Precision, serving the industry for over 25 years, is a one stop solutions provider for surface finishing needs such as de-burring, finishing, washing and cleaning of components and parts. The company offers the whole gamut of machines, processing media, compounds and services for surface finishing and parts. Gala has capability to build large finishing & cleaning equipment for challenging needs of defence, atomic and aerospace sectors. The finishing machines are capable of achieving Ra value of 0.05 microns while precision parts cleaning machines are capable of achieving a Millipore value of less than 1mg.
porcelain, steel or plastic materials. Compounds are used with water with concentration levels of 5 to 10%. Gala offers standard and customised products to suit specific customer needs. The finishing machines are of different types. These are:
• • • • •
Vibratory finishing Centrifugal Barrel Finishing Disc Finishing Customised finishing systems Complete automation of surface finishing processes is possible by using component loading system, conveyors, vibratory trolleys and dosing system using PLC based control panels.
Deburring and Finishing
Vibratory Finishing
The de-burring and surface finishing machines are used for mass finishing of metal, plastic, ceramic and rubber parts. Small parts weighing a few grams up to 25 Kg can be processed in a variety of machines available from Gala’s wide range of products. Use of de-burring and finishing machines is essential to achieve consistency and high production rates. In addition to finishing equipment, use of abrasive media and compounds is essential to achieve the desired process results. Abrasive media can be of ceramic,
The Vibratory finishing machine consists of a bowl lined with polyurethane material which is mounted on springs and uses vibratory motor and unbalanced weights to achieve gyroscopic motion to the workload. Vibratory finishing is used to achieve de-burring, edge radiusing, degreasing, de-scaling, polishing, mirror finishing and smoothening of a variety of components. This is the most common method used for de-burring and polishing of components which include sheet metal, machined, cast, forged & moulded parts.
Conveyorised Spray Cleaning System from Gala
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Gala’s Disc Finishing Machine
A wide range of components of Automotive, Aerospace, Defence and consumer products can be processed using vibratory finishing machines. Gala offers the following types of Vibratory machines based on the shape of the working bowl.
• Round Vibratory Finishing Machines are the most common type of machines used in manufacturing industry for a wide range of components. This machine can be used for small parts like rivets & screws to bigger parts like turbine blades. Gala offers machines from 70 to 1500 litre capacity. Standard and Auto Separation models are also available. • Spiral Machine is a modified version of Round vibratory finishing machine. This type of machine is used to ensure 100% separation of parts within a short time of 8 to 10 minutes. Due to the Spiral shape of bowl, the process efficiency is better as compared to round vibratory machine. Gala offers Spiral machines from 120 to 800 litre capacity. Spiral vibratory finishing machines are used for parts of bearing industry, brass valve bodies, furniture
COMPANY PROFILE industry, etc. • Elliptical Vibratory Finishing Machines are used where processing time is less than 10 minutes. This is used for removing light burrs and general finishing of small parts like bearing cages, ceramic insulation tiles, etc. Elliptical machines are available up to 250 litre capacity. • Trough Vibratory Finishing Machines are used for de-burring, degreasing and polishing of medium size parts like axles, shafts, rods, marble & granite tiles, turbine blades, aerospace parts, etc. Gala offers machines from 100 to 1200 litre capacity. • Segmented Machines are used for bigger parts to avoid part to part hitting while processing. Segments are provided to make compartments in working bowl where one or a few parts are loaded for finishing. Normally 3 to 8 compartments are provided. Gala offers segmented Round and trough vibratory finishing machines as per the customer needs. These machines are used for parts like machined aluminium die cast parts, parts of hydraulic industry and so on. Centrifugal Barrel Finishing
This is a more aggressive form of finishing
Multistage Ultrasonic Cleaning Equipment
as compared to Vibratory finishing. This machine uses 3 or 4 barrels mounted on turret assembly. The high rotation speed of turret results in high centrifugal forces which results in faster process. These machines are often used with variable frequency drives to adjust the rotational speed as per process need. The surface finish achieved with this process is more uniform and even. Such machines are used in various industry sectors like jewellery, bearing, compressor, automotive and aerospace. Centrifugal barrel finishing is capable of achieving high Ra values up to 0.06 microns for parts like textile rings, reed valves, bearing rollers, etc. Centrifugal Disc Finishing
This is the most aggressive form of surface finishing as compared to Vibratory finishing or Centrifugal barrel finishing.
The resulting forces are at least 10 times higher as compared to Vibratory finishing process. This machine consists of a tub or housing with a rotating disc at bottom driven by electric motor. Complete automation is possible with component loading, separation trolleys, and media reloading using PLC -based controls. These machines are popular in processing parts like coin blanks, medical implants, fine blanked components and precision components of automotive & aerospace sector. Customised Finishing Systems
Completely automated finishing systems can be offered along with Vibratory finishing and Disc finishing equipment. Automation results in achieving higher production rates and process consistency. Fully automatic finishing systems can be offered using component loading system, separation equipment, compound dosing system, conveyors and PLC- based control panel. Customised systems are popular in applications like processing of coin blanks, medical implants, fine blanked parts, drive chain components, bearing rollers & cages and so on. Parts Cleaning
Centrifugal Barrel Finishing System
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Parts cleaning is an essential process of the manufacturing industry. Parts cleaning equipment are used to remove all types of contaminants from the surfaces of components. Parts cleaning machines are used for degreasing, de-scaling, removing
TNC 640 – The new High-End Control for Milling and Turning Operations The new TNC 640: for the first time, milling and turning are combined in one TNC. Now users can switch as desired between milling and turning—within the same NC program. Switchover is independent of the machine kinematics. It automatically takes the respective operating mode into account and without any additional action.This new simplicity is complemented by dialog-guided plain language programming, the optimized user interface, powerful programming aids as well as comprehensive cycle packets taken from amply field-proven HEIDENHAIN controls into the new TNC 640.
HEIDENHAIN OPTICS & ELECTRONICS INDIA PRIVATE LIMITED
Angle Encoders
Linear Encoders
Chennai 600031, India
Contouring Controls
phone +91 44 3023 4000
Position Displays
Length Gauges
www.heidenhain.in
Rotary Encoders
COMPANY PROFILE metallic burr or particles and other solid particles of contamination. Parts cleaning can be achieved by using Immersion, Spray and Ultrasonic Techniques or combination of these techniques. Gala offers complete range of aqueous parts cleaning equipment which includes Spray cleaning, Ultrasonic cleaning, Rotary screw, Single Chamber multi-process and customised machines. The company also builds customised machines which include Ultrasonic machines with material handling system, drying with centrifuge arrangement, Single piece flow and so on. It is capable of building large machines as big as 5000 iitre capacity Ultrasonic cleaning machine for very big parts and 60 feet long conveyorised washers. It offers machines suitable for batch & continuous production and also for Single piece flow lean production. Gala equipment are preferred for precision cleaning of parts of industries such as aerospace, automotive hydraulic, engineering, electronics and many others. Machines can be built to meet stringent requirements of achieving Gravimetric (Millipore or NAS standards) values of less than 1 mg and particle size as per class A for precision cleaning. Gala is indeed a one stop solutions provider for equipment and cleaning compounds.
4 bar and basket rotation speed is in the range of 3 to 6 RPM. Rotary basket machines are suitable for general cleaning of small components such as machines parts, sheet metal parts, fasteners, springs, etc.
of medium and heavy parts such as housings, axle box, brake drums, machined castings & forgings. Parts can be loaded in basket or can be placed on work table. Wash, Rinse and dry cycle can be offered.
Rotary Indexing
Conveyorised Washing
This is suitable for small and medium size parts. Component loading can be at the same or at different locations. A single part is indexed in cleaning, rinsing and drying zone and follows single piece flow. Component loading and unloading can be manual or automatic with pick & place device or with robots. Rotary indexing machines are suitable for cylinder liners, shells, and machined cast parts.
Conveyorised washers are popular as they support continuous production and easy to operate. Components travel on conveyor with or without trays and pass through enclosed chambers. Spray, rinse and dry sections can be customised based on the cleaning requirements. Conveyor can be made of steel wire mesh and chain & rod type. Conveyorised washers are suitable for parts like aluminium or brass shells of ammunition, connecting rods, containers, bins, housings, wheels, rifle scopes, gears & sprockets, machined castings & forgings and reflectors.
Rotary Screw
Rotary screw spray cleaning machines are suitable for continuous production. The cleaning and drying stages can be customised. Machines are available from 30 kg/hr to 1500 kg/hr capacity. These washers can be integrated with other production equipment to maintain production flow in a uniform manner. These washers are popular for components such as stamped washers, fasteners, small arms ammunition shells, etc. Cabinet Front Loading
Spray Cleaning
Gala’s comprehensive manufacturing range also includes spray cleaning machines up to 100 bar spray pressure. Spray cleaning machines are widely used for washing of components such as machined parts, stamped parts, cylinder heads, cylinder blocks, connecting rods, crank shafts, housings, bearing parts, fasteners, transmission parts, ammunition shells, containers, etc. The spray cleaning machines are offered in the following configurations: Rotary Basket
Rotary basket washers are compact machines suitable for small parts in batches. These machines are simple to use with wash, rinse and dry options. Spray pressure is in the range of 2 to
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These washers can have fixed or rotating work table. This is suitable for cleaning Gala’s Phosphating Plant
Ultrasonic Cleaning
Gala manufactures a whole range of Ultrasonic Cleaning Machines from 20 to 5000 litre capacity. The company can offer material handling system for multistage ultrasonic cleaning machines for ease of handling of parts. Multistage machines are customised to suit customer needs with options of multiple cleaning, rinsing and drying. Ultrasonic cleaning machines are
COMPANY PROFILE used for precision cleaning of parts which are complex in configuration and geometry and / or which require stringent gravimetric values and particle size count as per class A. Ultrasonic cleaning machines are widely used for cleaning of precision parts of aerospace and automotive sector like engine valves, pistons, turbine blades, fuel injection parts, coil springs, bearing cages etc. This technology is ideal for cleaning of electronic parts & PCB’s, moulds, optical parts and lenses. Gala can provide ultrasonic transducers of tank bonded, immersible box and rod type, based on application. Operating frequency can be 25 KHz or 30 KHz or 40 kHz to suit cleaning application. Ultrasonic cleaning machines offered are: Table top, Multistage and Multistage with material handling system.
Customised Solutions
Gala also offers customised cleaning solutions to meet customer’s special requirements. It can build machines for Single piece flow or Robotic washing. Phosphating Plants
Gala also offers pre-treatment, passivation and phosphating plants. These plants can be fully automatic with material handling system, PLC based control panel and SCADA system.These are offered with features like basket rotation, auto dosing, walking beam material handling arrangement, etc.
Single Chamber Multi-process Cleaning
Material Handling
Machines (SCMP)
Gala also builds and offers material systems for conveying components. The
Single chamber multi process cleaning
54
machines offered by Gala are compact in size. Spray, Immerse flood wash and Ultrasonic wash cycles are possible in this configuration. Vacuum drying also can be provided on customer request.
MACHINE TOOLS WORLD MAY 2018
range includes Belt Conveyors, Inclined Conveyors, Component Loading Systems and Vibratory trolleys. Industrial Dryers
Drying is a natural corollary in the process of components cleaning. Hence Gala also offers Industrial Dryers of various types. These are Vibratory, Belt type, Rotary Screw, and Centrifuge Dryers. Undoubtedly, Gala Precision is a One-stop-shop for Solutions for Surface Finishing, Cleaning, Washing and Drying of Precious Machine Parts and Components. Quantity, size or criticality doesn’t deter Gala from offering a solution to any industry to the utmost satisfaction of the ultimate customer. - P.K. Balasubbramaniian
COMPANY PROFILE
Shavo Technologies offers high-tech tailor-made solutions
Rushil Shah, Managing Director, Shavo Technologies Pvt. Ltd.
S
havo Technologies Pvt. Ltd., a part of the Shavo Group founded by Mr. H.K Shah, a pioneer in the pneumatics field in 1960, is in the frontiers of niche high technologies cutting across diverse disciplines. The company headquartered in Pune and headed by Mr. Rushil Shah, Managing Director, 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 portfolio, the company serves over a thousand customers from diverse key sectors including semiconductor, aerospace, defense, chemical, oil & gas, automobile and so on. “Over the years, we have gone from selling components to systems and solutions and turnkey capability in an effort to keep offering better value by leveraging the technologies we
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provide,” says Mr. Rushil Shah. All its principals have specific technologies that would be classified ‘cutting edge’ considering the fact that all of them are world leaders in their fields. Following are brief details of their principals and business areas: TESCOM is a recognized leader in the manufacture of high-pressure regulators up to 20,000 psig designed to work with all types of fluids, both corrosive. Tescom range covers over 70 standard models of high-pressure regulators to meet almost any requirement. HAM-LET specializes in the design, development and production of high quality instrumentation valves and fittings in a wide variety of materials for high, pressure, temperature and vacuum applications. These products are used in diverse industries like petrochemical, semiconductor, energy, food, biotechnology, pharmaceutical, defense, pulp & paper and mining. CLASSIC FILTERS brings you filter
elements to filter housings to complete filter systems for almost any function. It delivers some of the most robust high quality, coalescing filters and particulate filters in the world. In order to manufacture high tech devices such as semiconductor devices, flat panel displays and even photo voltaic or solar cells, precise fluid control is a must. HORIBA is the established world leader in offering a full line-up of gas, liquid, and vapor delivery products. Applied Energy System Inc. is one of the world leaders in the field of ultra high purity gas delivery systems like gas cabinets and panel for solar, semiconductor, nano technology and other high purity industries. Gas specializes in design and manufacture of air moving products including vacuum pumps, compressors, air motors, gear motors, vacuum generators and regenerative blowers. “As a matter of fact, our journey of working with high technology
High pressure regulators
COMPANY PROFILE
High quality instrumentation valves
industries started with Gast which today remains one of the world leaders in air motors and fractional horse pumps,” reveals Mr. Shah. Meech’s forte is industrial electrostatics. With a standing of over 40 years, Meech has developed a wide range of products like ionizing bars, hand-held ionizing air curtains, etc. for effective static neutralization and dust removal. With the experience gained from more than 200 successful web cleaning installations, Meech can offer both non-contact and contact web cleaning systems. ITT Enidine is again a world leader in energy absorption and vibration isolation products, providing solutions to a wide range of industrial markets. ITT Corporation is a high-technology engineering and manufacturing company operating on all seven continents in three vital markets viz. water & fluid management, global defense & security, and motion & flow control. Shavo feels fortunate to work with some of India’s top companies and institutions like Reliance, Tata’s,, Biocon, GE, Department of Space, Ministry of Defense and many more. It has in excess of 1000 live accounts. The company has a full service
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Applied gas delivery systems
Electrostatics for effective static neutralization
capability at its Pune office and is in the process of building a world-class service center in its Bangalore factory. “Our service support is the key pillar of the value we provide,” says Mr. Shah. – P.K. Balasubbramaniian
For more information Web: www.shavogroup.com
MARPOSS 4.0 THE SMART FACTORY TOGETHER
ERGONOMIC DESIGN
INTERNET OF THINGS
REAL TIME SECURE DATA TRANSMISSION
SWITCH ON-OFF COMMANDED BY GUIDED SEQUENCE
WIRELESS HANDLE The innovative Marposs I-Wave2 wireless handle with its integrated colour display and ergonomic design is the perfect partner for any dimensional inspection requirement in today’s flexible workshop. Marposs Communication Software gives the user the opportunity to connect I-Wave2 to any computer for data collection. Marposs is the partner you need to make Industry 4.0 a working reality.
MARPOSS INDIA Pvt. Ltd.
147, Sector 7, IMT Manesar 122 050 - Tel. +91 124 4735700 | sales@in.marposs.com
TECH TRENDS
FACCIN’S PGS-ULTRA: CNC Control for Rolling Machines
T
oday CNC controlled machines can be found in almost all industries, from small-scale metalwork shops to big manufacturing companies. There is barely any phase of the manufacturing process that is not affected by automated CNC machines. Faccin SPA, world-leading manufacturer of plate rolling equipment foresaw back in THE EARLY 1980’s the need of the metal forming industry to have CNC-controlled rolling machines. After a continuous research and development, the first generation of Faccin-CNC bending rolls reached the metal forming manufacturers and for more than 30 years Faccin has been offering them all the benefits of the most advanced and powerful numerical control developed for bending rolls: the PGSULTRA. What benefits? The first benefit offered by Faccin’s CNC PGS-Ultra is improved automation for its plate rolls. The operator involvement linked to producing workpieces can be greatly reduced or eliminated. Therefore a CNC-controlled plate roll can run unattended during most of its rolling cycle, freeing the operator to do other tasks. This gives the CNC-controlled machine user other benefits like reduced operator fatigue, less mistakes triggered by human error and a steady and foreseeable rolling time and quality for each piece. Since the rolling machine will be running under program control, the skill level required of the operator will also be reduced, decreasing the dependability risk of the manufacturing company on a single highly skilled operator. The Faccin’s CNC PGS-Ultra, built with industrial SIEMENS hardware and a perfected user-friendly graphic interface, is so simple to use that even an
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unexperienced operator can program the rolling machine to produce simple circular shapes of different diameters and lengths or more complex pieces like polycentric tanks, spirals for ventilators, plates of variable lengths, and many more. The second major benefit of Faccin’s CNC-controlled plate-rolling technology is consistent and accurate rolled pieces. Today’s CNC-controlled machines manufactured by Faccin can claim unbelievable precision and repeatability of rolled pieces. This means that once a program is verified, no matter the quantity, identical rolled pieces can be effortlessly produced with precision and consistency. A third benefit offered by Faccin’s CNC-controlled plate rolling machines is flexibility. Since these machines are run from a very “easy-to-use” program, running a different workpiece is as easy as selecting it from a different shape option on the screen. Special and unique options are available in the standard configuration like the possibility to build programs for rolling variable thickness programs, calculation of the plate developed length, cycle time, etc. Once a program has been verified and executed for a production run, it can be easily recalled the next time the workpiece is to be run. This leads to yet another benefit, fast change-over. Finally yet importantly, a wide range of machine accessories like feeding table, plate centering, lateral and top supports, clamping devices, can be controlled with the CNC PGS-Ultra through an easy-touse motion control feature that manages 15 programmable directions (axes) allowing the operator
to configure all the accessories required in the manufacturing process of high quality rolled plates. Since programs can be easily loaded on the CNC PGS-Ultra, a very short setup time is required and therefore plate-rolling machines become very easy to set up and run which is imperative with today’s just-in-time production requirements. Faccin moves towards Industry 4.0 and fortifies competitiveness with its SMART solutions Manufacturing companies face today huge challenges, intensified pressure and the need to reduce production time, improve flexibility and increase quality with energy reduction. Faccin is ready for Industry 4.0 thanks to its Faccin SMART Package 4.0 that offers features like Systems Diagnosis, Teleservice, Management Control, Drawing Imports, Rolling and Production Lot Statistics and Flexible Network Solutions between others, helping the manufacturers of today, face the challenges of tomorrow. Do not miss the opportunity to BOOK A FACTORY VISIT (http://www.faccin.com/contact/) to see our latest developments!
TECH TRENDS
Global Tool Deterioration Analysis Looks Beyond Machining Cutting tools are fundamental elements of the metalcutting process. Depending on how the tools are chosen and applied, they offer the potential to maximise machining productivity or, on the other hand, create production bottlenecks. Much depends on how tool use is managed in relation to the overall manufacturing process
C
utting tools are by their nature consumable; they wear until they are no longer effective. A traditional approach to metal cutting tool management employs wear analysis alone, focused on manipulating tool materials, geometries and application parameters to improve part output and tool life in a selected operation. Maximising the efficiency of a facility’s entire manufacturing process, however, involves consideration of a broad range factors in addition to tool wear. It is essential to examine cutting tool wear or, more broadly, tool deterioration, in light of the overall or “global” manufacturing process.
Global Tool Deterioration Analysis (GTDA) goes beyond basic measurement of tool wear to include tooling-related considerations such as time spent in tool manipulation, problems other than wear, production economics, shop organization, personnel attitudes and assumptions, value stream management, and total manufacturing costs. GTDA is based on regular evaluation of a large number of a shop’s used cutting tools randomly selected to construct a comprehensive picture of their contributions to the facility’s manufacturing efforts overall.
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The Global Manufacturing Process Study of tool wear usually is limited to a single tool employed in a specific machining operation. However, to gain maximum benefits, it is essential to examine tool wear or deterioration in relation to all tooling in a facility’s manufacturing processes. The manufacturing process (Figure 2) begins with acquisition of raw materials and planning that involves utilisation of human intellect, technological resources and capital investment. The process advances through value-adding and value-enabling activities but may be restrained by waste-producing events that result in the loss of money, time and intellectual resources and consequently reduce part quality and yield. Output is measured in terms of part quality, the quantity required and desired production time and cost.
Manufacturing Process Evolution The methods used to analyse and predict tool life depend on the way in which the tools are applied. Over the centuries, manufacturing practices evolved from craft-level output of individual items to mass production of standardized parts. Improving manufacturing methods then brought about a second generation of mass production capable of producing
increasingly greater volumes of similar parts – a high volume, low product mix (HVLM) scenario. Most recently, digital technology as applied in programming, machine tool controls and workpiece handling systems is facilitating a third generation of mass production that permits cost-efficient, high-mix lowvolume (HMLV) production. Although the key performance issues remain the same – namely achieving cost and time efficiencies, a certain minimum quality and a certain level of yield – second- and third-generation mass production techniques require different approaches to tool life analysis. In a second-generation HVLM scenario, identical parts are machined from the same workpiece material in production runs that may last days, months or years using the same equipment and the same kind of cutting tools. In that situation, tool life management is relatively simple. Shop personnel use prototyping and trial runs to determine the best average tool life, then divide the desired volume of parts by the expected life of individual tools. Consistent tool life expectancy data enable a shop to plan tool changes that maximise tool utilisation and support continuous production. However, HVLM
TECH TRENDS
production methods are declining in prominence. To balance part inventory with demand and accommodate ongoing engineering changes, manufacturers are machining fewer and fewer parts in long, unchanging production runs. At the same time, third-generation HMLV mass production strategies are growing in acceptance. Rapidly adjustable HMLV processes match well with contemporary inventory and engineering goals, but the planning process is much more complex. A run of ten parts may be followed by part lots of two, five or even a single component. Workpiece materials may change from steel to aluminum to titanium, and part geometries from simple to complex. There is not enough time available to determine tool life through trials. In such cases, a workshop typically makes a conservative guess regarding a tool’s projected life and, to be safe, employs a new tool for each run then discards it well before the tool reaches its actual productive lifespan. A more global approach to tool wear analysis and predictions can help minimise waste of cutting tool capability. Binary Yield Possibilities Rapidly changing HMLV manufacturing methods increase the difficulty of achieving high percentage yields for machining operations. In the case of long-run HVLM production, trials and adjustments can produce yield percentages in the high nineties. On the other hand, yield in the HMLV situation may be binary. A successful single part run represents 100 percent yield, but when the part is unacceptable or a workpiece is ruined, the yield is zero. Demands for quality and cost and time efficiency remain the same, but
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first-time yield becomes an overriding requirement. In that case, avoiding tool breakage is perhaps the most important consideration. One advantage is that tool wear is a minimal concern in short run situations and a shop can apply, within reason, more aggressive and productive cutting parameters. Craftsmanship and the Human Contribution Lengthy and unchanging HVLM production runs tend to minimize the importance of human contributions to the manufacturing process. After a long run is initiated, operations can essentially be automated. Even in cases where an operator participates in every changeover between parts, the repetitive nature of these situations marginalizes the influence of operators and programmers. Flexibility is not required, and perhaps even discouraged. On the contrary, rapidly changing HMLV scenarios reemphasize the role of humans in the process, to the point that the operations require a form of traditional craftsmanship involving creativity and flexibility to efficiently adapt to the continually changing parts and cutting conditions characteristic of HMLV machining. Focus On Process Before Results Many manufacturing process analysis efforts focus on reviewing end results in relation to tool life and part output without thoroughly examining the process itself. Problems related to cutting tools, but not directly to tool life, may be missed and create production bottlenecks. For example, burrs typically are not related to tool life, but their occurrence interrupts the manufacturing process because another operation
must be developed and implemented to remove the burrs. Burr formation is, however, related to tool geometry and application parameters and therefore must be considered in tool deterioration analysis. Tool breakage, another problem not usually related to tool wear, does involve tool material, geometry, application parameters as well as machine tool factors. Elements of Operational Excellence The basic components of manufacturing efficiency are elimination of waste, inflexibility and variability. Comprehensive tool deterioration analysis takes into account five elements of operational excellence. First, it is essential to thoroughly understand the overall machining process and the relationship of the machining operation to the workpiece material. Second, attention must be given to waste reduction, through lean manufacturing strategies and other initiatives. Third, the concepts of production economics need to be employed to assure profitability. Fourth, percentage yield goals should be viewed in light of manufacturing volume and part variety; maximising flexibility must be viewed as a way to minimise bottlenecks, but variability has to be controlled to assure consistent part tolerances. Finally, it is necessary to emphasize the value of manufacturing personnel to gain maximum benefit from the unique and irreplaceable resource it represents. Considerations Beyond Tool Wear Global tool analysis supplements initial measurement of insert edge wear with analysis of the tools’ role in Cost of
TECH TRENDS www.mtwmag.com
Goods Sold (COGS) totals, Single-Minute Exchange of Die (SMED) analysis, Value Stream Management (VSM) results and Overall Equipment Effectiveness (OEE) percentages. The most basic tooling-related economic consideration is clear: tools cost money. Figure 4 presents the cost of various elements of the machining process and totals them as COGS. These data enable a shop to compare and contrast the various elements of production costs, with an eye on finding candidates for cost reductions that will boost operational profitability. Another tool-related economic factor is that tools cost time – the time involved in manipulating tooling outside of actual machining operations. Time spent in tool changeover and setup is analysed via SMED analytical techniques that also provide a view of costs beyond those generated by tool wear and replacement. Part of that expense is incurred in acquiring and organizing tooling and mounting it and loading programs into the machine tool. OEE determines how much of the available manufacturing time is used effectively. OEE analysis points out losses, benchmarks progress and improves productivity by eliminating waste. The total time available for production is identified, then the analysis subtracts planned downtime, unscheduled breakdowns, changeovers, minor stops and lost speed, and scrap and rework to arrive at effective
machining time expressed as a percentage of the total time available. A 100 percent OEE – a noble but practically unattainable goal –means a part is produced in the specified quality, as fast as possible, with no wasted time. VSM analysis illustrates the need to balance performance improvements among all the elements of the manufacturing process. Figure 5 is a graphic representation of the effects of improving the performance of one element of a system without improving others. Think of individuals rowing a boat. Higher performance by one rower would actually hurt the boat’s overall performance. Improvements in parts of the process must be made in view of their relation to production volume and variety, workpiece material characteristics, part geometries, machine tool and fixturing requirements and other considerations to achieve and maintain a manufacturing operation that is in balance overall. Global Tool Deterioration Analysis GTDA is basically a simple process. The cutting edges of a large number of randomly chosen tools from throughout
a shop are examined one edge at a time to determine which edges are worn. The wear is classified according to its type and amount. Traditional tool wear analysis concentrates on one tool in one operation; GTDA gathers information about tool wear and other tool-related issues from the entire shop, then applies COGS, SMED, VSM, OEE and other analytical tools to compile additional data that will guide planning and implementation of improvement programs. To be successful a shop must have the discipline to begin a GTDA program and, equally important, continue tool examination and data analysis on a regular basis. Another form of discipline – honesty – is required as well. A shop must honestly and objectively accept the results of the analysis and be willing to act on the findings without regard to shop traditions and politics or unsupported opinions regarding tool application parameters. Conclusion Tool wear is inevitable and managing it is essential to achieve successful machining operations. However, tool wear is just one example of the many influences of cutting tools on the efficiency of a facility’s overall manufacturing process. GTDA goes beyond wear analysis of single tools to include all the tools in a shop as well as a wide range of significant tool-related influences outside the cutting process.
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TECH TRENDS
HEIDENHAIN Encoders for industrial robots Significant accuracy improvement at the tool center point Speed, power and durability are key characteristics of industrial robots. These robots are typically used in applications such as welding or in lifting heavy components for vehicle assembly. Yet despite advanced calibration methods, the position accuracy of industrial robots has been inadequate for certain tasks. This is now changing thanks in part to highly accurate, output-side encoders from HEIDENHAIN and AMO.
T
he main driver behind this development has been the aerospace industry because it must perform highly accurate machining operations on very large components. Machine tools would achieve the required level of accuracy with ease but are either too inflexible or too expensive as special-purpose machines for the job sites and working spaces involved. A robot, however, can easily reach any position on a very large component, such as the fuselage of an aircraft, and can perform tasks on it such as drilling and milling.
• In order to achieve the desired level of maneuverability, robots with serial kinematics are required, such as articulated robots with six axes. • Each one of these axes is driven by a servo motor with a gear train. Zero position error, backlash, and joint elasticities are the main sources of inaccuracy. • Applied forces and dynamic effects during the machining process affect the rigidity of the robot’s mechanics and negatively influence the absolute position accuracy.
Accuracy is impaired by many factors For these kinds of applications, however, the tool center point (i.e., the tool at the end of the robot’s arm) must be positioned and guided with sufficient accuracy. This is where the classic industrial robot runs up against its limits. Deviations result from a variety of factors:
Thanks to advanced calibration methods, it is already possible to move a tool center point to a certain position repeatedly to within several hundredths of a millimeter. Depending on the manufacturer, the repeatability of articulated robots as per ISO 9283 is ±0.1 mm or better. However, when compared with
Figure 1: Classic HEIDENHAIN rotary encoder for motor feedback
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repeatability, the absolute position accuracy that can be achieved within the robot’s coordinate system is worse by a factor of ten. Depending on their design, maximum range, and maximum load capacity, articulated robots currently achieve an absolute position accuracy of ±1 mm. This is insufficient for meeting the accuracy requirements of industries such as the aerospace sector. Yet robot manufacturers have been responding to this problem. Step 1: highly dynamic motor control Classic rotary encoders continue to provide the servo motor feedback at the robot’s axes. Because servo motors require high control dynamics, the robust inductive rotary encoders from HEIDENHAIN, such as those of the ECI 1100 and 1300 series, or multiturn models of the EQI 110 and 1300 series, are ideal for this type of application. These encoders deliver high control quality and system accuracy, and they are resistant to strong vibrations. Since these encoders feature a purely serial EnDat interface, even applications exposed to strong electromagnetic interference do not impair data transfer quality or safety. These inductive rotary encoders support safety integrity level SIL 2, category 3 PL d. They can even attain SIL 3, or category 4 PL e, if additional measures are taken on the control. These encoders also provided the added safety advantage of mechanical fault exclusion against the loosening of the shaft and stator connection. With this safety package, these inductive rotary encoders can also be used in systems designed for human-robot collaboration.
TECH TRENDS Step 2: secondary encoders for highly accurate position measurement Robotics manufacturers can significantly improve the absolute position accuracy of their robots by using additional, high-accuracy angle encoders or rotary encoders at every robot axis. These socalled secondary encoders, which are
Figure 2: Improvement of the absolute position accuracy through the use of socalled secondary encoders on every axis
Figure 3: High-accuracy HEIDENHAIN and AMO encoders for absolute position measurement on robots
mounted after each gear train, capture the actual position of every robot joint. This allows the encoders to account for zero position error and backlash. The retroactive forces on each axis resulting from the machining task are measured as well. All of this results in a 70 to 80 percent improvement of the absolute position accuracy at the tool center point. Modular angle encoders, such as the HEIDENHAIN ECA 4000 with optical scanning, the HEIDENHAIN ECI 4000 rotary encoder with inductive scanning, and the AMO WMR angle encoder, are well-suited for these applications. Thanks to their modular design with a scale drum or scale tape and a separate scanning unit, these encoders are well suited for large hollow-shaft diameters and for the challenging installation requirements often encountered in robots due to space constraints. The signal quality of these secondary encoders is considerably better than that of the rotary encoders on the servo motor, meaning that the returned position values are significantly more accurate—even for highly dynamic movements. Step 3: accurate position measurement for movable robots In order to reach all of the machining positions on very large or long components, such as an aircraft fuselage or for manufacturing large composite fiber components, robots can be moved along the length of the component on linear axes. For the highly accurate
ECA 4000
ECI 4000
WMR
Scanning principle
Absolute, Optical
Absolute, Inductive
Incremental, inductive
Inside diameter
70 mm to 512 mm
90 mm / 180 mm 60 mm to 10 000 mm
Resolution
29 bits
20 bits
Depends on the subsequent electronics
System accuracy
±2“
±25“ / ±40“
±3“ per meter of arc length
Resistance to contamination
+
++
++
Mounting tolerances
+
++
+
Table 1: Comparison of the most important specifications for typical secondary encoders
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positioning of robots with a linear drive, enclosed linear encoders from HEIDENHAIN are available in lengths of up to 30 m. Position measurement from a linear encoder compensates for thermal errors and other factors that influence the feed mechanisms. These factors cannot be captured by means of conventional position detection methods based on the pitch of the recirculating ball screw and the angular position of the rotary encoder on the motor.
Figure 4 : HEIDENHAIN linear encoders
Conclusion: highly-accurate position measurement improves accuracy at the tool center point The use of secondary encoders on all of a robot’s axes, as well as the use of linear encoders for positioning the robot relative to the workpiece, enables a level of accuracy at the tool center point that allows appropriately equipped industrial robots to perform positionally accurate machining and handling tasks on components. Angle and linear encoders from HEIDENHAIN and AMO offer not only the required system accuracy but also the necessary flexibility for installation in complex and compact robot mechanisms. The suitability of these encoders for safety-related applications also makes it possible to implement human-robot collaboration systems.
For more information Web: www.heidenhain.com
Visit us at :
21st to 25th June 2018 Chennai Trade Centre, Chennai, India
Hall: C, Stall No.: C36
TECH TRENDS
Inter-stage Membrane Dryer: Lower Life Cycle Costs, Zero Maintenance
H
ow a submarine dives into the deep sea and re-surfaces is a question of simple physics. And aiding in this function is air compression technology. The vessel floats on the surface when the weight of water it displaces equals its own weight. This displacement of water creates an upward force called buoyancy that opposes the downward acting gravity. Since a submarine can control its buoyancy, it can submerge and re-surface. A submarine controls its buoyancy with the help of its ballast tanks; these tanks are filled with water to increase the overall weight of the submarine, thus allowing it to submerge. And when that water is pumped out by displacing it with compressed air, its weight is reduced and the submarine re-surfaces. So by either flooding the ballast tanks or venting it, the submarine can dive or rise. But compressed air is required not just for charging ballast tanks to change buoyancy but also for life support. A constant supply of compressed air is therefore maintained on board in large steel pressure vessels called air flasks. Clearly, the air compressor is a critical piece of equipment on board a submarine. However, storing a large amount of compressed air alone is not enough; that air also needs to be dry in order to ensure safe operation. Compressed air at a high
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pressure enters ballast tanks through a blowing valve. And since the air gets throttled in the process, its temperature drops substantially. If there is moisture in the air, there are chances of that moisture freezing in air passages or in the blowing valve itself. Hence in the humid marine environment, maintaining air quality is crucial not just for diving and rising but also for engine controls, weaponry and various other control systems. Compressed air is therefore maintained at a minimum of -20o C at atmospheric dew point. Failure to do this resulted in the sinking of the USS Thresher, a US navy nuclear submarine in 1963. The vessel sank as the presence of moisture in the compressed air led to icing in the blowing valve. Following this disaster, the usage of air dryers on all submarines has been made mandatory the world over. However, the traditional absorption technology that is widely used in air dryers has its disadvantages. The desiccant granules in dryers turn into clay or become powdery over time that need to be replaced periodically. J.P. Sauer took up this challenge and developed a high pressure dryer with a membrane that efficiently separates water vapour from an air stream. The membrane consists of thousands of hollow fibres bundled together. As moisture-laden air flows through the membrane, it travels
through and around the hollow fibres. The fibre bundle is enclosed in a long tubular container that ensures efficient flow of air. Moisture is removed by selective permeation and dry air exits at the opposite end. The dryer is fitted before the final stage of the compressor and hence the name Inter-stage Membrane Dehydrator (IMD). It improves the life of final stage valves and piston rings. This new technology is also cost effective. Another big advantage of IMD is that it is maintenance free throughout its service life, except for periodic replacement of the pre-filter element. These coalescing pre-filters installed before the membrane dryer remove the bulk of the water vapour and any trapped compressor oil. Since the IMD does not need electricity, it is ideal for use in remote applications. Moreover, since it has no moving parts, it is also ideal for heavy duty installations and work efficiently in harsh environments including shipboard systems and power plants. Its initial cost is higher than a desiccant dryer but its overall life cycle cost is far below other dryers that offer the same air quality.
The new control system PNOZmulti 2 with up to 80% less energy consumption …
… than comparable products. The power consumption of the new base unit PNOZ m B0 is a minimal 0.8 W with 20 safe inputs and 4 safe semiconductor outputs (PL e, SIL CL 3) and a width of just 45 mm. Rely on 10 years of innovation from the market leader in safe control technology! Count on the configurable control systems, the worldwide safety standard for all machine types. The simple, graphics configuration tool saves engineering costs because you can create your safety circuit simply and intuitively on the PC. Visit us at the Hannover Messe, Hall 9, Stand D17.
Further information about the PNOZmulti Configurator: www.pilz.com + Web code: web10522
Pilz IndiaPvt. Pvt.Ltd Ltd Pilz India 201, Shankar Seth Road, Pune - 411Sahakar 042 Nagar NO 1, Pune - 411009 Office‘CYBERNEX’, NO 102 & 202, Delite Square, Near Swargate, Aranyeshwar Temple, Telephone: +91 (0) (0) 20 20 49221100/101/102, Fax(0) +9120(0)24213996, 20 49221103, www.pilz.in, info@pilz.in Telephone: +91 24213994/95, Fax +91 Web: Web: www.pilz.in, Email: Email: info@pilz.in
TECH TRENDS
Pulsed MIG/MAG welding and its advantages over conventional MIG/MAG processes
P
ulsed MIG/MAG welding is a variant of the conventional MIG/ MAG welding process in which the current is pulsed. Pulsing was introduced originally for control of metal transfer at low mean current levels by imposing short duration high current pulses. The cycle consists of applying the repeated pulse current over a constant background current: Modern welding sets permit the use of a wide range of pulse amplitudes, durations and waveforms at frequencies from a few Hertz to a few hundred Hertz. Pulse amplitude and duration are best combined to melt and detach a single droplet of the same/slightly smaller diameter as the electrode wire. Selection of pulse parameters for a given wire feed speed is a complex operation. Pulse height and duration are a function of wire composition, diameter and to a lesser extent, shielding gas composition. This has lead to the advent of Synergic welding sets. Synergic MIG/ MAG (GMAW) welding is a variant of pulsed MIG/MAG welding. A synergic welding set provides unit current pulses to detach identical molten droplets of predetermined volume from the electrode wire, combined with the other parametric
relationships necessary for stable wire burn off. Unit pulses are unique to a given material and wire diameter and their details are programmed into a synergic welding set. Modern sets contain a variety of consumable and wire diameter combinations, including programmes for flux and metal-cored consumables. The three essential characteristics of synergic operation are: a. Pulse parameters are selected automatically. b. Pulse frequency or duration is directly related to wire feed rate. c. Electronic control of parameters ensures uniform penetration and weld bead profile. In practical terms, this allows an operator to pre-select wire material and diameter once for any welding operation, then adjust the one control that governs wire feed rate. The ‘one knob’ operation synonymous with this type of power source is the principal advantage of such a system compared to conventional non-synergic sets, which require that the pulse parameters (pulse frequency, peak/background current etc.) be individually set for a given wire feed speed. Thus synergic welding sets offer the
advantages associated with pulsed MIG/ MAG welding, combined with a ‘welder friendly’ control system. Synergic control is also used in conventional MIG/MAG, in which the voltage is adjusted in relation to the wire feed. It is now possible to buy a ‘synergic wire feeder’ which performs this function in conjunction with a standard rectifier power source. Advantages provided by pulsing machines include: 1) Wire and gas savings: Pulsed MIG machines offer a wider operating range because they extend the low and high range of each wire diameter. For instance, before the operator would have to stock .035”, .045” and .052” wire diameters for varying applications, but with Pulsed MIG, .045” can be extended on the low end and top end range so that it can be used for a variety of applications. What this means is that rather than having two or three different sized wires, an operator would only require one. Having one wire type minimizes inventory costs and reduces changeover times. The same is true with shielding gas – one gas can reach both the low and high ranges of the application. In addition, the different types of spare parts (gun, gun tips, liners, etc.) are decreased for additional cost savings. 2) Spatter and fume reduction Compared to Conventional MIG, Pulsing offers reduced spatter and fume. Reduction in spatter translates into significant cost savings because more of the melted wire is applied to the weld joint, not as surface spatter on the product and surrounding fixtures. This also means less clean-up time. A reduction in the welding fumes creates a safer and healthier environment for the entire plant or shop.
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TECH TRENDS 3) Heat reduction Pulsing offers controlled heat input leading to less distortion and improved overall quality and appearance which means fewer production problems. This is especially important with stainless, nickel and other alloys that are sensitive to heat input. 4) Improved productivity Pulsed MIG offers high deposition rates. In addition, since the new machines are simpler and adaptive, it is easier to weld with pulsed MIG than other transfer methods, less time is spent training. 5) Better quality All these advantages of Pulsed MIG outlined above result in overall better quality of the finished and a more stable arc. In addition, operators are receiving a better quality working environment since they are not dealing with fume, spatter & extra clean-up or grinding time. One more benefit is that synergic power sources allow for these high quality welds to be achieved by those with relatively less training. Pulsed MIG Compared to Other Transfer Methods Short Circuit In short circuit, the wire touches the work piece and shorts to itself. This is the coldest form of welding that still offers good fusion. Short circuit allows operators to weld on both thick and thin material in all positions. It also has the benefit of a small, quickly solidifying puddle. Its disadvantages include limited wire feed speed, and deposition rates. There is also a danger of “cold lapping” on thicker metals. This is where there is not enough energy in the puddle to fuse properly. Short circuit also produces an increased amount of spatter over the other transfer methods. Globular The globular transfer mode is basically uncontrolled short circuit. It is characterized by a large volume of weld metal coming
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off the electrode. These large droplets are pinched at the arc and drop into the puddle. This method of transfer produces a tremendous amount of spatter as well as high heat input. Also, globular is limited to flat and horizontal fillet welds. Less fusion is often common because the spatter disrupts the weld puddle. Also, because globular transfer uses more wire, it is generally considered less efficient. On the positive side, globular transfer runs at high wire feed speeds and amperages for good penetration on thick metals. Also, it can be used with inexpensive, CO2 shielding gas. It is used mainly when appearance is not an issue. Spray Arc Spray arc propels small molten droplet of the electrode to the work. It is a pure CV process that must produce enough current to send a constant stream of metal off the electrode. Its advantages include high deposition rates, good penetration, strong fusion, good weld appearance with little spatter. Its disadvantages include high heat input, a limited range of welding positions and proneness to burn-through on thin materials. Customization of the Waveform To take the pulsed MIG process a step further, complete customization of the welding waveform can be done through state-of-the-art Waveform Control Technology. This technology allows the power source to be finely tailored to the wire and process. The power source rapidly adjusts the pulse waveform for superior welding performance. It does this by providing a fast or slow front edge on the pulse to transfer the droplet at the proper rate, the back edge then falls at a controlled rate to add the heat needed to wet the droplet to the puddle. With Waveform Control Technology®, built-in templates are set up in the power source for standard usage on a variety of materials. Variables such as ramp rate, peak time, tail out, and step off, among others are controlled in a precise
manner so that when there is a change in the process set-up, there is a corresponding change in waveform configuration. Equipment Selection Pulsed MIG welding has evolved quite a bit since it was first introduced to the marketplace. In the 1980s, it was a highly complex process that could only be performed by the most skilled welders. That was because the operator would have to know exactly how to set the machine for the correct wire feed speed to perform this type of welding. Today, this is all done for him or her as part of the synergic control. When the operator adjusts wire feed speed, the synergic operation adjusts the wave-shape and frequency automatically. The synergic operation of the machine makes it easy to use, even for the beginning welder, with a single knob that controls all operations. In addition, its sophisticated internal electronics are even “adaptive” to adjust for variations in stickout, gap or the torch angle. Ador welding has introduced the latest generation pulsed mig equipment Salient features • Synergic function for automatic selection of welding parameters with respect to • Job thickness • Joint Geometry • Wire feeder with remote parameter setting facility • Pulse MIG Power Source • Water Cooled MIG Torch • Water Cooling Unit Conclusion : Cost savings, better quality, improved productivity and easier operation… all these factors make Pulsed MIG an option that should not be overlooked. Although the high price tag may scare you, carefully weigh the initial investment with the benefits that will be derived over the long term. Take advantage of the new technological advantages provided by Pulsed MIG – one machine to handle virtually any application, flawlessly. (Courtesy: Ador Welding Ltd.).
TECH TRENDS
Tru-Edge Grinding increases productivity by changing power infrastructure
Replacing power boards and rewiring the facility achieved greater machine uptime and reduced operational costs for a successful precision tooling specialist.
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NC machines rely on certain fundamentals to achieve peak performance for maximum productivity. This not only includes the machine but importantly the infrastructure of the facility - specifically ancillary services such as power, air and coolant. Andrew Ritchie, ANCA Product Manager said: “We partner with our customers to help them install their machines correctly, yet they also need to understand the basics to get the most out of their CNC machines.” Tru-Edge Grinding found first-hand what can be achieved by setting up a facility to ensure high performance of machines, where they reduced power consumption by 4% while increasing productivity by double digit gains. Tru-Edge Grinding are in St. Henry, Ohio, USA. They serve their customers with precision tool manufacture and reconditioning services, in a wide range of industries including aerospace, automotive, food service, medical,
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mining, tool, die and mould, and woodworking. Director of Manufacturing, David Balster said: “At Tru-Edge we struggled for years with electrical related problems and the failure of machine electronics. After reviewing the three-phase electrical supply to our sixteen ANCA machines, we upgraded the power boards and replaced the cables to a higher quality with large gauge wires.” Director of Engineering, Frank Seger added: “Replacing power boards and rewiring our facility proved to be more than a worthy investment from a view of machine uptime and importantly cutting costs.” Balster continued: “We no longer turn off the power to the machines on weekends as this was creating problems when the machines were powered back up again due to power spikes. With ANCA’s idle shutdown feature, we found that there was no increase in our overall power usage by leaving the machines powered on.”
Andrew finished: “Investing in the best infrastructure for your facility will result in significant productivity benefits and cost savings, as well as increasing the life of your machine. The Site Preparation and Installation Manual supplied by ANCA outlines required auxiliary services. Before your machine is installed we encourage customers to read the manual and contact your nearest ANCA representative with additional questions.”
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TECH TRENDS
Realtime communication with KUKA.PLC mxAutomation Simple software integration of robots in production machinery and automation systems
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utomation with industrial robots is increasingly proving to be a key technology and thus an answer to current challenges. This can only be done successfully when the robots and the environment to be automated – machines, handling equipment, etc. This is where the software functions of KUKA.PLC mxAutomation come in, which, in combination with modern industrial realtime communication, allow efficient and sufficiently granular remote operation of the robot. Robots are not an end in themselves, rather they fulfill a wide variety of tasks that contribute to an overall automation solution. They can be used, for example, for preparation or post-processing of tools or workpieces of production machinery, or for handling tasks, such as loading and unloading. The end customer friendly automation of machine tools requires the integration of industrial robots in machining cells in such a way that modifications that have to
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be made by the operator, e.g. retrofits, are either applied to the robot automatically or at least ergonomically comply with machine operation requirements. Furthermore, all cell related operator actions, including those affecting the robot, must be possible from a single operator control unit in accordance with
the “Single Point of Operation” principle. This includes interaction such as normal operator control, safe retraction, teaching and diagnosis. In order to coordinate the operation of production machines and robots, communication is thus necessary between their control systems. Originally such
TECH TRENDS www.mtwmag.com
tasks were fulfilled by signals wired in parallel, until conventional field buses took over these functions. Some industries, such as injection molding, also standardized the meaning of individual signals with the Euromap67 interface. Only one programming interface In order to be able to program the movements of the robot and the machine at just one location, KUKA has created the KUKA.PLC mxAutomation interface. By this means, machine builders or system integrators can essentially integrate the KUKA robot controller into their machine controller. All programming and operator tasks for the robot can be performed exclusively from the machine controller and its operator panel. Special knowledge of robot programming is no longer necessary. Operator control of the machine/robot cell can of course be carried out from one source at the familiar machine panel. KUKA.PLC mxAutomation consists conceptionally of two main parts. A server program created by KUKA runs on the robot controller, which waits for commands for the robot to arrive via one of the field buses mentioned above. The actual robot control program runs on the machine controller; this program is created in the programming language and with the programming methods of the machine controller. In order to make this possible, KUKA provides the KUKA.PLC
mxAutomation library for the individual controllers. This is integrated by the machine programmer into his programs and it then packs the programmed robot commands and their parameters into corresponding data, which are then transferred via the field bus to the KUKA. PLC mxAutomation server running on the robot controller. The server interprets the data that arrive, executes the desired robot commands and sends return parameters, status messages, etc. back to the library on the machine controller. In order for the data transfer of the robot commands and their return values to take place as quickly as possible and deterministically, the cyclical process data of the particular field bus are used exclusively for this purpose. Up to five robots can be remotely controlled simultaneously by the machine controller in this way. The Application Programming Interface (API) of the KUKA.PLC mxAutomation library is based on the programming paradigm of PLCOpen’s Motion Control Function Blocks (MCFBs) and has been specifically expanded for KUKA robots. Nearly all functions which can be directly programmed on the robot are also available via the library. This includes general functions, such as reading of the current robot position, speed and acceleration, and also functions such as reading and writing local robot I/Os and variables. An application example for the advantageous
use of system variables is sensitive gripping of workpieces or packaged goods, where the use of axis-specific torque limitation is a proven means. Within the KUKA.PLC mxAutomation configuration, the system variable TORQMON_DEF can be assigned to a KUKA.PLC mxAutomation variable, which can then be written via the KRC_SetSysVar function. For the axis specific or Cartesian motion of the robot with LIN, PTP or CIRC, corresponding blocks are available. Here approximate positioning is also possible, as are exact time- distance functions or interrupts, for example. There are likewise functions for manual jogging of the robot and for teaching of specific points in space, which means that these operator actions can also be carried out from the machine terminal. Advantages over other approaches The KUKA.PLC mxAutomation approach has several advantages over other comparable solutions, in which the machine controller takes over control of the robot drives or motors, for example. The machine controller does not have to master complex robot transformations, and it does not need to know detailed machine data and metrics of the robot arms. KUKA.PLC mxAutomation works straight away with all KR C4 based KUKA robot types – from the KR AGILUS to the KR 1000 titan. KUKA has a proven, adaptable and integrated portfolio of robot arms: various reaches, payloads, shelf-mounted models, arm extensions, and optimized dead weights, etc. There is no risk that the machine controller, due to lack of knowledge of the mechanical limits of robot motors, gear units and mechanical components, will exceed these load limits, resulting in premature failure of the robot. Additionally the machine controller retains all advantages and features of the KUKA robot controller, such as energy efficient motion algorithms adapted for the specific robot arms, loads and moments of inertia, sophisticated exception handling routines or the entire safety functions.
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TECH TRENDS
Precise 2D/3D measurement using laser profile scanners The principle of triangulation - the geometric measurement using three-point relationships - has been known for many centuries. In the 18th century, this land survey method established itself in Europe. However, the procedure can also be applied on a significantly smaller scale. Using laser line triangulation, geometries can be measured very precisely on different surfaces. Sensors from Micro-Epsilon are based on this principle and can be used in many applications.
Multi-blade razor production requires a perfect angle position of the single blades in relation to the head, as this is critical for the final shaving performance.
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n order to operate a triangulation sensor using laser light, a laser beam is focused onto a target. A sensor array with high spatial resolution, which is tilted at a fixed angle to the laser beam, detects the diffuse reflection on the surface. If the distance between the sensor and the target changes, the angle at which the reflected light is transmitted onto the sensor array changes too and therefore also the position of the reflected light on the sensor array. The distance between the sensor and the target surface can be calculated via the angular relationships in the triangle. This measuring technique enables measurement accuracies in the submicrometre range. This measuring principle can also be extended to two dimensions by focusing the laser to a line rather than to a point. This procedure is then known as laser line triangulation. A two-dimensional sensor
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element instead of a sensor array acts as the sensor. When the laser line is projected onto a shaped surface, the straight laser line becomes a surface profile - this is why they are also called laser profile sensors. This surface profile can be calculated from the intensity values of the reflected light, which is transmitted onto a positionsensitive sensor element. Even if a third dimension is added, the target can be moved vertically to the laser line or the profile sensor can be moved vertically over the target. The sensor becomes a 3D laser profile scanner and so can produce a three-dimensional image of the surface. Key factors to consider in laser triangulation The performance of laser profile scanners depends on many factors. When all essential components including the laser source, the focussing lens for the
laser line, the receiving optics and the sensor element, are housed in one body, the conditions are perfect. The thermal and mechanical stability of the laser profile scanner is therefore much easier to control. Also, the distance between the sensor and the target, as well as the lighting, influence the quality of the measurement results. In order to suppress light interference, a filter is installed in front of the receiving optics, which is only permeable to the wavelength of the laser light applied. In addition to these key factors, other technical characteristics of the laser profile scanner also play an important role. The quality of the lens and the laser diode used decide how sharp the line can be focused onto the target. The spatial resolution of the sensor matrix and the performance of the processor used are primarily responsible for how precise and fast a surface profile can be calculated from the reflected light. In addition, the wavelength of the laser light plays a part in determining the precision of measure-
The scanCONTROL Configuration Tools software enables the configuration of scanCONTROL sensors using a PC under full support of Windows 10.
TECH TRENDS
In terms of their size, accuracy and measuring rate, the scanCONTROL series of laser scanners are among the highest performing laser profile sensors in the world.
One of the numerous application examples from different industries is the inspection of punch depth of the so-called stay-on-tab closure of beverage cans.
ment results. The laser line of a blue laser diode can be more sharply focussed onto the target than conventional red laser diodes. As blue laser light does not penetrate the surface too deeply, the measurement results are further improved. Only surfaces that are difficult to measure using conventional red laser profile scanners e.g. organic materials such as wood and food, or semi-transparent materials - are significantly better detected using blue laser profile scanners. Powerful scanners Micro-Epsilon offers a wide range of laser profile scanners based on the laser line triangulation measuring principle. The scanCONTROL series is among the highest performing profile sensors in the world. The scanners operate using a CMOS sensor matrix that provides a resolution along the x-axis - the direction of the laser line on the surface - of up to 1,280 points. The scanCONTROL 29xx-10/ BL version sets a new standard in terms
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of profile resolution, with a laser line length of 10mm. This results in a point distance of just 7.8µm, which enables the laser profile scanner to provide twice the resolution of previous laser scanners with a 25mm measuring range. The resolution in the z-axis can, depending on the sensor version, be less than 1µm. Their high accuracy enables the laser profile scanners to detect even the smallest of parts to the highest precision. The resolution along the y-axis essentially depends on how precise the target can be moved relatively to the scanner. With measuring rates up to 4,000Hz, surfaces can be measured very precisely and at very high speeds. The scanCONTROL laser profile scanners are equipped with a powerful controller that is already integrated inside the housing. The controller calculates the two-dimensional surface profile from the intensity values on the CMOS sensor matrix. Also, an evaluation of the profile is possible by using the SMART sensor versions. These enable frequently recurring, easy and complex measurement tasks to be performed directly in the sensor and to output these as measurement values. Set up and configuration is carried out via the Configuration Tools PC software, which enables, for example, the measurement of steps, angles and grooves. Parameter sets are recorded in the sensor. In addition, output of an OK/NOK signal is possible. The user does not require any external control and evaluation unit. For example, the height of a step on a surface can be measured. The height can then be output
as an analogue or digital signal via the interfaces. Alternatively, the scanner can output the “OK” signal if the value is in a predefined range; otherwise the signal is “NOK”. From a total of 26 measurement programs, an individual parameter set with up to eight programs can be used with the scanner (‘user modes’). Furthermore, it is possible to save up to 15 parameter sets in the scanner and to switch these via digital inputs. If the user wishes to evaluate the profile data externally, the laser profile scanner can also output all raw profiles of the sensor matrix. An Ethernet interface with GigE Vision enables connection to a PC. In order to simplify the integration into a customer’s own software, Micro-Epsilon offers libraries for C, C++ and C#, as well as LabView drivers. Integration into Linux environments is not a problem either due to corresponding libraries. Versatile application possibilities The laser profile scanners from MicroEpsilon are used in many different applications. Where high measurement accuracy and resolution are required, the scanCONTROL series demonstrates its strength. Typical applications can be found in precision mechanics, electronics and in the manufacture of precision parts. Also quality control in laser welding is possible. For these and other applications in harsh environments, Micro-Epsilon offers special accessories to protect the scanner. For example, a protective housing with exchangeable windows is available for welding applications. A special compressed-air purge system protects the optical components from dust. The scanCONTROL can be inserted into a cooling jacket for use in high ambient temperatures. The position of razor blades, the completeness of weld seams, the optimum dose of an adhesive and the correct gap size on a car chassis - all of these applications have been successfully solved in recent years using precision laser profile scanners from Micro-Epsilon. For more information, Website: www.micro-epsilon.com
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.
Intelligent Microprocessor-based, High Efficiency, Energy Savers specially designed for CNC machines
Our equipment are approved by major OEMs and exported (up to 2000 KVA) to countries in Europe, Middle East, Africa
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and Asia Pacific. So leave power quality and energy management to the experts – Unity Controls. With our nationwide network we are only a phone call away!
Contact us for Power Quality & Harmonic Audits to Conserve Energy and Save Costs.
The power quality & energy experts
D-137, TTC MIDC Industrial Area, Nerul, 405, Sapphire Arcade, 42 M.G. Road, Ghatkopar (E),400 Mumbai 400 077, India Navi Mumbai 706, INDIA +91-22-2501 3832 +91-22-2761 1872/ 33 / 4612 sales@unitycontrols.in www.unitycontrols.in
Ahmedabad l Bangalore l Chennai l Delhi l Gurgaon l Hardwar Indore l Jalandhar l Jamshedpur l Kolkata l Kanpur l Mumbai l Pune l Rajkot
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UNITY CONTROLS PVT. LTD
TECH TRENDS
Safely Hand in Hand A safe robot application is not created until the safety concept has been implemented by choosing the right robot and its safety functions and combining them with intelligent safety components.
Separate working areas with no direct interaction between man and machine: these are the principles that have applied to robot applications for more than 50 years. Up to now, people have thought that humans and robots sharing a workspace or a living area was something from the realm of science fiction. However, the new generation of robots, safe sensors and control systems, along with the new ISO/TS 15066 standard, offer practicable ways towards safe collaboration.
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urrent developments in the field of robot applications are characterised by the desire to allow man and machine to work as closely as possible with one another. Instead of man and machine cooperating by means of defined static transfer points, in future both partners will collaborate in a shared workspace and be deployed together on a flexible basis such that they can exploit their respective strengths. A new type of industrial robot is ready for this task, which is referred to as cobots. Cobot is a combination of the words “collaboration” and “robot”. The lightweight robots that are used can move loads of about 10 kg and have a sensory, tactile capability. As service robots, they are intended to “give humans a hand” with physically burdensome or monotonous tasks. Typical uses are pick-and-place applications, handling operations between different production steps or follow-the-line applications
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where the robot has to follow precisely a specified trajectory (e.g. when tracing a contour or for bonding tasks). In human-robot collaborations (HRCs) like this, the workspaces of humans and robots overlap both spatially and chronologically. By contrast with cooperation, humans and robots share a single working space in the case of human-robot collaboration. This combines the strengths and advantages of the machine, such as reliability, endurance and repeat accuracy, with human strengths, in other words dexterity, flexibility and the capacity to make decisions. The most conspicuous difference between “classic”, enclosed robot applications and human-robot collaboration is that collisions between machines and humans are a real possibility. But they must not be allowed to result in any injuries. This results in additional safety challenges.
Only the application can be safe Despite the new cobots, the following applies: robots cannot provide safety on their own. There are no safe robots, there are only safe robot applications. Safety results from the interaction of normative boundary conditions, the risk analysis that is based on it, the selection of a robot with the corresponding safety functions and the matching additional safety components, and finally from validation. This means that the ISO/TS 15066 “Robots and Robotic Devices Collaborative industrial robots”, which was published this spring, plays a key role. This Technical Specification makes it possible to implement safe human-robot collaborations following appropriate validation. Four types of collaboration are described in ISO/TS 15066 as protection principles. • Safety-rated monitored stop • Hand guiding
TECH TRENDS www.mtwmag.com
• Speed and separation monitoring • Power and force limiting When implementing a safe human-robot collaboration (HRC), system integrators can choose one of these “types of collaboration” or a combination of them for their application. The Technical Specification is moreover the first standard that provides detailed information on pain thresholds for various parts of the body, in its Annex A. These values form the basis for implementing the application with “power and force limiting”. In practice, it has been found that human-robot collaborations can often be achieved by combining a “speed and separation monitoring” and “power and force limiting” in ISO/TS 15066. The Annex to Technical Specification ISO/TS 15066 describes a body model. It provides information for each part of the body (e.g. on the head, the hand, the arm or the leg) about the respective collision limit values. If the application remains between these limits when a human encounters a robot, then it is standard-compliant. These pain threshold values are used in practice to validate a safe HRC. Pilz has developed a collision measuring device PROBms to measure forces and speeds. Equipped with springs
and appropriate sensors, the device can record precisely the forces generated in a collision with a robot, evaluate them in software and compare them with the specifications from ISO/TS 15066. As a member of this international standardisation body, Pilz has been actively involved with robot manufacturers, integrators, notified bodies, like German employers’ liability insurance associations, for example, and other automation companies in defining this pioneering standard for human-robot collaboration in the industrial environment. The final step is CE marking Manufacturers of robot applications are likewise subject to the principle that, by law, if they are exporting to European Union, they must carry out a conformity assessment procedure with CE marking. Attaching the CE mark confirms that the robot application meets all the necessary health and safety requirements. The challenge in the basic “risk assessment” for robot applications is that the boundaries between separate working areas for man and machine have ceased to exist. As well as the hazards presented by a robot, the human’s movements need to be taken into consideration. But they are not always calculable in terms of speed,
Pilz has developed a force measuring device to measure forces and speeds. Equipped with springs and accompanying sensors, the forces generated in a collision with a robot can be recorded precisely & compared with the specifications from ISO/TS 15066.
reflexes or the sudden arrival of another person. There then follow the “safety concept” and “safety design” steps including selection of the components. These are usually a combination of intelligent sensors that are interlinked, and control systems that make the necessary dynamic working processes possible in the first place. The selected safety measures are then documented in the risk assessment and implemented in the “system integration” step. This is followed by “validation”, when the previous steps are scrutinised again. The ultimate, safe robot or the ultimate, safe sensor technology to cover all possible safety scenarios in practice has not yet been achieved. The demands on safety technology always depend on the respective application. Safe robot cells can only be set up within the overall context of the robot, tool and workpiece plus any associated machinery such as the conveyor technology, for example. This means in practice that every application calls for a separate safety assessment. Implementing human-robot collaborations in an industrial environment is definitely going to increase; however, its growth will be heavily dependent on innovations in the fields of sensor technology and robotics. In practice, every application will then require its own separate safety assessment. Together, automation engineers, robot manufacturers, integrators and notified bodies will be able to make the vision of a robot workmate reality on a step-by-step and applicationby-application basis. Pilz as a solution supplier provides the relevant services and products and systems for safe robot applications. The company supports users with a services portfolio tailored to the individual life cycle phases of a robot system: from process analysis to risk assessment and beyond to CE marking. A specific training package on robot safety completes the range of services. For more information, Website: www.pilz.in
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Collaborative Robots: A vision to create better skilled jobs
Sharath Babu N, Head - Operations, MAC Machine Tools and Automation
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n our increasingly globalized society, technology disruption is taking place at a tremendous pace. Technology advancements are constantly being challenged to enhance process, improve product quality and reduce manufacturing costs. It’s time for us to venture more into understanding how we can leverage the intelligence of humans and delegate the complex but monotonous tasks to the robots. With the result of a collaborative environment between humans and robots, we can reach new heights in terms of production efficiency while focusing on the “thinking work” rather than the “physical work”. The technological advancements in the robotics’ space is going to prove paramount as companies try to explore new ways to retain the aging workforce proving to be more expensive for a plateaued year on year output. At the same time, being prudent, with the younger generations stepping into the shop floor, they would be more interested in value added work rather than rote tasks. One the main drivers of such technology is ensuring safety when humans and robots share the same workspace. The guarantee of lesser risk to human injury is high with standards such as ISO/TS 15066 coming into effect. It is becoming increasingly popular for robots to embed technologies having power and force limiting wherein the
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robot completely stops on human impact without harming the individual. These robots can also be integrated with 3-D scanning systems, vision systems etc., which enables it to respond to variations in input conditions accordingly. With OEMs and end users handling repetitive tasks to complex assemblies, this technology can prove its worth across different industries and applications. The flexibility and adaptability of these robots also means that they can now be put to work on smaller batches, with high mix, low volume manufacturing, opening automation opportunities even to SMEs. Flexibility is another important component to drive higher return on investments with lower costs of ownership. Multiple changes in component requirements pecked with the expectation of high quality standards, a collaborative robot can simply be programmed to the needs of the new application. In an industry that spends a considerable amount on tooling up
the production line, collaborative robots offer the prospect of nimbler and more responsive manufacturing. Digital and information technology will also play a key role when it comes together with robots to learn from past, predict what’s next and prescribe actions to drive positive outcomes. The robots can now be an enabler to collect several data points to measure the performance. With such data points being measured, we’ll be able to predict and single out defects, change motions to speed up and take on more work in a given span of time. The introduction of artificial intelligence and machine learning will pave a new way to leverage increased levels of collaboration with the robots as well. This allows for a leap in operational maturity of the supply chain. To conclude, while collaborative robots (known as “cobots”) might not be a direct substitute for industrial robots, it certainly is a lesser expensive option, friendlier to high-mix, low volume tasks adapting to process changes easily.
Team from MAC with a Cobot from Universal Robots
TECH TRENDS www.mtwmag.com
Nurturing Human Capital in Machine / Cutting Tools Manufacturing Industry
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n today’s world of business, it’s time we move beyond the concept of ‘Human Resources’ rightfully engaging to unearth ‘Human Potential’. Striving to fuel growth of ethical business with this Human potential-HP, this horsepower can be Giga watt equivalents creating value to their clients’ businesses by leveraging ‘Human Capital’. Human capital echoes the ingrained value base coupled with the thought of ‘Investment’.
K.V. Balasubramanya, Chief Human Resources Officer, MAC Group of Companies
Nurturing - A phenomenally powerful word, it denotes present continuous state, with no limits – reiterating growth is a continuous process. Human Capital - The collective consciousness of human beings in an organized corporate environment, represents the strongest capital that corporate has access to fuel its growth but understated & unrepresented in its accounting books.
Relevance of Human Capital in Machine / Cutting Tools Manufacturing Currently, Corporates are driven through globally networked economies operating under the sphere of VUCA, Volatility - Nature & dynamics of change, Nature and speed of change forces & change catalysts Uncertainty - Lack of predictability, the prospects for surprise Complexity - Multiplex of forces, confounding of issues & chaos and confusion that surround it Ambiguity - Haziness of reality, the potential for misreads & the mixed meanings of conditions In this environment, success of sustaining & growing organizations would depend on how people in the organization view the conditions under which they make decisions, foster change & solve problems. While VUCA makes it imperative that to sustain any business, nurturing human capital today is a prerequisite. Unique to the Machine / Cutting Tools Manufacturing sector is the need of professionals with high technology adoption with absolute humanitarian sensitivities. While professionals are needed to design, develop, test, install, commission, resolve problems & maintain the industrial process & shop floors productions, they should ensure preservation of ‘HSE
(Health, Safety & Environment)’ leading to quality of life and future. Nurturing the Human Capital • Right motivation, fair engagements, transparent communications and aligned rewards & recognition can create teams to be innovative and yield results beyond expectations. • Formulate teams and give them clear GOALS (KRAs) & KPIs, building healthy competition among teams and institutionalizing effective rewards & recognition practices with clear human connect, empathy & performance rigor. • Engaging with them in sharing & evolving direction setting & broader visioning of the company across all layers of the organization, making them feel a part of organization allows the organization to receive fresh inputs & innovative thinking. • Cross linked incentives, celebrating team achievements & collaborative successes celebrating combined success, builds a healthy human capital. Some facets to be considered for implementation by organization • Learning & Development: Keep the ORG focus, conduct TNA (Training Need Analysis), draw up a curriculum & plot a calendar to effectively administer. Capture the effectiveness post the learning intervention to learn on the ‘Gaps’ still prevailing. • Multi-Skills approach: Promote cross & multi-skill approach to build good Machine Tools knowledge. While this serves the constant hunger for learning new technology, platform & domain by Production Engineers / Supervisors / Operators, it also enhances one’s own capability & confidence. • Site / Plant visits & working environments at remote locations:
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TECH TRENDS
Typical Human Capital Nurturing Model for Machine Tools Vertical
Organizations should engage all people in site visits, understanding physical plants & engaging in integration & testing as a prerogative. This creates people to learn on the nuances of the processes involved. How can we ‘value’ human capital?
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Recognize those who are truly loyal, who trust & carry the DNA of the Organization in their blood & behavioral attributes along with performance. Motivate, Recognize and Remunerate them suitably. Celebrate performing people & achievers who have their organization loyalty, commitment & alignment.
In the eastern world like India, organizations that engage with their team meaningfully close enough to know their strengths, shortcomings, aspirations, family dynamics & support, but still be professional in their approach to build a performing team, have a unique approach to nurturing human capital.
Linear solutions global provider.
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ROLLON India Pvt. Ltd. - INDIA 1st oor Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA www.rollonindia.in - info@rollonindia.in
Linear Line
Actuator Line
Telescopic Line
Actuator System Line
Rollon is a global provider of linear motion solutions for several industrial sectors, such as: industrial machines, railway, automation, packaging and logistics, aerospace.
TECH TRENDS
Hardened Solutions in Linear Motion The benefits of induction hardened linear guides in heavy duty application
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o better manage heavy loads and to better resist both wear and deformation, thus ensuring a greater number of cycles and an higher performance.These are just some of the benefits that an adequate hardening process can offer to a linear guide in industrial and heavy duty applications. Rollon Group, global provider of solutions for linear motion, has gained significant knowledge in raceways induction hardening. This particular heat treating process allows to achieve considerable results in terms of quality, durability and reliability of linear guides. Efficiency of the Linear Guide : An Hidden Quality When it comes to linear motion rails, a high hardness value is critical. The less the surfaces is hardened, the sooner the
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rail will become susceptible to damage. If hardness doesn’t extend to a sufficient depth, the component won’t be able to withstand heavy loads over the course of its lifetime, which can result in time-consuming and costly downtime for the system. For Rollon, when choosing a linear guide for an industrial application, three main factors have to be considered: • INDUCTION HARDENED RACEWAYS: this heat treating process brings out the tough natural properties of steel, creating a thick zone around the raceway and ensuring hardness levels are achieved at critical depth and effective hardness. • MATERIAL PURITY: to achieve maximum hardness levels, rails
should be made from highquality, high-carbon composition steel that is specifically made for bearing applications. • ADDITIONAL SURFACE FINISH: once a raceway undergoes induction hardening, its surface can be further machined to improve its anti-friction capabilities. Induction hardening and subsequent grinding and honing remove tool marks and high spots. The extra smoothness, along with the hardness, both work to extend the life of the system. An Efficient Hardening Process: How is it possible to achieve an efficient hardening process? Unfortunately, some rail manufacturing processes don’t impart sufficient hardness to the rails. When
TECH TRENDS www.mtwmag.com
you consider the kinds of heavy loads that are applied to industrial raceways in warehouse automation, robotic cells, railway, machine tools and more, rails that have thin hardened surfaces will tend to crack under load. To avoid bearing failure, it’s important to know the location of the point of stress between the bearing and the rail. The maximum stresses, which are called Hertzian contact stresses, aren’t on the surface at all, but beneath it. For that reason, a rail’s hardened layer needs to extend deep enough below the surface— something many other processes simply cannot achieve. That’s where Rollon’s induction hardening comes in. Rollon’s Induction Hardening: Rather than creating a case-hardened surface, induction hardening creates a zone around the raceway with effective depths of 1.2 mm, successfully encompassing the maximum point of stress located beneath the rail’s surface. As a result of this process, an induction hardened rail can operate under heavy loads with no damage to the raceways over the course of its lifetime. In properly sized linear bearings, typical
life ratings range from thousands to hundreds of thousands of kilometers of travel. In this form of heat treatment, the metal first undergoes induction heating, a non-contact process that uses an electric current to create heat in the surface layer of a conductive material. The surface layer is then quenched, causing it to undergo a martensitic transformation and become harder than the base metal. Compared to other conventional heat treatments, induction hardening offers several advantages, including fast heating rates, low energy consumption and cost savings. It also refines the structure and mechanical properties of the treated parts. Because the subsurface stresses on a loaded raceway can hit 500,000 psi, both rail hardness and hardness depth are critical values to measure during the induction hardening process. Measured on a “C” scale, Rollon’s bearings hardness varies from 58 to 62 HRC. A rail’s hardness depth will vary, as will the rail’s overall size, based on the requirements of your applica-tion. Small models, such as Rollon’s size 18 Compact Rail, integrate a hardness depth of
2 mm. By contrast, large rails, such as Rollon’s size 63 Compact Rail, feature a hardness depth of 1.2 mm. BOX: Lubricating the hardened rail A lack of effective lubrication on the surface of your linear bearing can reduce its lifespan by a factor of 10. Although lubrication is something you can’t avoid, you can choose bearings that have minimal lubrication needs by design, such as those with well-sealed rolling elements. Rollon’s Compact Rails, for example, integrate sealed rolling elements that require only a small amount of external lubrication every 2 millions cycles, depending on the application. The need to add lubrication in Compact Rail linear guides is therefore very limited. 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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PHOTO FEATURE
MACHINE TOOLS WORLD magazine marks it successful presence in DIEMOULD INDIA 2018 at MUMBAI - NSE
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PHOTO FEATURE www.mtwmag.com
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TECH PROFILE
Optimising Cutting Tool Performance! Accusharp strongly believes that the most important expectation of any customer, from any metal cutting tool, always remains that the tool should Cut Fast & Cut Cost. And therefore, Accusharp has its prime objective to offer the most appropriate tools to customers, which would fulfill both the above expectations.
Mr. Ilyas Shaikh, Managing Director, Accusharp Cutting Tools Pvt. Ltd.
Metal Cutting Process can be analysed as below :
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Performance of any cutting tool is the result of complex combination of many factors in the machining process.
ollowing are some of the influencing factors to be considered to yield out the optimised performance from a metal cutting tool and a machining process. Type of Tool Metal Cutting Processes and Cutting Tools Used : a) Drilling, b) Reaming, c) Milling, d) Turning, e) Threading, etc. are some of the common metal cutting processes. Types of Cutting Tools used for the above processes are: Drills, Step Drills, Reamers, Endmills, Taper Endmills, Ball-Nose Endmills, and various types of Insert, etc. Cutting geometry of a tool depends upon the type of machining operation to be performed by the tool. Work Material and its Condition: Various types of ferrous materials are:
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Cast irons, Carbon steel, Alloy-steel, ToolSteel, Stainless steel, etc. Non Ferrous materials are: Aluminium, Copper, Brass, Titanium or cobalt based alloys, etc. Work Material properties like its Strength, Hardness, Toughness, Elasticity, Plasticity, Heat Conductivity, Alloying Ability, etc. affect the machinability the work material. ISO Grade
Work Piece Material
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Steel (Un-alloyed, Low-alloyed, High-alloyed) Steel castings
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Malleable Cast iron, Grey Cast iron
Machinability is a measure of ease with which a metal can be machined, acceptably. Each of the above work material has different machinability property and
therefore different suitable tool material, tool geometry; machining parameters need to be selected, accordingly. Selection of Tool Material w.r.t. WorkPiece Material: Tungsten Carbide has been found to be the most suitable and commonly used as a Tool Material for metal cutting applications for ferrous work material. Tungsten Carbide grades have been standardised by ISO Grades; and Tool Material can be selected as per the guidelines below for Work Material and its condition accordingly. For manufacturing of cutting tools, Accusharp uses world class quality Tungsten Carbide as raw material, of suitable grades, procured from Global brands, like Sandvik, Kennametal, Arno Friedrichs, etc.
TECH PROFILE www.mtwmag.com
Tool Geometry: It describes overall dimensions of the tool and general geometry of cutting edge of the tool: e. g. Tool Size, Flute Geometry, Rake Angles, Land, Front Geometry, etc. Our application engineers provide technical guidance to customers in this matter, for their specific applications needs. Grinding Process used for manufacturing the Cutting Tools: Tungsten Carbide being a brittle material, it is highly sensitive to shocks during its grinding process. Grinding process used for manufacturing Tungsten Carbide tools is therefore critical; and needs proper selection of a stable grinding equipment, having rigid grinding wheel spindle, and ‘creep’ feed arrangement. Diamond wheels having suitable grit size and free cutting bond is another critical requirement to achieve desired surface finish and also to avoid micro cracks on the cutting edges of the tool. Micro cracks occur due to machining vibrations or due to use of unsuitable grinding wheel. Such micro cracks are not easily visible on the tool; however may cause premature failure of the tool in the machining operation and sometimes likely to damage the work piece. Therefore, Tool grinding process needs to be carried out carefully. Accusharp tools are ground on rigid and high power, modern CNC equipment. Suitable imported, world class quality diamond wheels are used for grinding the tools. Dimensional and surface quality norms on the tools are checked on Zoller Q.C. equipment. Micro Geometry of Cutting Edge: ‘Micro Geometry’ of cutting edge rounding (ER) really contributes towards the Major Performance of machining process. Sharpness of cutting edge provides penetration ability to a tool, and Roundness on edge provides stress bearing ability against cutting forces on the tool. However, sharper edge may break at even lower cutting forces; and bigger roundness edge will have lower penetration ability. Therefore, scientifically de-
signed ER Norm and ER profile on cutting edge is the most important requirement to have optimised penetration, as well as, stress bearing ability of the cutting edge. Accusharp cutting tool designers design such ER norms according to the respective cutting application requirements. ER is done on sophisticated equipment with controlled process parameters, ensuring high accuracy norms. ER measurement is also done on special Zoller systems. PVD Coating on Tools: PVD (Physical Vapor Deposition) coating adds increased cutting efficiency and extended tool life. PVD coating on our tools is done at our sister unit, Pune Carbide - an authorised Coating Center of ‘CemeCon’ AG, Germany. We offer following coating solutions, according to customer’s application requirements: 1. TINALOX® SN² : Premium and 1st preferred choice of coating, most suitable for Drills, End Mills, Taps, Reamers, Inserts and Hobs. 2. HYPERLOX® : Extremely smooth, Specialty coating designed for high performance of End Mills and Gear Cutting Tools (Hobs) 3. ALOX® SN² : Very thick, ultra-modern super nitride coating recommended for Drills and Inserts. 4. HSN² : Unique advance coating for HARD material machining. It is a 2nd Generation TiAlxN super nitride Nanocomposit, 3- layer coating. Most effective solution for applications above 50 HRC. Coolant System: Heat generated during metal cutting process causes thermal stresses on the cutting edge, and affects cutting performance and tool life. Efficient coolant system, as per the application requirement, helps to keep temperature of cutting edge stable during the machining process. This helps to have longer tool life. Adequate pressure and flow of coolant helps for chips disposal. Coolant also provides
lubrication between tool edge and work material contact, and assists for better surface finish on the work piece thereby. Chips Disposal Mechanism: During machining process, it is essential to remove chips quickly away from the cutting edge, to avoid damages to cutting edge quality due to chip attack on the cutting edge. Clogging of chips, near the cutting edge, spoils the cutting performance of the tool. And therefore, higher rate of chip disposal is recommended for better cutting performance of the tools Metal Cutting Machine and Tool-Holding System: Machine power, RPM, rigidity and accuracy of tool-holwding system, machining parameters, etc. have a vital role and influence on the cutting tool performance. Accusharp has a special division named TMS (Tooling Management System). Tooling experts from TMS division carry out detailed study of the entire metal cutting process, at the customer end. This study includes collection of data about dimensional and surface finish requirements on work component, work material properties, machine power, RPM, holding system, coolant system, etc. According to the recommendations from TMS experts, cutting tools with specific tool material, special cutting geometry and special PVD coating are manufactured and supplied to respective customers. TMS experts also recommend customers about the suitable machining parameters for the optimal performance of the machining process. Our TMS team offers ‘Total-Solution’ to customers to help them to perform their machining operations at higher metal removal rates, coupled with increased tool life. This sounds to be the most techno-economic solution for customers. And therefore, Accusharp would always be there to assist you as ‘Your Productivity Partner’, With our mission to give customers the most appropriate tools, which “Cut Fast & Cut Cost”.
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MGM-Pubblicità(210x297)_Layout 1 08/04/13 10.33 Pagina 1
HIGH QUALITY FOR YOUR MACHINERY
MGM brake motor main features
VARVEL production lines
• TEFC 3-ph asynchronous brake motor (0.09kW-130kW) • AC 3-ph brake (no rectifier) or DC brake on request • Oversized brake disc for higher brake torque, longer life and reduced maintenance • Fine and easy brake torque adjustment (as standard) • Very quick brake reaction time • Frequent START/STOP cycle applications • Manual brake release (as standard) • Hexagonal hole on non drive end of the shaft for manual rotation • Single speed or two speeds motors • All motors designed for inverter duty
• RS-RT worm gearboxes: 28 to 150 mm centres. One stage worm, helical/worm and double worm. • RD helical gearboxes: 50 to 2300 Nm. Two and three stages. • RN parallel shaft gearboxes: 180 to 3300 Nm. Two and three stages. • RO-RV bevel/helical gearboxes: 180 to 3300 Nm. Three stages. • RG precision planetary gearboxes: 10 to 230 Nm. One and two stages. • VR dry friction speed variators: IEC63 to IEC90 1 to 5 stepless speed range, 300 to 1500 rpm. • VS planetary speed variators: IEC71 to IEC112 1 to 5 stepless speed range, 200 to 1000 rpm.
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A new generation of electric motors and gearboxes for power transmission quality from the alliance of two dynamic italian companies. For those who want quality.
MGM-VARVEL Power Transmission Pvt Ltd Ware House No. G3 and G4 • Ground Floor • Indus Valley's Logistic Park • Unit 3 • Mel Ayanambakkam • Vellala Street Chennai - 600 095 • Tamil Nadu, INDIA • Phone: +91 44 64627008 • info@mgmvarvelindia.com • www.mgmvarvelindia.com REGIONAL OFFICE: KOHLI TOWERS • 4th Floor, Dapodi • Near Bharat Petrol Pump • Pune - 411012
A GLOBAL DISPLAY OF IN
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Awards by
Registered Office: 3rd Floor, Kailash-A, Sumangalam Society, Above HDFC Bank, Opp. Drive-In Cinema, Bodakdev, Ahmedabad-380054, Gujarat. M +91-98795 66567 admin@imtos.com +91-79-40048594, 40305602 www.kdclglobal.com
PRODUCTS SHOWCASE
PRODUCT SHOWCASE Elesa+Ganter tubular handles : standard or customised solutions with an ergonomic and original design
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 E-mail: info@elesaganter-india.com Website: www.elesa-ganter.in
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Elesa+Ganter, makers of standard machine elements also offers a wide range of tubular handles that, by virtue of the wide variety of production materials, polymer, aluminium, steel or stainless steel, design and ergonomics makes it unique in size and able to meet the most varied market requirements. Some Elesa+Ganter tubular handles, which generally are widely used for manœuvering of large heavy doors in different industrial sectors, thanks to the possibility of modularity are also suitable to be used for the realisation of handrails. Elesa+Ganter, thanks to the know-how and the continuous R&D activities can also provide customised technical solutions to meet specific customer needs. For example, M.1043-HEI tubular handle, equipped with handle shanks in technopolymer and tube in glass-fibre reinforced polyester, it has been designed to provide a high electrical insulation. The different standard solutions available in the catalogue can also be supplied in different colours or personalised with wording or pad-printed or laser engraved logo. Elesa+Ganter tubular handles are available with technopolymer or metal shanks matched with tubes (diameter from 20 mm to 35 mm) in anodised aluminium, epoxy coating or stainless steel. Some executions have a special antirotation tube assembly system, studied to prevent rotation during manœuvering operations, ensuring a safe and comfortable grip. Versions without side supports are set up by bars or aluminium tubes according to the diameter (20 mm or 28 mm), and are also available in double curve. Completing the range, tubular handles with oval section, which thanks to the tube assembly to the side handle shanks by means of screws, offer a high stability during manoeuvring operations. Modern and ergonomic design without any protrusions or recesses for a firm and secure grip are the main features of Elesa+Ganter tubular handles. Products technical data sheets, along with drawings and tables with codes and dimensions, are available on our website www.elesa-ganter.in
PRODUCTS SHOWCASE www.mtwmag.com
The new Gast 86/87R Series of oil-less rocking piston compressors and vacuum pumps While other manufacturers have been busy selling rocking piston compressors that produce a lot of noise and less-than-ideal pressure, Gast has been quietly setting the new standard by re-engineering our oil-less rocking piston from the ground up. The result is a unit that delivers quieter performance, higher pressure, a longer life and greater application flexibility. The sleek, new 86/87R Series is not just another pretty product. It’s beauty runs deep as it performs in ways not yet seen in the industry. The patented crossover chamber design regulates and controls airflow to dampen sound and optimize performance, while delivering a wide range of pressure level options. Because the 86/87R Series can easily retrofit into an existing footprint, it’s also a smart, flexible solution for a wide range of markets and applications, viz. Environmental, General industrial, medical, printing & packaging, food and beverage, transportation, laboratory, and material handling.
Designed to performs
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
“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.
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.
The Filter is designed for continuous indoor operation under the following climatic conditions:
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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Air temperature from +10 deg. C to +45 deg. C. Relative humidity : 80% at 25 deg. C The compact construction integrates the filter, extraction arm and fan The filter can be used at workplaces unreachable to other ventilating equipment, & The filter requires connection to a general compressed air supply.
The standard delivery set includes Built-in fan, Control console, Filtering cartridge of respective type, Spark arrester, Oil separator with reduction box for compressed air system, and Electrical grounded cable L= 5 m with plug.
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PRODUCTS SHOWCASE
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.
Following are some of its unique features:
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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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.
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-theart ISO 9001-23008 certified facility is equipped with dedicated men and machines to chisel out products of impeccable quality and reliability.
PRODUCTS SHOWCASE www.mtwmag.com
New Extech Laser Distance Meters Measure up to Jobsite Challenges Three-meter series provides accurate readings & advanced capabilities
For Product Enquiry Contact FLIR Systems India Pvt. Ltd 1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034, INDIA Tel: +91-11-4560 3555 | Fax: +91-11-4721 2006 Email: flirindia@flir.com.hk Webiste: www.flir.in www.extech.com
Extech Instruments, (www.extech.com), a world leader in test and measurement tools, announced the launch of the DT-M series of pro-grade laser distance meters. The three new Extech meters make it easy to measure distances, compute area and volume, measure angles, and stake out distances between objects. Users can quickly take measurements with one-button, point-and-shoot convenience, saving time and dollars resulting from estimating errors. The DT-M series includes three meters with distance capabilities for a range of jobs: DT40M: 131ft, 40m, DT60M: 196ft, 60m and DT100M: 330ft, 100m. The DT-M meters’ bright laser and large, backlit, 4-line display make it easy to measure targets with 0.08” (2mm) accuracy. With their compact, rugged double-molded design and wrist strap, users can take these distance meters anywhere. The pocket-sized meters are ideal for one-hand operation and measurements can be taken from the front or rear edge. A builtin bubble level ensures the accuracy of horizontal measurements. Useful functions include Min/Max readings; indirect height measurements using Pythagorean calculations (standard height, height in two segments, and partial height) from two or three other measurements; 20 successive reading memory; easy addition and subtraction of multiple readings; and auto power off to conserve battery life. With the stake-out function, users can mark recurring distance intervals, such as the distance between studs for wall framing, between fence posts, lampposts on a path, etc. The meter’s beeping cues and numerical readings indicate if a distance is greater or less than the desired interval. The laser distance meters are designed for construction workers, contractors, realtors, home appraisers, renovation and remodeling professionals, electrical and HVAC estimators and others who routinely need quick measurements at a job site. The DT-M series is backed by Extech’s one-year warranty and comes with two AAA batteries.
MSR linear guideway
For Product Enquiry Contact Precision Motion Industries, INC. (PMI) No.71, PRECISION Ln. 20, Dafu MOTION Rd., Shengang INDUSTRIES, Dist., INC. Taichung City 42946, Taiwan TEL: +886-4-25282984, FAX: +886-4-25120834 Email: sales@pmi-amt.com.tw / sales@superslides.in Websit: www.pmi-amt.com
The full roller type linear guideway, MSR series, equip with rollers instead of the ball, and therefore the MSR series can provide higher rigidity and loading than the normal type with the same size. Especially suit for the requests of high accuracy, heavy load and high rigidity. MSR linear guideway through rollers have a line contact with carriage and rail. Relative to the general type linear guideway through balls have a point contact; the MSR type linear guideway can off¬er lower elastic deformation while bearing the same load. Base on the rollers have the same outer diameter with balls, the roller can bear the heavier load. The excellent characteristics of high rigidity and ultra heavy load can suitable for the high accuracy application that heavy load is processed even more. Through the structure stress analysis of finite element method, MSR series have four trains of rollers are designed to a contact angle of 45° and the section design for high rigidity. Except for bearing heavier loads in radial, reversed radial and lateral directions, a sufficient preload can be achieved to increase rigidity, and this makes it suitable for any kind of installation.
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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.
GEARS, GEAR COMPONENTS & ASSEMBLIES
For Product Enquiry Contact Eppinger Tooling Asia Private Limited S.F. No. 345/2A-2B, Kondampatty Village, Kinathukadavu Taluk, Coimbatore - 641 202. Tel: 04259-201132, 33, 34; Mobile: +91 88700 13053; Fax: 04259-201118 E-mail: marketing@eta-tools.com; eppinger@dataone.in Web: www.eppinger-gears.com / www.eppinger.de
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MACHINE TOOLS WORLD MAY 2018
Eppinger Tooling Asia Private Limited offers a wide range of Gears, Gear Components and Gear Assemblies. Established in 1925 in Denkendorf, Germany, today the company is well equipped to offer a wide range of gear assemblies, gear components and high precision gears - both standard and custom built. State–of– the-art manufacturing and quality control facilities ensure top quality, way above the local makes. The product range of Eppinger covers: spiral bevel gear sets – 10 to 1 ratio dia 457 mm; 2 to 1 ratio – dia 406 mm, module up to 12.7; 1 to 1 ratio – dia 323 mm; hobbed gear – dia 500 mm x 8 m; hardened and profile ground spur and helical gears – dia 330 mm x 5 m; internal gears – dia 152 mm x 3 m; and custom built/non-standard gears and gear assemblies. While Eppinger Gears are exported to Europe, Korea, etc., in the domestic market, it is very well received for almost all critical applications like machine tools, railways, textiles, automation, automotives, engineering, pumps, compressors, printing machines, etc., Attention to details, superior engineering practices, ultra modern manufacturing facilities, very high degree of process discipline and “cutting edge” quality control techniques help Eppinger Gears roll out products which are unmatched in quality and performance. This USP makes Eppinger Gears an icon among the equals.
PRODUCT INDEX A
Engraver Cutter
FALSE COVER
P
Planetary Gear Boxes
78 - 79
AC I DC Geared Motor
83
AC Linear Servo Motor
83
Actuator
67
Flex Clamps
77
Position Displays
51
Actuator Line
91
Flexible Couplings
83
Power Conditioners
85
Air Compressors
27
Precision Air Moving Products
73
Alloy Wheel Machining Solutions
53
Precision Ball Screws
83
Aluminium Profiles
83
Gas Flow Products
73
Angle Encoders
51
Gas Management
73
Pressure Control Solutions
73
Automation Products
61
Gear Manufacturing System
33
Project Engineering Solutions
61
Gears, Racks & Pinions
83
Grinding Machines
23
B
Ball Transfer Units
83
Ballscrews
67
Bevel Gear Boxes
78 - 79
Brake Motors
99
Plasma CNC Cutting Machines
F
G
Harmonic Filters
85
High Pressure Filtration
73
Hydraulic Press
75
Hypid Gear Boxes
C
Cam Driven Systems
78 - 79
55
Centre Drills
FALSE COVER
Chamfers
FALSE COVER
Clamp Meters
77
Clamps for Linear Guides
83
CNC Grinding Machines
57
I
Inserts
R
Real Time Power Factor System Reamers
H
FRONT GATEFOLD
Instrumentation Fittings & Valves
73
85
FALSE COVER
Reffnlng Furnace
15
Rotary Encoders
51
S
Safety Fence Solution INNER GATEFOLD Safety Relays
71
Screwiacks
83
Sensor Systems
47
Slewing Ring
83
Spotting Drills
L
61
FALSE COVER
CNC Horizontal Boring Machine
53
Laser-Line Scanner
47
Spray Cleaning
CNC Lathe
53
Lathe Machines
19
Stabilizers
85
CNC Smart Mills
53
Length Gauges
51
Static Elimination Solutions
73
CNC Solutions
13
Light Energy Management Systems
85
Stepper & BLDC Motor
83
9
Linear Actuators
83
Surface Cleaning
73
BACK PAGE
Linear Encoders
51
CNC Tool Grinding Machine CNC Turning Machines Coatings
43
Linear Guideway
67
Colling Towers
37
Linear Line
91
Consumables
61
Linear Motion Guides
83
Contouring Controls
51
Curvic Coupling
83
Cycloidal Gear Boxes
78 - 79
D
M
Machining Centers
11, 35
Mass Flow Controllers
73
Metal Cutting Tools
69
Dimensional Measurement Systems
65
Metal Forming Machines
25
Double Column Machining Centers
53
Moisture Meters
77
Drill Tap Center
53
Motion Toolpaths INSIDE BACK COVER
Drills
FRONT GATEFOLD, FALSE COVER
Drive Systems
Mould Makers
21
Multimeters
77
Non-Contact Tool Setting System
E
End Mills Cutters
45
FRONT GATEFOLD FALSE COVER
Energy Absorption & Vibration Isolation Products
73
T
Taps
FRONT GATEFOLD, 63
Telescopic Line
91
Test & Measurement Tools
77
Test Instruments
77
Thermal Imaging Cameras
77
Tool Holders
FRONT GATEFOLD
U
Ultra Isolation Transformers
85
Ultrasonic Cleaning
49
Universal Machining Centers
39 V
31 N
End Mills
49
Vacuum Drying
49
Vertical Machining Centers
53
Voltage Detector
77
O
Oil/ Coolant Mist Cleaner
83
Oxy-Fuel CNC Cutting Machines
61
W
Welding Equipments MAY 2018
MACHINE TOOLS WORLD
61
109
ADVERTISERS INDEX COMPANY NAME
PG. NO.
A ACCUSHARP CUTTING TOOLS PVT. LTD.
69
ACE DESIGNERS LTD.
BACK PAGE
ACMEE - 2018
17
ADOR WELDING LIMITED
COMPANY NAME
PG. NO.
COMPANY NAME
FATTY TUNA INDIA PVT. LTD.
53
N
FLIR SYSTEMS INDIA PVT. LTD.
77
NORD DRIVESYSTEMS PVT. LTD.
G
31
O
GALA PRECISION ENGINEERING PVT LTD
49
OERLIKON BALZERS COATING INDIA PVT. LTD.
61
GEDEE WEILER PRIVATE LIMITED
19
P
AMTEX - 2018
29
GEM EQUIPMENTS (P) LTD.
37
PARAGON MACHINERY CO. LTD.
57
ANCA MACHINE TOOLS PRIVATE LTD
9
GLOBE-TECH ENGINEERING EXPO - 2018
103
PILZ INDIA PVT. LTD.
71
APEX PRECISION MECHATRONIX PVT. LTD.
83
GROB MACHINE TOOLS INDIA PVT. LTD.
39
PRECISION MOTION INDUSTRIES, INC. ( PMI )
67
QVI INDIA PVT. LTD.
BETTINELLI AUTOMATION COMPONENTS PVT. LTD.
55
HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED
51
BIRLA PRECISION TECHNOLOGIES LIMITED
63
HOSABETTU HEAVY MACHINERY LLP
35
HYUNDAI WIA INDIA PVT. LTD.
11
C CNC SOFTWARE, INC.
INSIDE BACK COVER
D DOWEL ENGINEERING WORKS
75
E
I IMTOS - 2019
100
INDO AFRICA B2B TRADE EXPO - 2018
98
INTERTOOL DELHI - 2018
102
ELECTROTHERM (INDIA) LTD.
15
M
ELGI EQUIPMENTS LTD.
27
MARPOSS INDIA PVT. LTD.
59
33
MGM-VARVEL POWER TRANSMISSION PVT LTD
99
MICRO-EPSILON INDIA PRIVATE LIMITED
47
MITSUBISHI ELECTRIC INDIA PVT. LTD.
13
MMC HARDMETAL INDIA PVT. LTD.
INSIDE FRONT COVER
EMAG INDIA PVT. LTD. EPPINGER TOOLING ASIA PVT. LTD.
78 - 79
ERWIN JUNKER MASCHINENFABRIK GMBH
23
43
Q
H
B
65
R RAJKOT MACHINE TOOLS SHOW - 2018
101
RENISHAW INDIA (PUNE)
45
ROLLON INDIA PVT. LTD. - INDIA
91
S SCHMERSAL INDIA PVT LTD
INNER GATEFOLD
SHAVO TECHNOLOGIES PVT. LTD.
73
SRIDEVI TOOL ENGINEERS PVT. LTD.
21
T TRUCUT PRECISION TOOLS PVT. LTD.
FALSE COVER
U UNITY CONTROLS PVT. LTD.
85
Y
F FACCIN S. P. A. 110
PG. NO.
25
MACHINE TOOLS WORLD MAY 2018
YG-1 INDUSTRIES INDIA PVT. LTD.
FRONT GATEFOLD
DIFFICULT MATERIALS MADE EASY
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For more information, visit mastercam.com/dynamic
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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