Volume 04 No. 06 | November 2018 | ` 150
Pages 112 | RNI No. MAHENG/2015/64267
FX Linear provides exceptional value for money offering a wide range of options to increase productivity and accuracy.
ANCA Machine Tools Private Ltd 8/1 , Dr. M H Marigowda Road, Arekempanahalli , (Wilson Garden ), Bangalore - 560027, Karnataka, India T: +91 (80) 6759 2100, M: +91 96637 6991 E: indiainfo@anca.com
anca.com
linkedin.com/company/anca
CEO CORNER Precision Machining : The demand & need The precision machining industry has several unique characteristics that make it a relatively steady performer in the economy. Because our shops serve a range of industries and markets, volatility in one area is usually compensated by steady performance in another. While industrial production is seen as a major driver, the automotive and aerospace markets have shown themselves to be indicators of the industry’s shipments. Just as technology improves your company’s ability to manufacture world-class parts, so does training improve the capability of your people to meet the challenges they encounter in daily operations. Many people think that customer loyalty is out of their control and subject to the fickle whim of the lowest price. Savvy shop owners would smile and nod and perhaps say nothing. That’s because those shop owners know their percentage of repeat business. They also know the costs to find and deliver new customers. This is the master key for success in our machining businesses. You see, it is only management attention that can assure that the latest technology is deployed, that people are trained and continuing to upgrade their skills and that customer service is practiced to create customer loyalty. To recap, technology contributes to maintaining your company’s quality performance by improving capability, reducing variability and by creating more robust processes. Training reduces the chance for errors and misunderstanding, and improves the capability of your team. Training deserves to be paid more than token attention. Customer loyalty is a result of the relationship between people at your customer’s and your company. It is built on favorable customer service. Just as quality is “conformance to requirements,” customer loyalty is based on how customers perceive their interactions with your team. Do your people put the customers’ needs first? Or are they always quoting some policy or rule that gets in the way of great customer service? It seems like everyone has a “quality system” these days. Management attention to the indicators of an organization’s quality—and its efficiency and effectiveness, just like its costs—is essential. It is essential to assuring that the other four keys are in place to unlock the profits that your business can manufacture, using your shop’s unique technology and talent.
CEO
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MACHINE TOOLS WORLD NOVEMBER 2018
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
www.mtwmag.com
Publisher & Printer
Contents
Shirish Dongre
CEO
Vol 4 Issue 06 | NOVEMBER 2018
COVER STORY
Shekhar D.
Editor Shilpa Dongre
Assistant Editor Shweta Nanda
Marketing Team Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, Vinod Surve, Kamlesh Balkrishna, Kavita Chaudhari
Digital Marketing Kailash P.
Designer & Layout
Cognitive heritage of three decades for excellence & innovation
Arun P. Shinde, Nandan S. Moghe, Dinesh S. Gawade
Online Division Ganesh Mahale
Circulation Executive Satish Kadam, Amol Ranshur
Mr. Brian Summers, Executive Vice President, CNC Software, Inc.
34
Branch Offices (Zonal)
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 NOVEMBER 2018
BUSINESS NEWS
20
Oerlikon Balzers inaugurates largest customer centre in India
20
DMG MORI declares good results in the 3rd quarter of 2018
24
24
COMPANY PROFILE
Renishaw XM-600 system enables faster and easier CMM error mapping
26
Seco Innovates Jetstream Tooling for ISO Turning Operations
26
36
LANXESS India bags two awards for its Sustainable practices and CSR initiatives
We give strategic advantages to our customers from dustries
38
44
50
Mazak’s Global Leadership in Machine Tools & Metalworking
WIL’s Eminence in High-tech Manufacturing
Tapping India’s huge potential in Industrial Automation
ELGi launches oil-free aircompressor range
IN FOCUS
Contents
Vol 4 Issue 06 | NOVEMBER 2018
CASE STUDY
EVENT PROFILE
54
96
Blaser Swisslube: Demonstrating the Potential of Liquid Tool
TECH TRENDS
66
Vacuum casting technology facilitates record development cycles for Zumex
ANCA’s patented PremierPlus technology maintains tool runout of ≤ 7 microns
PRODUCTS SHOWCASE
104
KING CUT PRO – The Large Gantry Type CNC Cutting Machine
62
105
How to become an Expert Dished end Manufacturer
Steady Volt Servo Voltage Stabilizers
105
The new Gast 86/87R Series of oil-less rocking piston compressors & vacuum pumps
78 Multi-dimensional automation
Rollon & Universal Robots together at Motek, with a new Seventh Axis suitable for cobot
106
Cross Linear Guideway-MSH Series
106
64
Load capacity meets manœuvrability
107
70 84 HEIDENHAIN Encoders for industrial robots 12
MACHINE TOOLS WORLD NOVEMBER 2018
IO-Link makes sensors fit for Industry 4.0
FARO SUPER 6DOF (6 DEGREES OF FREEDOM) TRACKARM
92
Click & Ready!
107
URX Series Rotary Tables
Editorial Board
Editorial Index A
M
Ador Welding
58, 104
ANCA
66
B
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
Oerlikon
Delta Electronics
50
Renishaw
DMG MORI
20
ROLLON INDIA
Dormer Pramet
68
S
89, 106 24
24, 94, 96 78
Schmersal
90
SCHUNK
76
Seco Tools
26, 70
Shavo Technologies
FARO Technologies
62 107
H
Bettinelli Automation Components Pvt. Ltd.
20
R
Faccin SPA
Renishaw Metrology Systems Ltd.
64
54
F
Effica Automation Ltd.
Micro-Epsilon
Blaser Swisslube
ELGi
Mr. Rupesh Paparaju Director,
38
O
Elesa+Ganter
Ms.Samina Khalid Marketing Manager
Mazak
36
E
Mr. Arjun Prakash Managing Director
34
Bettinelli
D Mr. Arun Mahajan General Manager
MasterCam
STUDER
Superslides & Ballscrews 106
HARTING
92
UCAM
107
HEIDENHAIN
86
Unity Controls
105
I
V 84
L
Vesconite Bearings
26
Walchandnagar Industries 44
For editorial contribution contact E-mail: shweta@divyamediaonline.com
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 NOVEMBER 2018
Mr. Jayant Vaidyanathan VP - Sales & Application Tsugami Precision Engineering India Pvt. Ltd.
72
W
LANXESS
Manjit Singh Matharoo General Secretary
82
U
ifm electronic
Mr. Dinesh Khambhayta President MTMA-RAJKOT
105
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
CHINA/South Korea/Taiwan Mepax - Konaxis Shanghai Julien PENARD Tel : (+86) 21 6252 2731/ china@mepax.com
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Mail: sales@far.co.in
BUSINESS NEWS
Oerlikon Balzers inaugurates largest customer centre in India On 12 October, Oerlikon Balzers India, a leading provider of surface solutions, inaugurated its largest Indian production centre in Manesar in the presence of Hereditary Prince Alois of Liechtenstein and Dr Doris Frick, the Ambassador of Liechtenstein in Switzerland. The new facility represents a further major commitment by Oerlikon Balzers to the Indian market as it continues to grow, and this significant investment in the future and in India will allow Oerlikon Balzers to serve its customers across various industries even more effectively. With its 20th anniversary of service in Northern India and the commissioning of Oerlikon Balzers’ largest coating system, the inauguration of the new customer centre also marked another milestone in the history of Oerlikon Balzers in India. H.S.H. Hereditary Prince Alois of Liechtenstein praised the diplomatic
and economic relationship between India and Liechtenstein, which stretches back many years: “Liechtenstein’s economy is very diversified, and almost 40% of its GDP is created by people in the manufacturing sector in companies operating internationally like Oerlikon Balzers. I am very pleased that the longstanding diplomatic and economic relations between the two countries – and Oerlikon Balzers’ commitment to India is a perfect example – have
contributed to continuous growth, and I am proud that Liechtenstein has consistently created a large number of jobs in this industrial sector for so many years.” Marc Desrayaud, Head of Business Unit Balzers Industrial Solutions, said in his speech: “I am absolutely delighted with the growth that all eight of our customer centres in India have achieved in the 24 years of our operations here in India. It is not by chance that
India is one of our key markets, where we are constantly investing in our geographical footprint, in the technology being developed here, in our employees in terms of pure numbers and by developing their professional skills, and of course in enlarging our range of products and services so that we can meet all our customers’ expectations.” Oerlikon Balzers strongly supports “MAKE IN INDIA”, the programme for economic growth launched by the Department of Industrial Policy and Promotion (DIPP), the Ministry of Commerce and Industry and the Indian Government. With the opening of the company’s largest customer centre in India in the presence of Hereditary Prince Alois of Liechtenstein, Oerlikon Balzers has proved the reality and importance of trilateral economic relations between Liechtenstein, Switzerland and India.
DMG MORI declares good results in the 3rd quarter of 2018 DMG MORI AKTIENGESELLSCHAFT looks back on a successful business performance in the first nine months with high rates of growth in order intake, sales revenues, results and free cash flow. Order intake rose by 9% to € 2,270.6 million. Sales revenues increased by 12% to € 1,857.3 million. EBIT amounted to €.143.1 million – an increase of 20%. Free cash flow improved by € 79.9 to € 115.5 million. Chairman of the Executive Board Christian Thönes said, “DMG MORI is on track. We are dynamically pushing forward our future topics automation, digitization and
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MACHINE TOOLS WORLD NOVEMBER 2018
ADDITIVE MANUFACTURING. We have thus recently extended and continuously digitized our production plant FAMOT in Poland.” Order intake in the third quarter of 2018 amounted to € 693.5 million (previous year: € 704.4 million). As at 30 September, order intake rose by 9% to € 2,270.6 million (previous year: € 2,088.6 million). Domestic orders were € 681.9 million (+7%; previous year: € 639.3 million). International orders grew by 10% to € 1,588.7 million (previous year: € 1,449.3 million). International orders accounted for 70% of all orders
(previous year: 69%). Sales revenues increased in the third quarter by 17% to € 642.6 million (previous year: € 548.2 million). As at 30 September, sales revenues were up 12% at € 1,857.7 million (previous year: € 1,656.2 million). The export share was 69% as in the previous year. On 30 September 2018 the order backlog amounted to € 1,705.8 million (31 Dec. 2017: € 1,309.1 million). The high order backlog and the very high capacity utilization at the production plants are causing long delivery times at present. Earnings continued to develop
positively: In the third quarter EBITDA reached € 63.7 million (previous year: € 55.5 million). EBIT amounted to € 50.1 million (previous year: € 41.6 million) and EBT increased to € 49.4 million (previous year: € 41.2 million). EAT was € 34.6 million (previous year: € 28.5 million). As at 30 September, EBITDA improved to € 184.2 million (+13%; previous year: € 162.8 million).
For more information, Web: www.ag.dmgmori.com
BUSINESS NEWS
ELGi launches oil-free air-compressor range Reiterates commitment to enabling energy efficiency and meeting high purity air demands ELGi Equipments (BSE: 522074 NSE: ELGIEQUIP), one of India’s leading air-compressor manufacturers, recently launched its range of oilfree air-compressors at the recently held “Compressed Air Best Practices Conference” in Chicago at the O’Hare Crowne Plaza Conference Center from the 17th to the 19th of September 2018. The 3-day four-track conference saw leading experts from the compressed air industry convene and aimed to bridge the gap between the suppliers and users of compressed air to introduce compressed air users to best practices. ELGi’s oil free range comprises machines ranging from 60 horsepower and 100 horsepower with 7 and 8.8 Bar pressure options. The air cooled designed will ensure ease of installation at all customers, while the aluminium coolers will ensure efficient cooling. High efficiency NEMA motors power the
machines with separate ducting for noise reduction. ELGi is one of five companies in the world with a proprietary oil-free Airend design. The new models are supported by ELGi’s class leading four year Airend warranty and a strong service network. The added models will ensure that ELGi is able to service all oil free- air needs in the US market. Anvar Jay Varadaraj, Global Head Marketing & Corporate Communications said, “All of us at
ELGi are extremely thrilled by the response we received at the launch of our oil-free compressors at the Compressed Air Best Practices Conference. Though small relative to the lubricated screw compressor segment, oil free compressors are growing in prominence owing to environmental and clean air considerations. In traditional oil flooded compressors, oil plays the roles of lubricant, sealant, and coolant. As a result, the discharged
air has trace amounts of oil, which would be unacceptable to sensitive industries such as food and beverage and pharmaceutical manufacturing. Oil Free compressors produce oil free air, by having no oil in the compression chamber. We are constantly striving to achieve higher levels of sophistication for all our products, and are gratified by the feedback from vendors and partners at this conference.” The global market demand for oil free air compressors is US$4 billion in 2017 with an estimated growth rate of 3 - 4% by 2024. These compressors are being used across a variety of manufacturing applications, witnessing strong demand from the food & beverage sector, owing to mandatory health and safety requirements. An industry focus on economical manufacturing methods, lower installation and maintenance costs, also contributing to growth.
Renishaw XM-600 system enables faster and easier CMM error mapping Renishaw’s newly launched XM600 laser measurement system offers enhanced capability to connect directly with Renishaw’s range of UCC CMM controllers. Using technology developed for the XM-60 multi-axis calibrator, this enables faster and easier error mapping, measuring all six degrees of freedom from a single set-up, in any orientation for linear axes. XM-600 communicates easily with Renishaw UCC software during the calibration routine to
24
MACHINE TOOLS WORLD NOVEMBER 2018
quickly build a complete error map of the CMM. This functionality is supported from within UCCsuite V5.4.1 and onwards, enabling the complete error map of a CMM within half a day.
For more information, Website: www.renishaw.com
Creating Tool Performance
A member of the UNITED GRINDING Group
COMPACT LINE The versatile solution for indexable inserts
IMTEX 2019 Visit us at hall 4, booth B103
The COMPACT LINE offers maximum grinding performance with the smallest possible footprint. In production and/or regrinding operations, it grinds indexable inserts made of carbide, cermet, ceramic or PCB/PCD. Depending on the clamping system, the minimum inscribed circle diameter is 4 mm for the pin clamping system and 3 mm for the indexable insert clamping system. www.ewag.com
United Grinding GmbH – India Branch Office & Technology Center No. 487, D1 & D2A, 4th Phase – KIADB Main Road, Peenya Industrial Area · 560 058 Bangalore · India Tel. +91 80 3025 7600 · sales.in@grinding.ch · www.grinding.ch
Creating Tool Performance
BUSINESS NEWS
Seco Innovates Jetstream Tooling for ISO Turning Operations Seco has expanded its industryleading Jetstream Tooling® solutions with new toolholders, coolant clamps and shank adapters that together optimize turning operations. The ISO turning toolholders feature coolant clamps with Seco’s JETI (Jetstream Integrated) technology, as do the VDI machine-side shank adapters. The JETI technology keeps machines up and running while effectively controlling chips and heat generation. While the new toolholders provide internal coolant flow, they can still be used with external coolant hoses. Seco’s internal JETI technology channels coolant
directly from the machine tool into the tool holder and out through the new coolant clamps. Because the clamps are made by additive manufacturing, their internal coolant channels are optimized specifically for turning applications to stabilize control of chips and
tool life on a new, higher level. The clamps also allow for quick and effortless insert changes with the turn of only one screw. With Seco’s new range of VDI machine-side shank adapters, those manufacturers with VDI-type turning machine turrets can now
also benefit from Seco Jetstream Tooling® capability. The new adapters give shops the high levels of productivity and long tool life that come as a result of using high pressure coolant. The ISO turning holders are available in square shank size 2020 and 2525, and the initial range of holders encompasses 28 items. Adapters are either left or right hand for VDI size 30, 40 and 50 turrets, come in star mount style for VDI size 30 and 40 turrets and accommodate square shanks in 20mm and 25mm sizes. For more information, Website: www.secotools.com
LANXESS India bags two awards for its Sustainable practices and CSR initiatives ANXESS India Private Limited, the leading specialty chemicals company has been acknowledged for its diligent adherence towards sustainable practices and concerted efforts in the field of corporate social responsibility (CSR), and has been conferred with the IndoGerman Chamber of Commerce (IGCC) Award for ‘Outstanding Contribution towards best Sustainable Business Practices by a Large Enterprise’ for the year 2018 and the Indian Chemical Council (ICC) Award 2017 Certificate of Merit for Social Responsibility. Both the awards were presented to LANXESS at different events held in Mumbai towards the end of September after a detailed study by eminent juries constituted by the organizing committees of both the
26
MACHINE TOOLS WORLD NOVEMBER 2018
organizations. Mr. Namitesh Roy Choudhary, Vice President, PTSE, LANXESS India, received the IGCC Award for Sustainable practices on behalf of LANXESS at the Taj Hotel, Mumbai on 20th September. The award came on the back of the organization’s specific processes and systems to ensure that it
follows social and environmental policies in the supply chain and conforms to all standards. LANXESS’ sites focus on optimal use of natural resources ensuring minimum impact on the environment. At its Jhagadia site, LANXESS has spent 20 percent of total building cost on sustainability projects like Effluent
treatment plant, Sewage treatment plant, Multi-fuel boiler, Off-gas Incinerator and creating a Green zone. Similarly, the Nagda site has Co-generation plant, Waste water treatment, Sewage treatment plant, Waste water post treatment plant and Off-gas Incinerator. Further, to significantly reduce Carbon footprint, 96% of Jhagadia’s and 60% of Nagda’s export consignments have been shifted from road to railways. The ICC Award 2017 Certificate of Merit for Social Responsibility was presented to LANXESS India on the 27th September in Mumbai and was received by Mr. Neelanjan Banerjee, Vice Chairman and Managing Director, LANXESS India and Mr. Sunder Rajan, Head – CSR, LANXESS India.
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COVER STORY
Cognitive heritage of three decades for excellence & innovation Q. Please brief us about recent initiatives undertaken in the CAD/CAM space? What are your focus areas? The main focus is always to make the software easier and more intelligent, and the machining faster and more efficient with less wear and tear on machines and tools. Mastercam has introduced several pieces of technology in the last few years that assist with this need. The most game changing has been Dynamic Motion technology to create material-aware toolpaths where the angle of the tool engagement is constantly changing to keep a more consistent chip load on the tool and use more flute length. The result is a faster machine time, for example, when roughing for 2D parts, the cutting time can be cut by 75%. It’s much easier on the tools, because the entire cutting surface is being used, and it’s much safer. Our shop at CNC Software headquarters uses Dynamic Motion technology exclusively, instead of conventional cutting. Another exciting advancement in CAD/CAM is Accelerated Finishing. This technique delivers better finishes in a much shorter time on a variety of complex surfaces. With new classes of shaped tools being introduced, we work closely with tool manufacturers to develop toolpath motion that takes the most advantage of what can be done with these emerging tool shapes.
Q. What are the market opportunities for your products in India? How do you plan to position these products? The indicators for Indian manufacturing under the Make in India initiative are encouraging for Mastercam. We expect
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MACHINE TOOLS WORLD NOVEMBER 2018
an expanding manufacturing sector in 2019 followed by an even stronger 2020. Automotive, aviation, and electronics are just a few of the sectors that we are looking at to deliver steady, sustained growth. As the world’s most widely-used CAM software, we’re fortunate to have an enormous pool of practical shop experience in a variety of industries on which to draw. This is is invaluable in determining the changing needs of specific industries. We use this collaboration with our user community, combined with our internal expertise, to provide the tools that those industries need to thrive.
Q. What is your strategy for India? We have a three-part strategy for serving the needs of Indian manufacturing. 1. Forge a strong and wide-reaching sales and support partnership in India to ensure Mastercam users will have the technical backing they need to succeed. 2. Carefully watch the evolving Indian manufacturing sectors, evaluate what specific applications they need to reach their goals, and provide focus in those areas. 3. Work with our Indian users as partners to gain insight into both what they need to expand their current business, enter into new sectors of manufacturing, and improve their day-to-day operation.
Q. What factors affect your business? Any shift in the manufacturing markets or technology has an impact on our business, so we are always looking to emerging trends to make sure we’re
positioned to make the most of those opportunities. It’s not just important for us and our business – it’s critical for the global community of Mastercam shops to make sure they’re prepared for change.
Q. What are key technological trends that are driving your industry? The primary driver has been – and remains – increasing productivity through faster and more flexible manufacturing output. This remains a common trend among all shops regardless of industry. But another rapidly growing trend that is being embraced by Make in India is connectivity, or Industry 4.0. We address this by focusing on how many places Mastercam can touch to ensure that information can be brought in, used and coordinated elsewhere in a shop’s process as needed. Mastercam powers the machine tools, but that is just one part of what a shop needs to do. Mastercam also provides a platform for the shop to do a variety of things like metrology, robotics or digital tool management—all of these pieces roll up into the growing connectivity of Industry 4.0.
Q. What is your vision for Mastercam in India? In India, our goal is to empower manufacturing with superior products and support. No matter the industry, shop size, or manufacturing challenge, some things are consistent in every shop across the globe. Our vision for Mastercam in India is the same as it is anywhere people need to make parts – to create software and services that solve the world’s manufacturing challenges.
COVER STORY www.mtwmag.com
Mr. Brian Summers, Executive Vice President, CNC Software, Inc.
NOVEMBER 2018
MACHINE TOOLS WORLD
35
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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MACHINE TOOLS WORLD NOVEMBER 2018
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
200 YEARS COMBINED EXPERIENCE FORMING TODAY’S FUTURE
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IN FOCUS
Mazak’s Global Leadership in Machine Tools & Metalworking
Mr. Anil Bhardwaj, Managing Director, Mazak India
Mazak is undoubtedly the world’s largest machine tool builder. The conglomerate with a strength of 8,331 employees on its roll, operations in 26 countries worldwide and a product portfolio covering some 260 types of systems encompassing the entire gamut of sophisticated machine tools designed to enhance flexibility, productivity and automation in the manufacturing arena, is indeed flexing its muscle and proving its mettle in spearheading technological innovations, discovers P.K. Balasubbramaniian in a one to one with Mazak India’s Managing Director, Anil Bharadwaj. Excerpts: Q. You are a world leader in machine tools. Could you brief us on your history and present standing? Yamazaki Mazak was established in 1919 and has been contributing to the development of the machine tool industry as the global company. Mazak manufactures not only advanced machine tools such as multi-tasking centers, CNC turning centers, machining
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centers and laser processing machines, but also automation systems with the concept of ‘all in one’ to support global manufacturing by providing exceptional productivity and versatility. We use contemporary technologies and are committed to develop advanced machine tools and provide cutting-edge solutions for the progress of manufacturing as well as society.
Q. What’s your range of manufacture today? As I said, we manufacture a range of advanced machine tools such as multi-tasking centers, CNC turning centers, vertical machining centers, double column machining centers, horizontal machining centers, CNC laser processing machines, flexible manufacturing systems, CNC systems, CAD/CAM systems and production
IN FOCUS
support software, besides automation systems. In our standard range, we have something like 260 types of machines. We also make customized systems to meet specific customer needs.
Q. What’s Multi-Tasking? Multi-tasking is when you combine several cutting processes, including turning, milling, drilling, tapping and deep-hole boring on one machine as opposed to having those same processes handled by multiple machines. When you can process an entire workpiece from raw material input to final machining in one single set-up, we refer to it as ‘done in one’ operation.
Q. Could you elaborate 5-Axis Machining? 5-Axis Machining provides infinite possibilities as to the part sizes and shapes you can effectively process. The term ‘5-axis’ refers to the number of directions in which the cutting tool can move. On a 5-axis machining center the cutting tool moves across the X, Y and Z linear axes as well as rotates on the A and B axes to approach the workpiece from any direction. In other words, you can process five sides of a part in a single setup.
Q. What’s special about your automation systems? By automation, we refer to our so-
called Palletech System. The Palletech System is exclusive to Mazak. It brings advanced, pre-engineered automation to today’s machining environments. It is a multi-tasking solution for any manufacturing or volume reqirement, and is compatible with all our horizontal machining centers as well as most of our vertical and 5-axis machining centers. With our Palletech Manufacturing Cell controller software over standard PCs and networks, shop management can monitor operations, view and change schedules on-the-fly, manage part program files from anywhere on the network, track tool life / breakage and issue instructions to the shop floor. With this system users are able to interrupt a planned machining queue and produce an emergency part with no cost penalty. That is the advantage.
Q. Could you give some idea of your production facilities and support bases network wordwide? We have five production facilities in Japan alone. We also have manufacturing facilities in US, UK, Singapore, and China. In China itself we have two plants. Worldwide we have 83 support bases. These comprise 38 Technology Centers and 45 Technical Centers in 26 countries. Our Group companies are spread across Japan, North America, Central & South America, Europe, as well as Asia which
includes Malaysia, Taiwan, Korea, Thailand, Indonesia and Vietnam.
Q. Could you throw some light on your operations in India? Mazak India with National Head Office at Pune has its network spread all over India to cater to the customer needs. A strong workforce, especially trained in Japan helps to provide total solutions to the customer. Mazak India Head Office is spread across a 5-acre land with a built up area of 1,75,000 sq. ft. The Technology Centre showcases a spread of Multi-Tasking Machines, Horizontal and Vertical Machining Centers, Lathes and Laser Cutting Machines. The Technology Center showcases the latest and proven solutions to demonstrate the technical capabilities of Mazak India.
Q. What are the support services you offer? If you are referring to Mazak India, we have our pan-India presence to stay closer to our customers at large. We provide online service support to our customers. Be it trouble-shooting or quick delivery of machines or spares, we are only a phone call away to reach out to the customer. In order to maintain efficient service support, the regional part center stores up to a variety of 8,000 spare parts with a total quantity of 4,50,000 items. In addition,
Mazak’s world-class Technology Center in Pune
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at: See us 019 2 IMTEX B103 n , sta d Hall 3A
Introducing the Equator™ 500 gauge – intelligent process control for larger parts The larger Equator 500 system now enables the gauging of larger parts, with a working volume of 500 mm diameter, up to 400 mm height and a payload capacity of 100 kg. • High speed gauging of size, position and geometry • Accuracy with rapid temperature changes, now over a 45°C range • Automatic update of tool offsets directly from Equator 500 • Available with new automatic part loading system
For more information visit www.renishaw.com/equator500
Renishaw India [Pune] S.No.283, Hissa No.3, Raisoni Industrial Estate, Village Mann, Tal:Mulshi, Pune 411057 T +91 20 6674 6400 F +91 20 6674 6211 E india@renishaw.com
www.renishaw.com
IN FOCUS it is connected to our Japan Global Part Center for fast and efficient response to customer requirements. This apart, we provide extensive training in operation, programming and maintenance of our machines to all our customers. Our Technology Center is equipped with all our state-of-the-art machines and we can arrange demo of all our typical systems there.
Q. We understand you have a Spindle Rebuild Unit too. Please tell us more about this facility. Spindle is the heart of any machine and is easily susceptible to damage due to accidents. Repair / replacement of the spindle can be expensive and time consuming. In order to support customers, Mazak India has installed a spindle cartridge repair facility with advanced testing and condition monitoring equipment such as dynamic balancing machine, test jig with simulators, vibration, temperature and lubrication monitoring devices. With
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Mazak’s Multi-Tasking Equipment - An engineering marvel the new facility, spindle repairs can be carried out quickly and at affordable costs. Mazak India also offers spindle exchange program which cuts downtime and provides the highest levels of quality and reduces costs.
Q. So what’s your differentiated offer to the Indian customer? In today’s competitive manufacturing world where demands are high and enhanced quality, efficiency and productivity are cirtical for success,
manufacturers need a machine tool partner with proven competence and who can deliver what they need and when they need it the most. And that’s exactly what they can expect from Mazak. By virtue of our technology base, global presence and wherewithal of high order, we are eminently placed to provide cutting-edge solutions, while further solidifying our position as a leader capable of providing innovative, productive and futuristic products and solutions to the end user.
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
01_MTW_Monthly_Magazine_190x250mm.indd 1
www.grobgroup.com
15.02.2018 10:20:47
IN FOCUS
WIL’s Eminence in High-tech Manufacturing
G.K. Pillai, Managing Director & CEO, Walchandnagar Industries Ltd.
Q. How do you define High-tech Manufacturing? I’m glad the question came up. Whenever a topic of High-tech manufacturing kicks in, our imagination intuitively glides to a place with sophisticated machines performing multiple operations and producing quintessential components. However, one should not forget the prominence of activities associated with the entire manufacturing process. Advances are happening in all levels of product development whether it be designing, setting up the processes, managing the raw materials or even packaging of the final product. Hightech manufacturing can thus only be achieved by accommodating all these aspects to harvest the final product. Only a synergy of these advances will provide the maximum efficiency and produce an immaculate product and only then the process can be titled as High-tech manufacturing. Achieving this synergy becomes a prime objective in industries such as ours where complex geometry, close tolerances, stringent specifications, and the usage of exotic raw material becomes a common occurrence.
Q. What are your capabilities and facilities for high-tech manufacturing? Walchandnagar, today, have three
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High-tech manufacturing is not everyone’s cup of tea. Having a sophisticated manufacturing set-up with the best of men and machines performing multiple operations for producing quintessential components is only part of the high-tech story. It also presupposes design and process capabilities and the entire chain of manufacturing including raw material management and in-process quality check to ensure that the final product meets the complex geometries, close tolerances and stringent specifications, discovers P.K. Balasubbramniian in an interview with G.K. Pillai, Managing Director & CEO of Walchandnagar Industries Ltd. WIL is known for its eminence in high-tech manufacturing to cater to the stringent requirements of products and equipment of priority sectors like defense, aerospace, nuclear, missile and energy. Excerpts: manufacturing facilities which are located in Walchandnagar (135 km from Pune), Satara, and Dharwad (Near Hubli, Karnataka). The Walchandnagar plant carries out production activities for Defense, Aerospace, Nuclear, Missile, Gear, Cement, Sugar and Energy, and Centrifugal businesses. We have our Foundry business running in Satara and Instrumentation division in Dharwad. As Walchandnagar is associated with the manufacturing of different types of products and equipments, our facility has been fortified with machines of not only different sorts but also sizes. CNC multi-axis boring machines, milling machines, Gear cutting and grinding, Plate bending machines, Lathes are some of the machines available in different sizes in our plants. We respect the quality requirements and uniqueness of different businesses and thus have ensured that the machines are allocated to different divisions to provide superlative efficiency and quality. Our Missile, Aerospace, and Nuclear businesses involve working with exotic materials which are very challenging to work with. We have sophisticated Automatic Welding Systems to deal with these subjects. Our qualified and
dedicated welding engineers deployed in the Welding Development Section and skilled welders have also proved themselves on multiple occasions. Our plant is also equipped with Dustfree enclosements for critical welding and assembly of intricate components utilized in Nuclear, Aerospace and Missile divisions. And not to forget the Heat treatment facility comprising furnaces of wide ranging sizes. The quality aspect is taken care by the Optical tooling and measuring instruments. Our material handling system is also well advanced which not only consists of overhead cranes (25 tons to 250 tons) with an area under the crane of 56,000 sq mtr but also hydraulic cranes, industrial lifters, trolleys, etc. Apart from this we also have equipped our engineers with high-end design and analysis softwares which help us create products that define our superiority in the market. It is this why we proudly say that our gearboxes, cement equipment, centrifugal machines deliver a life not less than 20 years. Apart from this, we also have our own Hydraulic test facility for Missile, Aerospace and Defence jobs and test facility for Gearboxes. I would also like to update you on
IN FOCUS
Series of Horizontal Boring Machines
Large Capacity Lathe and Double Column Plano Miller
Heavy Duty Vertical Boring Machine
Heavy Duty Plate Bending Machine
4-Axis Vertical Milling Centre
the fact that WIL maintains a dedicated design team ‘Walchand Technology Group’ and Tooling design team which is essential keeping in mind the fact that we manufacture special project based products. Apart from this, we are also proud of our 1000 plus workers and 200 plus engineers.
Q. What are the business opportunities available for your Division? Walchandnagar has a portfolio of wideranging businesses under its canvas. With Defense, Nuclear, Aerospace already in its DNA, we also provide tailormade Gearboxes, Cement equipment, and castings. Walchandnagar is also distinguished for its ability to provide EPC plants to its Sugar and Co-gen customers. Our business segments allow us to serve both Government as well as Private organizations. The current growth emphasized government has brought to the table all-round reforms, in turn, creating many growth-oriented prospects. The foremost “Make in India” program now also followed by the “Buy in India”, Finalising the long pending CLND Act, Union Budget 2017 which focussed on infrastructure growth and Agriculture; They all have unlocked new business mines. It is thus not surprising to note that we carry a good load of orders in our kitty and envisage much more shortly.
Q. What do you offer to critical segments like nuclear power, aerospace, defense and missiles? Nuclear Sector The nuclear sector in India saw a very tepid growth over the last decade. A lot of
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projects were stagnant due to the CLND Act. But a complete turnaround of this scenario has happened with the finalization of the crucial points in the act and suddenly the market has been inundated with new Nuclear Power Plant projects that will be undertaken by the NPCIL. We have supplied, in the past, critical components for Nuclear Power Plants of capacity 220, 540, and 700 MWe. Some of the components include Calandria, Moderator Heat Exchangers, End Shields, Air Heat Exchangers, Core support, Core Catcher, etc. and we look forward to supplying them in the future too. Aerospace WIL has been an integral part of all space projects/ programs driven by Indian Space Research Organization (ISRO). This association has been spanning over 4 decades. ISRO views WIL as a reliable manufacturer of various strategic and critical components for various space programs. • SLV-3 (Year -1980) Weight- 17 tons, Payload Capacity – 40kg, Height – 22 m • ASLV (Year – 1987) Weight- 19 tons, Payload Capacity – 150kg, Height – 23.5 m
Process Layout for Missile Manufacturing • PSLV(Year- 1993) Weight- 295 tons, Payload Capacity – 1600kg, Height – 44 m • GSLV(Year- 2003) Weight- 414 tons, Payload Capacity – 2.5 tons, Height – 49 m • GSLV MK-III(Year- 2014) Weight- 620 tons, Payload Capacity – 4 tons, Height – 42 m WIL is currently supplying PSLV, GSLV, and GSLV MK-II on a continuous basis. The GSLV MK-III launch that took place on 5th June 2017 had S-200 motor casings supplied by WIL. It gives me immense pleasure to state that WIL has played a crucial role in Chandrayaan-I (India’s first Moon Mission) and Mangalyaan (India’s Mars Mission) Defense WIL has been closely functioning with
IN FOCUS DRDO, R&DE, and other defense organizations on various defense projects and have supplied Aluminum alloy bridges, Container and Launchers, Surface launchers. Currently, WIL is executing surface launcher projects (Wagon mounted and Trailer mounted) with associated hydraulics and control systems for the Missile programs and other confidential projects. WIL has also contributed to the Indian Naval ships and has a track record for supplying high-speed gearboxes (up to 18 MW) for frigates, corvettes, fleet tankers, and survey vessels and submarines. Over the last 11 years, WIL has successfully met various stringent program requirements with demonstrated capabilities for indigenous design, engineering, manufacturing, testing and supply of gearboxes. Missiles WIL is one of the very few industries that partnered with DRDO during the development phase of its ambitious missiles programs viz., Akash and Agni. It was more than two decades ago that DRDO approached WIL for their flagship projects. The combined expertise of the WIL engineers and the DRDO scientists as well as extensive R&D has helped in the development of critical manufacturing techniques to meet the design and stringent quality parameters for its strategic and tactical missile programs. The development phase of Akash missiles demanded a strong knowledge of the manufacturing technology in order to convert the designs into actual products and today a dedicated facility is established in Walchandnagar to supply
these critical components with close tolerances and stringent quality checks.
Q. Could you give a brief account of your recent achievements? Our list of achievements come from the combined efforts of all businesses. Aerospace Division allowed us to be a part of the elite group which supplied critical components for “Chandrayaan-I” and “Mangalyaan”. We are a trusted source to the Indian Navy for supplying Marine Gearboxes and I’m proud to state that we have recently supplied a gearbox to the DMDE (18400 HP). It gives me immense pleasure to point the fact that WIL has supplied 50+ gearboxes to the Indian Navy. We have contributed in supplying the critical components for India’s “Agni-V” and continue to do so. Apart from Akash, our missile division has also added Astra and QRSAM to its portfolio. Our Defense business is also involved with many confidential programs. Recently our Instrumentation business has also started catering to the needs of PSUs which is a great breakthrough for us. We are also going to play a major role
Marine Gearboxes
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in Government’s vision to increase the utilization of Nuclear Power as an energy source by supplying components for the Nuclear Power plants, orders to which have already started to flow in. In the past, we have already supplied critical equipment to 20 Nuclear Power Plants in India and it is a big achievement when the total count of Nuclear Power Plants is 22 for our nation. Apart from this, WIL’s Centrifugal business has also flourished owning a market share of 60%.
Q. What are the challenges you face and how are you geared to meet them? Being a project-based manufacturing firm, every new project brings with it new complexities and complications. Efforts are indispensable when it comes to design and engineering, process planning, project management and even hunting for new suppliers. This on occasion, makes it difficult for us to adhere to the delivery schedules resulting in delays in product delivery. But as previously mentioned, to bring in Hi-tech manufacturing, improvements in all these sectors is imperative. These issues are critically studied and improvements are planned to bring about the change. Our engineers are even burning the midnight oil to standardize the process wherever possible. With new developments happening daily, it is also very crucial to keep in step with the latest technology and maintain the skill set of employees to be at par with the competition. Actions are being taken in this aspect too with our firm planning to establish new business lines.
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IN FOCUS
Tapping India’s huge potential in Industrial Automation While Delta Electronics’ India operations have spread into various industrial products, its focus on providing solutions for industrial automation will surely reap rich dividends. In this interview with Huned Contractor, the HoD of the industrial automation business, Manish Walia, elaborates about the company’s products and growth strategies partners, we are continuously growing and expanding our footprint in India. We not only cater to the Indian market but also export to several neighbouring countries including Nepal, Bangladesh and Sri Lanka. Mr. Manish Walia, HOD of the Industrial Automation Business, Delta Electronics’ India
Q. Could you provide an overview of Delta Electronics in terms of history, products and infrastructure? We have been operating in India since 2003 as a 100% subsidiary of Delta Electronics (Thailand) PCL, a leading power and energy management company. In India, we are a leading provider of telecom power solutions and a major source of industrial automation, display solutions, UPS, DC fans and blowers, components, bio-medical, LED lighting, automotive and renewable energy products. With a wide array of power and energy solutions, we at Delta have registered strong and stable financial performance in the Indian market, achieving a CAGR of 26.5% over the last five years. Our competitive advantage in the Indian marketplace has been the portfolio of energy-efficient products, strong system and solution integration expertise and extensive service and support network across India. Delta’s presence in the country includes 12 regional offices, three manufacturing facilities at Rudrapur, Gurgaon and Hosur and two research and development centers at Gurgaon and Bangalore. With the current network of more than 200 channel
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Q. Could you illustrate the benefits derived from your solutions in industrial automation with a case study? As a leading producer and enabler of industrial automation and extensive knowledge in control technology, Delta Electronics plays the role of a key catalyst in the industrial controls marketplace. We offer a wide range of solutions and applications to kick-start the automation process of industries across sectors. Delta offers AC motor drives, servo drives and motors, temperature controllers, programmable logic controllers, human machine interface modules (HMI), optical encoders, communication converter modules and CTA timer. The extensive industrial technology solutions and product offerings provide a total solution for machine control and automation.
Q. What are the solutions offered by the company to clients who wish to implement Industry 4.0? Industry 4.0 can have a revolutionary impact across various industry segments as it allows advanced production and operations systems with smart digital technologies to create a digitalized organisation which is not only interconnected and autonomous but can communicate, analyse and use insights to drive further actions. Industry 4.0 represents the ways in which smart, connected technology would become embedded within organisations, people and assets, and is marked by the emergence of capabilities like artificial intelligence, machine learning, robotics, analytics, etc. Our forte in power electronics and extensive knowledge of control technology has made the organisation a leader in the automation marketplace. The company offers a wide range of products for industrial applications like AC motor drives, servo drives and motors, temperature controllers, programmable logic controllers, human machine interface
IN FOCUS modules, optical encoders, communication converter modules, and CTA timer/ counter/tachometer. It also offers programmable logic controllers (PLC), which are used to control automation processes. Delta Electronics also offers human machine interface (HMI) products that offer fast and convenient control of manufacturing automation through a userfriendly graphical interface.
Q. What are the research and development activities of the company? Innovation puts research and development at the core of our operations. With two state-of-the-art research and development centers we not only work on core product areas and applications but also on complete solutions for smart grid applications and automotive applications. We are constantly enhancing the efficiency rate of the power converters and infrastructure monitoring solutions for telecom sites. We offer highly customized products and research and development facilities in India working for indigenization of UPS and display solutions’ products suited to India and SAARC customer requirements and environment. Developing custom power supply for storage and network equipment is another core area for Delta India’s development activity. The continuous enhancement of our engineering capabilities allows us to develop products with better value and performance.
Q. Which are the emerging areas where the company thinks industrial automation will reap rich dividends? In order to enhance and grow, industries are opting for modern and ever-changing technologies in control systems for efficient production and manufacturing processes. They are utilising high-quality and reliable control systems with a well-defined and formulated strategy. Today, most of the industrial sectors are loaded with data and there are so many mundane tasks lined up with human resource that they are not able to devote their time towards more important and growth-oriented tasks that can lead the sector towards achieving newer heights. We believe that every
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industry, in order to reduce their laborious workload, should start adoption of automation technologies. Specific sectors such as healthcare, renewable energy and manufacturing are among the few major industries that would be getting many dividends from the automation process.
Q. What is the company’s strategy for growth in the coming 2-3 years? India as a market holds immense potential for the growth of our company. In the coming years we have plans of investment and expansion in the Indian market. We will focus our investment mainly on two areas – the new factory in Krishnagiri and the large innovation and research and development center we are building in Bangalore.
Q. What are the challenges faced when it comes to Indian companies moving toward industrial automation? The fourth industrial revolution represents a broad, pervasive shift that should be dealt with comprehensively if organisations are to thrive. All revolutions are disruptive, and Industry 4.0 is no exception. While it poses risks, it also offers tremendous opportunities– serve customers in a better way, new products and services, new jobs, and new business models. The major bottleneck for adoption of automation is the lack of skilled workforce. Organisations will require a big shift in capabilities and mindsets to successfully adopt Industry 4.0. Only then can one make use of advanced analytics and build a data backbone. Data security is another concern.
Q. Are there any government initiatives that will take trigger growth in the industrial automation segment? We are expecting a new industrial policy in the coming months. The policy may incentivize research and development with the objective of positioning India as a test bed for emerging technologies and creating an environment for ease of innovation. The government aims
to increase the manufacturing sector’s contribution to 25% of GDP by 2025 from the existing 17%. Industrial automation will be a major contributor to the GDP of the manufacturing sector. In addition, the government has been encouraging the growth of new technologies through the ‘Make in India’ and ‘Digital India’ initiatives. With India being the hotspot of digital innovation, the Digital India programme has boosted the adoption of new technologies for automation in the country.
Q. What is the size of industrial automation products market in India and what is the estimated rate at which it will grow? Industrial automation promises to play a role of significant importance. It offers a competitive advantage, cuts production cost and ensures high quality, further increasing its demand. According to the latest report by Ken Research, “The industrial automation industry in India is expected to reach Rs 197 billion by 2020 with growth driven by rapid adoption of modern technology backed by cost-saving features. The Make in India initiative and relaxation of FDI policies in the manufacturing sector will certainly help the industry grow at a faster pace. Also, since the government is aiming at increasing the manufacturing sector’s contribution to 25% of GDP by 2025, we will see faster adoption of automation across sectors. The industrial automation sector will witness deeper connections between the plant floor and the business along with a broader ecosystem which surrounds the manufacturer.
EVENT PROFILE
T
Blaser Swisslube: Demonstrating the Potential of Liquid Tool
he importance of coolant in the manufacturing process cannot be undermined. Coolants play a crucial role in maintaining the quality and enhancing the efficiency and productivity of machines. Thus, selecting the right coolant is an important business requirement for manufacturing. One leading provider that has established itself as a solid and reliable coolant brand is Blaser Swisslube. The company provided high technology coolants along with expertise and knowhow, which bring in lots of benefits to customers. This value proposition is referred to as Liquid Tools, to serve the unique requirements of customers and increase their competiveness. To emphasize the impact coolants can have on the overall productivity and cost, Blaser Swisslube recently organized the 3rd edition of Blaser Swisslube Productivity Trophy Awards
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2017-2018. The award this year acknowledged five customers across the country that achieved excellent results using the Blaser liquid tool. The winners were recognized across five different categories, namely Tool Optimisation, Total Costs of Ownership, Metalworking
Fluid Optimisation, Productivity Increase and Process Optimisation. Rajiv Gandhi, Sr. Executive Director - Production, Maruti Suzuki India was the chief guest for the award ceremony who gave an insightful speech on productivity & competitiveness in the automotive industry.
Panel at the Blaser Swisslube Productivity Trophy Awards 2017-18
P R OBL E M S OLV E D
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EVENT PROFILE Patrick Mathys, Managing Director, Blaser Swisslube APAC shared interesting observations on the topic, ‘Being a true partner in the industry.’ Harbhajan Singh, Director - General & Corporate Affairs, Honda Motorcycle & Scooter India gave a talk on the topic, ‘Role of human capital in Productivity,’ while Carl Chakravarthy, Associate Director, KPMG India shared his views on ‘Productivity enhancement @Shop Floor.’ Recognizing the Leaders
Bajaj Motors emerged as the winner in the category Tool Optimisation, as the company demonstrated tangible benefits with the usage of Blaser Swisslube’s Blasocut BC 4000 Strong. With the Liquid Tools solution, Bajaj Motors was able to reduce tool costs and improve surface quality. The investment paid back in a month’s time and generated an annual net saving of almost Rs 5.6 million. In the category, Total Cost of Ownership, Carbide Cutting Tools ( OSG India) was named as the winner. By using Blaser’s innovative hydrocracked formulation Blasogrind HC 5, Carbide Cutting Tools was able to reduce cycle time and achieve a 12% productivity increase with an annual savings impact of Rs 14 million. The winner in the category Metalworking Fluid Optimisation was Highway Industries, which used the Blasocut formulation with an objective of improving sump life, tool-life and
coolant stability, as well as preventing corrosion and reducing machine breakdowns. This optimisation achieved annual saving of Rs 1.1 million for 23 machines. Mahindra Vehicle Manufacturers was felicitated in the category Productivity Increase. The company registered huge saving of Rs 3.6 million by deploying the Blaser coolant Blasocut BC25 to the entire Cylinder Block line. The accuracy in machining cylinder blocks improved by more than 33%, which was an added value. In the category, Process Optimisation, Cummins Technologies India emerged as the winner with the usage of Blaser’s innovative formulation B-Cool 9665. Cummins Technologies has benefitted from excellent corrosion protection behaviour and a good cutting performance.
Highway Industries receiving the award in Metalworking Fluid Optimisation category
Mahindra Vehicle Manufacturers accepting the award in the category Productivity Increase
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Bajaj Motors receiving the award in Tool Optimisation category
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.).
Shavo Technologies Pvt. Ltd. 29/2 Kharadi, Off Pune Nagar Road, Old Kharadi Mundhwa Road, Pune: 411 014 Tel. No.: +(91) (0) 7030938211, 7410004817, Fax No.: +(91) (080) 28395963 Email: shavogroup@vsnl.com | Website : www.shavogroup.com
TECH TRENDS
How to become an Expert Dished end Manufacturer
The Trusted Partner in Metal Forming Machines
An introduction to the dishing and flanging process
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here are hundreds of manufacturers of tanks, silos, pressure vessels, truck tanks, and metal rolls components all over the world. Most of these companies need to produce or source dished ends of various types, sizes, and specifications to complete their products. However, there are only a few dished end manufacturers that can supply this kind of product, a significant reason dished end production has become a very profitable business and a craft that companies are carrying on and conserving generation after generation. Tanks, pressure vessels, silos, truck tanks, and more all require dished ends. Fabricators make these ends using various processes. One popular method is dishing and flanging. The dishing and flanging occurs in two sequential operations that each require specific machinery: the dishing of the blank and the forming of the plate edge. The Dishing Process
Boldrini hydraulic dished end press PAO series
Once the plate has been cut to size in a circular shape (using a circular shear, laser, plasma, or other method), the resulting dish is formed under a press that, with multiple hits distributed over the entire surface, will crown the plate. To make different types of dished ends and different diameters, a dishing press must be equipped with a set of dies
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shaped with different radii. The dishing process is rather slow. It generally requires several hours depending on the plate dimensions and the material. This procedure can be automated with the use of a numerically controlled manipulator. It is possible to find presses with CNCs that can handle more than 10 axes and run automatically for hours like the presses series designed and manufactured by Faccin and Boldrini. The Dishing of Polycentric Ends
Faccin hydroforming press PPH series
A particular kind of dished end is widely used by the manufacturers of truck tanks: the polycentric dished end. These dished ends, often made of aluminium or stainless steel, are normally prepared with thin plates up to a maximum of 6 mm. This thickness allows the forming of polycentric-dished ends using a technique called hydroforming. Faccin provides under its PPH series hydroforming presses that use highpressure water against the sheet to form the dished end, which will take the shape of the holding die. A hydroforming press, together with a precise CNC measuring laser for dishedend depth control and an efficient plate handling system, is the most productive technique for manufacturing oval and polycentric-dished ends for truck tanks. The Flanging Process The operation that follows dishing is the forming of the edge, which will allow the
Boldrini flanging machine RIBO series
dished end to be welded to the tank body to support the pressure inside. During the flanging operation, the plate edge is formed with a flanging roll moving against and with the radius of the shaping roll. The two rolls turn and bend the material at the desired radius. This operation may cause lamination of the plate. The best-quality machines, like the BF series from Faccin and Ribo series from Boldrini, should be powerful enough to do the flanging in a minimum number of passes, causing a minimum thinning of the dished end. A good flanging machine also should feature controls that always allow for the best contact of the rolls with the plate. This includes the ability to tilt the flanging and shaping rolls. The electric and hydraulic units make the difference between a good-quality and a low-quality flanging machine. The hydraulic unit must allow the movements to be proportional and simultaneous; it is of major importance, for example, to have simultaneous, fast movement of the carriage that holds the dished end to the rest of the axis. Dishing and flanging machines are machines with many important technical aspects that should be properly evaluated. Selecting the right machine can make the difference between a successful and unsuccessful business. Andrea Comparin Sales Manager For more information, www.faccin.com & www.boldrini.com
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
TECH TRENDS
Multi-dimensional automation 2D/3D laser scanners guarantee production quality using red and blue laser diodes As well as determining one-dimensional sizes (material thick-ness, vibrations and distance), processed multi-dimensional quality controls (profile and contour measurement) may also be required during the production process, where optical non-contact metrology is ideal due to its high precision, measure-ment speed and flexibility with respect to the surface of the measurement object. Laser scanners carry out complex 2D/3D measurement tasks. Two new models using a blue laser diode additionally extend the field of application.
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he laser line triangulation principle is based on the light intersection method. The point-shaped laser beam is extended to a line via special lenses. Together with the distance information (z-axis), the integrated controller calculates the position of the measurement point along the laser line (x-axis) and outputs both values as 2D coordinates. If the measurement object or the sensor is moved, a 3D image of the object is provided. The scanCONTROL 2600/2900 series of laser scanners from Micro-Epsilon detect up to 2.56 million points per second. The laser scanners owe their compact design to an integrated controller. The sensor is the size of a cigarette packet and stands out due to its comprehensive range of features. Up to 4,000 profiles per second can be transmitted to a PC for further processing. At the same time, digital inputs can be used for synchronisation, triggering or as encoder in-puts. Laser scanners are equipped with an integrated, highly sensitive receiving matrix that enables measurements on almost all industrial materials, largely independent of the surface reflexion. The scan-CONTROL laser scanner is used for profile and contour measurements during running production processes of high volume, continu-ously produced goods (extrusion, milling, drawing, etc.) or single piec-es. An extremely powerful integrated controller unit and Ethernet inter-face make the laser scanner suitable for use with robots and for dy-namic production technologies e.g. in the automotive production when
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to measure red-hot glowing rail tracks and bogies. The red glow normally “dazzles” red profile scanners, but blue scan-ners remain unaffected. Of course, such an application requires spe-cial protection measures (cooling, protection housing) that can with-stand the high ambient temperatures in a forging plant. In the case of (semi-) transparent materials, the blue laser line penetrates significantly less into the surface than the red laser. Particularly with white plas-tics, the red laser point penetrates into the measurement surface. When penetrating the material, the measurement line expands, result-ing in a blurred laser line. Also with organic materials, the slight pene-tration behaviour of the blue laser results in higher measurement ac-curacy.
mounting the windscreens. A laser profile scanner serves to measure the height and position of the adhesive beading on the screen edges. The laser scanners that use a red laser diode are universally applica-ble. This proven technology is widespread, and the components used are therefore produced in large volumes and at relatively low cost. For extremely difficult surfaces, Micro-Epsilon offers its scanCONTROL 2600/2900 BL series of laser profile scanners that use a blue laser di-ode. These laser profile scanners are used, for example, in steel forg-ing plants in order
As Dipl.-Ing. Christian Kämmerer,MBA, Product Manager scanCON-TROL comments: There is an increasing demand for high precision measurements in automated processes, and optical measurement methods are becom-ing increasingly popular. They can perform dimensional measurements, capture measuring points much faster, and measurement data is typically available in real time in digital format. This enables the au-tomatic correction and control of live processes, of which the aim is to produce “good parts” only. Dipl.-Ing. Christian Kämmerer, MBA For more information, Website: www.micro-epsilon.de
visit us at
HALL 1A STALL A106
VerSys VF15
FENWICK AND RAVI your productivity solution partner
Web: www.far.co.in www.farglobal.in
Phone: +91-80-23254935 +91-80-23253901
E Mail: sales@far.co.in
TECH TRENDS
ANCA’s patented PremierPlus technology maintains tool runout of ≤ 7 microns ANCA’s new PremierPlus Collet Adaptor range has several design improvements and complements our range of collet adaptors for shank tooling
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NCA second generation PremierPlus technology ensures consistent and efficient tool runout. With three times greater clamping force, tools are held more securely when grinding, increasing the consistency of tool geometry across a batch of tools. As the clamping force is increased it means more force is required to open the collet. This is enabled by a hydraulic pressure intensifier unit at the rear of the PremierPlus Adaptor. used for this purpose. Simon Richardson, ANCA Product Manager said: “The PremierPlus has been designed to control tool runout as it enables operators to radially adjust the
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collet via adjustment screws. As the clamp force is pre-set via the preload of the clamping mechanism inside the adaptor, the operator does not need to remove the adaptor from the machine when changing the collet.” “Simplifying the grinding process reduces set-up time and saves money. Adjusting the preload of the internal clamping mechanism ensures that larger diameter tools can be rigidly held particularly when fluting tools at higher grinding forces,” Simon concluded. PremierPlus Collet Adaptor gives a cutting edge • Consistent and repeatable tool runout
of ≤ 7 microns during production runs. • Rigid clamping improves quality of the finished tool. • Easy set-up means less downtime. • Can be retrofitted for existing MX, TX and FX machines in the field with no need for modifications to the machine headstock.
TECH TRENDS
Shaping productivity in die & mold Dormer Pramet’s family of economical milling tools has been enhanced with several new ranges for semi-finishing and finishing in die and mold applications
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he launch features an assortment of CNHX05 double-sided inserts, with up to four cutting edges. Its unique patented wiper edges generate a high-quality surface finish, resulting in reduced machining time in both shoulder and face milling applications. This is supported by a range of SCN05C cutters for productive copy milling of steels, hardened steels and cast irons. Available in 12mm20mm diameters, the tool’s close pitch increases the number of teeth and enables at least 20% higher productivity than standard pitch cutters. It has been designed for contouring, profiling, plunging and face milling applications. Offering decreased levels of vibration, the tool has been optimized for smooth cutting of corners and pockets. Meanwhile, Dormer Pramet has launched an insert with six-cutting edges, the double-sided WNHX04 insert. This too features a unique patented wiper edge to generate
superior finish on component walls and face, reducing time in cut. This latest insert is compatible with a new range of economical and productive copy milling tools. The SWN04C cutter, available in diameters between 20-35mm, offers a variety of differential pitch options to enhance surface finish and support the sixcutting edge insert. Designed for smooth cutting in operations with long overhang, it can be used in contouring, profiling, plunging and face milling applications with a depth of cut up to 2mm. As with the SCN05C cutter, the SWN04C range is suitable for semi-finishing and finishing applications in steels, hardened steels and cast irons for the mold and die segment.
In a recent example, the WNHX insert with WM geometry and new M4310 grade was used to machine tool steel at 0.50mm depth of cut. With a cutting speed of 196m/min and feed rate of 3,600mm/min, the tool reduced machining time by 45%, compared to a competitor’s equivalent.
For more information, Website: www.dormerpramet.com The double-sided WNHX04 insert has six-cutting edges.
Dormer Pramet’s CNHX05 double-sided inserts have up to four cutting edges.
Dormer Pramet’s economical milling tools support die and mold applications.
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TECH TRENDS
Seco Deepens Turning Capabilities with Steadyline® Tooling Additions
Seco Tools expands its long-reach turning and boring capabilities with additions to its wellknown series of Steadyline® vibration-damping turning/boring bars and their respective heads
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eco Tools’ new products include 25 mm (1.00”) diameter Steadyline® bars, GL25 turning heads, 100 mm (4.00”) diameter Steadyline® bars, and additions to the range of rough and fine boring heads for Steadyline® bars. Steadyline® turning bars use the most-effective vibration damping system in the industry for easy turning and boring to depths up to 10xD on small and large holes. The system’s passive/dynamic vibration damping uses a damping mass inside the toolholder bar and short, compact cutting tool heads to maximize vibration absorption, making it possible to use tool lengths up to 10 times the bar diameter without tool chatter or work interruptions. With Steadyline®, shops can exchange turning and boring tool heads quickly and effortlessly using the unique Seco
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GL connection. The GL connection mounts heads to Steadyline® bars quickly and firmly, with centering accuracy and repeatability of 5 microns and 180° head orientation capability if required. The 25 mm (1.00”) diameter bars with GL25 workpiece-side connection for 6xD, 8xD and 10xD reaches include carbide-reinforced bars for the deepest tool overhang challenges, along with
Steadyline® turning bars use the most-effective vibration damping system in the industry for easy turning and boring to depths up to 10xD on small and large holes
Seco-Capto™, HSK-T/A and cylindrical shank machine-side interfaces. The 16 new GL25 turning heads target applications including general turning, recessing and back boring with DN..11, CC..09, DC..07, DC..11, TC..11 and VB..11 inserts. Larger 100 mm (4.00”) diameter bars accommodate existing GL50 turning heads and incorporate Jetstream Tooling® high-pressure coolant technology through BA-to-GL50 adapters. Boring heads with BA060 and BA080 machine-side interfaces allow for rough and fine boring at diameters from 66 mm to 115 mm (2.60” to 4.53”).
For moreinformation, Website: www.secotools.com
TECH TRENDS
Vesconite Bearings - adding to its globally-recognised machine shop Self-lubricated polymer bearings and bushes manufacturer Vesconite Bearings will next month add three computer numerically controlled lathes and machining centres to its machine shop
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mong the equipment added will be a Mazak slant turn lathe with a C axis, a Gate ECL 550 gap bed lathe and a Haas HS-1 horizontal machining centre. “We are excited to be adding these machines to our machine shop,” says Chairperson Dr Jean-Patrick Leger. “We want to have additional capacity to allow for our ambitious growth targets.” The machines are similar to existing equipment that Vesconite Bearings has on hand but have been purchased to ensure that the company has an additional 10% capacity to ramp up its production by ten times in the next ten years. This is in line with the company’s objective to gain 10% of the world market share of the type of niche polymers that the company produces, thereby increasing sales by ten times within ten years, says Leger. The company’s extensive machining capacity, which will increase to 70 machines next month, is well regarded
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globally and allows the company to manufacture precision machined custom wear parts made out of various polymers as well as finish moulded products. Vesconite Bearings has a factory floor space of 20,000m2, and its factory includes polymer compounding, extrusion and moulding shops in addition to its extensive machine shop. The company makes rods, machined plates and bushings as stock parts, as well as high-quality finished parts for the agriculture, railways, mining, pump, heavy transport, hydro, renewable, earthmoving and marine industries. The polymer bushings and wear-materials manufacturer prides itself on fast production, turnaround and delivery, with an average global delivery time, using various courier companies with global experience, of three to seven working days. The company also focuses
significantly on training and skills development, and is currently mentoring 23 young people as part of its apprenticeship programmes. Vesconite Bearings boasts customers in more than 100 countries, exports over half of its total sales, and dispatches large orders regularly to the US, China, South America and Australasia.
For more information, Website: www.vesconite.com
INDUSTRY APPLICATIONS:
SYSTEM OPTIMISATION AND MONITORING HAS NEVER BEEN EASIER GRUNDFOS iSOLUTIONS
A SMART SOLUTION FOR YOU
INTELLIGENT SOLUTIONS FOR INDUSTRIAL APPLICATIONS Digitalisation is opening up a new era of possibilities for industrial applications with increased production optimisation, intelligence and data collection. That’s why Grundfos iSOLUTIONS looks beyond individual components to optimise the entire system with intelligent pumps, cloud connectivity and digital services. Intelligent pump solutions can reduce downtime, system stress, maintenance and system complexity, all while lowering lifecycle costs. Discover more at grundfos.in
TECH TRENDS
SCHUNK extends its modular system for workpiece direct clamping The SCHUNK VERO-S quick-change pallet modules offer a whole bundle of advantages for users when it comes to direct workpiece clamping without interfering contours: free 5-sided access to the workpiece, a defined clamping situation, high repeat and positioning accuracy, as well as high pull-down forces for challenging operations
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CHUNK further extends its modular system for workpiece direct clamping in order to ensure that the efficient principle will also work in the field of tool and mold making industries for free-form parts with complex geometries, small lot sizes, and high precision requirements. By using SCHUNK WDB basic modules, WDS staple modules, or WDN direct clamping modules (Ă˜ 99 mm), which can be flexibly combined with the clamping pillars in various heights, the molding plates, free-form parts, and other workpieces can be directly clamped on the machine table in no time at all. No additional clamping devices are required, so there are no interfering contours. The compressed air supply of the direct clamping modules is ensured via media transfer. Monitoring of the workpiece presence is also possible. The clamping pillars ensure a defined clamping situation, a reliable simulation, and a collision-free, highly efficient operation. Due to the high accuracy of the clamping solution, workpiece changes can be implemented quickly. In addition, parts clamping can be done precisely and easily according to the existing retrofitting plan and the parts can be machined again. Flexible components for free-form parts Due to the modular nature of the product, custom solutions are not required. The new module sizes of the extended modular system from height 80 mm on are finely graduated in 10 mm steps and are easy to implement: The staple modules are available in five heights (30
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pneumatically actuated (6 bar) with a fixed Z-axis reference, and manually or pneumatically actuated with integrated compensating function in Z-direction (11 mm). The latter is used for deformationfree support of the workpieces. For system implementation the system on every common machine table, the modular system includes basic module versions for T-slot plates, grid plates, and VERO-S clamping stations. Standard fixed clamping pins without recess mount, cylindrical clamping pins, and conical clamping pin extensions are available as an interface to the workpiece. Special clamping pins with floating pitch compensation in one or two axes (each +/- 1mm) can be used for compensating workpiece tolerances or thermal expansion.
mm, 50 mm, 80 mm, 120 mm, and 160 mm), and can be actuated with a hexagon key in no time at all. The force- and form-fit clamping connections lock the individual modules with pull-down forces of up to 25,000 N (at an actuation torque of 50 Nm). Thereby the integrated pulldown function ensures maximum hold, and in turn for maximum stability. The direct clamping modules are available in three versions, that connect the clamping pillars with the workpiece:
High accuracy Every interface uses a scope-free taper centering, which ensures a repeat accuracy of < 0.005 mm. Feed chamfers at the module interfaces allow quick joining of the clamping pillars. The workpiece is clamped via spring force in a self-locking and form-fit fashion without needing compressed air. The workpieces remain safely clamped even in the case of a sudden pressure drop in the air system. In order to increase service life and process reliability, every functional part such as base body or clamping slide are made of hardened, stainless steel, are absolutely corrosion resistant and easy to clean.
For more information, Website: www.schunk.com
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.
agency.com
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
TECH TRENDS
Rollon & Universal Robots together at Motek, with a new Seventh Axis suitable for cobot The Group based in Vimercate (Italy) has developed a solution capable of extending the range of action of the collaborative robots produced by the Danish multinational, further improving their performance and retaining their easy-to-use features for small and medium businesses
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he system is easy to install and can be programmed using a Universal Robots tablet Simple, immediate and with an even broader range. This is the new solution that Rollon and Universal Robots presented at the Motek in Stuttgart: the Group based in Vimercate specializing in solutions for linear motion has in fact developed a demo for a seventh axis designed specifically for the cobots of the leading Danish company in the collaborative robots sector.
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The aim? To increase the range of action, further improving the performance of UR robots in automated processes in various sectors without sacrificing ease of use. This is a feature that has made the Universal Robots solution a reference point for small and medium businesses venturing into the world of robotics. There are various applications, from industrial machine feeding to assembly, pick and place and palletizing in which an axis can make all the
difference, increasing the range of action of UR cobots. An improvement which will be even easier: simple and quick to assemble and start up, the new â&#x20AC;&#x153;Seventh Axisâ&#x20AC;? from Rollon can be programmed using the Universal Robots tablet. The frame is made up of anodized aluminum profiles that offer considerable benefits in terms of weight, transportability and modularity, while maintaining a high degree of stiffness. These are characteristics that the research and development team of
Linear solutions global provider.
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ROLLON India Pvt. Ltd. - INDIA 1st ďŹ&#x201A;oor Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA www.rollonindia.in - info@rollonindia.in
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
Rollon has enhanced by developing a solution capable of operating in vertical and horizontal applications. The Seventh Axis, fitted with ball recirculating linear guides and belt drive, enables the robots of Universal Robots to move at a speed of 1 m/s with an acceleration of 1.2 m/s and a repeatability of ± 0.05 mm. The demo of the new “Seventh Axis” has debuted in Stuttgart at the Rollon Stand. More in detail, a Sev 220-1 moved a UR10, the largest in the range of cobots from Universal Robots, which can move loads of up to 10 kilos. And the UR3 and UR5? These didn’t be on display in Germany, but Rollon has also given them some thought with two further versions of its Seventh Axis, the Sev 160-1 and Sev 130-1 respectively: a modularity that enables everyone
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to choose the turnkey solution most suitable for their needs. A commitment that bears witness to Rollon’s desire to keep growing in the robotics sector and also by cooperation with innovative players looking to the future such as Universal Robots. About Rollon Rollon Group has its headquarters in Vimercate (MB), and offices in Germany, France, the United States, China, India, and Japan. It produces linear and telescopic guides and actuators for many sectors, such as railway, aeronautical, logistics, packaging, machine tools, and medical. Numerous end markets and a vast clientele are Rollon’s strong points. The company is known for high quality standards in its products, pre-sales support and
a high level of product customization. All these characteristics have made it a leader outside of Italy, where 85% of production is sold. Thanks to its growth strategy in recent years, the Italian company has established itself as a provider of increasingly complex solutions for linear handling, thus reinforcing its position in the sectors of automation and robotics.
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
TECH TRENDS
Why invest in a STUDER grinding machine? The customer care of STUDER is close to its customer with experienced employees worldwide. It ensures that the machines work reliably and are available at all times
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grinding machine, on which as many applications as possible can be executed efficiently and precisely and which is still easy to handle? STUDER builds perhaps the best cylindrical grinding machines in the world. For internal, external, form grinding, high-speed and profile grinding. In a short time adapted to customer requirements and highly economical in production. “I think I’m a very good grinding technician”. But I know it’s the machine that does it all for me, “says Fumitaka Matsubara, General Manager of Ohba Seiken, Toyohashi City. His company manufactures high-precision parts for smart phones, robotics, electronics and prototyping. In his hall, in addition to automatic lathes, there are also internal/ external cylindrical grinding machines as well as surface and jig grinders. Ohba Seiken has had a STUDER S41 in its company for 11 months, Fumitaka Matsubara is thrilled. “Especially when we are not sure how and if we can grind parts, the S41 gives us the best solution - the software StuderWIN makes it possible. The machine grinds extremely precisely. We were able to significantly reduce the processing costs, especially for complex work-pieces. Ohba Seiken chose STUDER machines for five reasons: 1. Quality and precision 2. Flexibility and versatility 3. Wide range of applications 4. Innovative software 5. Technical Support. Quality and precision “STUDER is a strong brand“, Fumitaka Matsubara states. For over 100 years and with more than 1,000 employees, it has stood for experience in the development
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Ohba Seiken employee Mr. Fukui (left) and Mr. Sasagawa (right) discuss grinding process improvements in front of the STUDER S41
and manufacture of precision cylindrical grinding machines. STUDER promises Swiss top quality hardware, software, system integration and service. Fumitaka Matsubara is convinced of the high precision of the S41. In his hall are various cylindrical grinding machines from Japanese and European manufacturers. “I experience the quality of STUDER every day, especially the positioning accuracy of the fully automatic B-axis is unbeatable.” Flexibility and versatility STUDER machines have a wide range of possible applications. What is perhaps less known: STUDER is also strong in internal cylindrical grinding, form, contour and thread grinding, as well as high-speed and jig grinding. Another STUDER machine that can do all this is the S141. It is available in three sizes for workpiece lengths, incl. clamping device, of 300mm, 700mm resp. 1300mm. The
maximum internal grinding length is 250 mm, the external 150 mm. The S141 is the ideal machine for grinding spindle shafts, spindle housings, rotor shaft axes or flange parts. Many workpieces can be found in the fields of machine tools, drive components, aerospace and toolmaking. A S141 is also located at Kato Kenma in Tokyo. The plus point of the machine is its simple set-up: Once put into operation, the grinding technology support software StuderTechnology ensures high productivity from day one. If you ask Hajime Suzuki, Factory Director at Kato Kenma about the main advantages of his S141, he says: “It is finally possible to grind the shapes and angles exactly according to the program you have entered, and we have almost no dimensional deviations, especially on the Z -Axis”. Yes, we can produce for our needs, with the best machine in the world. “Where Hajime Suzuki in the past had to search for the optimum result, the
TECH TRENDS www.mtwmag.com
S141 now gives him the perfectly ground workpiece right from the start, which means extremely high process reliability. Easy access to the machine interior, as well as to the hydraulic components and the electrical interfaces, ensure easy handling. The grinding wheel can be replaced within a short time with just a single Allen key and a few simple steps. Thanks to air lift, the workhead and tailstock can be easily moved. Very handy is also the hand-held PCU with colour display. This allows the operator to control the grinding process more closely and better, as well as trigger different functions and change values. Software The requirements of a software? Shortest set-up, programming and grinding times with maximum availability of the machine. Thanks to the modular STUDER software concept, the machine is quickly set up and intuitive to use: simply enter the workpiece dimensions and material and StuderTechnology automatically generates the grinding program, based on over 100 years of grinding experience. Here, more than 300 machine parameters are taken into consideration and can be individually edited based on your own experience. The visual language StuderPictogramming simplifies programming and subsequently the operation. Particular mention should be made of the StuderContour software which allows the high-precision machining of longitudinal contours. Whether step drills, drawing dies or other
A Kato Kenma employee Mr. Hashimoto operates the STUDER S141
rotationally symmetrical shaft parts - the different diameters can be ground out of the solid. “I have never achieved such accuracy in contour grinding before,” says Hajime Suzuki of Kato Kenma. Support The customer care of STUDER is close to its customer with experienced employees worldwide. It ensures that the machines work reliably and are available at all times. Customer Care provides quick and easy support, helps increase productivity, and provides a professional, reliable solution in the event of a problem. It accompanies commissioning, trains customer employees, maintains, refurbishes machines and assemblies, converts, equips, supplies spare parts and accessories. But above all, with a comprehensive service, it is always close to the customer respectively quickly in front of the machine. “The
STUDER service is friendly and works competently,” says Hajime Suzuki from Kato Kenma. Customer Care has already arrived in the age of Industry 4.0 with its Digital SolutionsTM. For example, with the Remote Service: With secure Internet connections, expert support is possible with just one click - immediately on the machine, with no time lost due to travel time - with data security being the topmost priority. “It was worth investing in a STUDER machine. We can now grind even more precisely in a very short time, which makes us more economical. Since the dressing is eliminated after the grinding wheel is swivelled, we are more productive and expect lower tooling costs “ says Fumitaka Matsubara from Obha Seiken with satisfaction. It is also clear to Hajime Suzuki from Kato Kenma: “In the next 10 years we will be acquiring additional machines from STUDER.”
SNAP www.qviindia.com
Instantly measure small parts automatically with accuracy assured by traceable calibration.
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TECH TRENDS
IO-Link makes sensors fit for Industry 4.0 Sensors play an important role as “organs of perception” in automated solutions. To implement Industry 4.0 concepts in the automation industry, sensors do not only need to provide measured values or signals, but the latter also need to be communicated. This type of communication should always be simple and efficient – from sensor level via control and process control level up to company level. This is the only way to benefit from the many advantages offered by Industry 4.0.
i
fm opts for IO-Link to ensure simple and efficient digital sensor communication. This interface, which is integrated in almost all new sensors that ifm puts on the market, is added to the standard analogue interfaces such as 4...20 mA. What is more, IO-Link has the potential for replacing analogue transfer of measured values. Since IO-Link data transmission is digital, measured values cannot be distorted by interference on the cable. Another great advantage of IO-Link transmission is the option to add further information, such as status information of the sensor, and to communicate it simultaneously. Also when it comes to sensor configuration, IO-Link offers many advantages: since parameter settings can, for example, be directly adopted from an IO master. Hence, time-consuming sensor setting is no longer necessary. The new generation of IO-Link masters from ifm is extremely robust and offers two Ethernet ports with a switch for Profinet. The LR Device software is used to configure the connected sensors and actuators. The intuitive software finds all IO-Link masters in the Ethernet network and creates an overview of the whole plant. This is something entirely new on the market. Additionally, integrating sensors with IO-Link makes it possible to use sensor data for higher-level ERP systems. For this, ifm offers the Linerecorder. It enables bidirectional communication between many different interfaces. This allows communication between ERP
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systems and data from units at field, control and process control level. With this system, the data can be transmitted directly to the ERP system without putting additional strain on the PLC in the automation solution. ifm has termed this direct sensor data path, which bypasses the control level, “Y path” because the data reaches both the PLC and the company management level by splitting up like the letter Y. ifm is fully convinced that IO-Link is the foundation for a successful implementation of all Industry 4.0 concepts. This is why all new ifm sensors come with an IO-Link interface
as a standard feature. Currently, ifm’s product range includes about 500 IOLink products, and every year 100 to 150 new products are added.
For more information, Website: www.ifm.com
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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.
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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
TECH TRENDS www.mtwmag.com
Spring hinges for automatic return
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lesa+Ganter offer a wide range of hinges made of engineering plastics, steel, stainless steel, aluminium or zinc-alloy and with different types of assembly, rotation angles, load resistance values or with integrated safety switch. Such a wide range of variants in production allows customers to choose the suitable hinge for their application whatever the market sector. The brand new CFMR spring hinges enrich the range of plastic hinges. In fact, this new technical solution allows the automatic closing or opening of doors, thanks to an integrated return spring housed in the rotating pin. CFMR body is made of SUPER-technopolymer, one of the latest evolutions in engineering polymer materials characterised by high mechanical and thermal performance. A new technopolymer combining favourably the advantages of engineering plastics with metal ones. The aluminium rotating pin and the
stainless steel return spring guarantee maximum wear and corrosion resistance. To suit at the best different applications, the hinges are available in different standard executions with opened (CFMR-NO) or closed (CFMR-NC) return position and with spring with different stiffness corresponding to different maximum return torque (0.35 Nm and0.70 Nm). CFMR hinges have undergone specific
stress test in our laboratories, where the return spring has successfully exceeded 100,000 cycles without affecting torque values. Furthermore, it is available without return spring(CFMR-NS) for a better aesthetical integration of the hinges on the machinery on which they are mounted. For more information, Website: www.elesa-ganter.in
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Machining centre 4.0 with innovative safety solution Mandelli Sistemi employs a 5-axis machining centre to process hard titanium alloys for the aerospace industry. The company uses a safe solenoid interlock with Bowden cable from Schmersal to automate and secure the closing process on the large sliding doors fitted to the titanium machine. dynamic, allowing for high acceleration in the complex machining phase for both the workpiece geometries and the material composition (titanium, HRSA - heatresistant super alloys).
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ver its 80-year history, Mandelli Sistemi S.p.A. has continuously focused on innovation and custom-made solutions. Based in the northern Italian town of Piacenza, this medium-sized enterprise, now a part of the Riello Sistemi Group, has become one of the leading Italian companies for the manufacturer of machine tools. Over the past decade, Mandelli has turned its focus to industries such as aerospace and energy, where difficult-to-machine materials combined with complex geometries require demanding turning and milling operations. At the turn of the millennium, Mandelli Sistemi completed the development of a new series of five-axis machining centres, the SPARK series — fast, highperformance machining centres with compact dimensions and outstanding productivity. In 2015, Mandelli Sistemi added a new version to the SPARK series in the form of the Spark Ti (for titanium),
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a five-axis horizontal machining centre, with a fixed machine bench capable of very precise machining, in spite of high material volumes. The machine is able to process very hard titanium, steel and HRSA alloys that are typically used in the aerospace industry. At the heart of the Spark Ti is a continuously controlled hightorque swivel head equipped with an automatic mechanical backlash recovery system, plus a dual-drive rotary axis with 12,000 Nm of power and a vibration damping system on every machine axis. In addition, all turning tables are highly
A new generation of machining centres for Industry 4.0 The new generation of machining centres from Mandelli Sistemi is already compatible with Industry 4.0 concepts, with all machines incorporating a complex system of anti-vibration, noise and vibration sensors to be able to detect critical conditions early on and adapt machine parameters when required. This helps to avoid machine downtime and minimise production waste. Mandelli Sistemi has also developed the new iPum@Suite 4.0 software package for the ‘factory of the future’. This software guarantees that networked machines can be fully monitored by a remote setup through a series of sensors and an intelligent vibration monitoring system — an intelligent diagnostics system in which the operating data from the machining centre is transferred to a cloud database where statistical calculations are carried out to identify faults before a malfunction occurs. ‘For our high-performance Spark Ti, with its considerable size, we need to have a robust safety system in place. If a machine operator accidentally finds himself trapped inside the accessible part of the machine, the safety solution needs to allow the operator to leave the area as quickly as possible and needs to block the system at the same time,’ explains Ing. Giuseppe Galbiati, Project Manager at Mandelli Sistemi. The safety system requirements for the Spark Ti
TECH TRENDS www.mtwmag.com
were mapped out at a meeting of the engineering department of Mandelli Sistemi and safety machinery experts from Schmersal, a leading international provider of machine safety products. A safety locking system that satisfies all of these requirements is the AZM400 secure bolt retention system from Schmersal, in conjunction with Bowden cable release. Mandelli Sistemi has been impressed by the extraordinarily high locking force of the AZM400 when used on the heavy protective doors on its Spark Ti, but, when used in conjunction with the Bowden cable, the AZM400 also offers high protective performance, a feature that is particularly valuable in the event that an operator becomes trapped in the machining centre accidentally, such as when carrying out maintenance work. Within the hazard area, the Bowden cable can, therefore, be used as an emergency release, with the operator merely having to pull on the pull rope. When used outside of the hazard area, the device can be used as an emergency unlock. The pull rope has a standard overall length of 6 m and a sheath length of 4 m, thereby allowing for protection of large systems as well. Solenoid interlock especially for large machining centres Schmersal launched the AZM400 solenoid interlock in 2015. The system comprises the locking unit with sensor system, a motor-driven locking pin and the actuator. The actuator contains an encoded RFID tag and a locking opening into which the locking pin is inserted. As soon as
the locking pin has reached a sufficient insertion depth into the locking opening in the actuator, the safety device can be considered safely locked. In developing the AZM400, Schmersal kept the special requirements of large machining centres in sharp focus, particularly the fact that most machining centres require very high locking forces capable of locking heavy protective doors, many of which have motorised actuators. The AZM400 safety locking system has a locking force of 10,000 N, which is an exceptional feature amongst solenoid interlocks. The AZM400 achieves safety level PL e and Cat. 4 in accordance with DIN EN ISO 13849-1 and SIL3 in accordance with DIN EN 61508 for both the interlock and locking functions. The high safety level of the locking function is achieved by features including a two-channel unlocking signal, which ensures that should, for example, a cross-fault occur, the system remains locked to prevent unauthorised access to the hazard area.
High level of safety and maximum plant availability The AZM400 ensures not only a high level of safety but also seamless process execution for maximum plant availability. For example: protective doors often have dampening at their limit stops such that, when they are closed, they spring back a little. As a consequence, the locking pin does not sit fully in the centre of the locking opening in the actuator and must overcome cross forces. If it is unable to overcome the cross forces, the protective door is not opened and the production process is delayed. The solenoid interlock AZM400 offers the advantage of unlocking against a cross force of up to 300 N. In addition, the electronic system combined with the sensor system offers numerous additional functions, including error state identification: if the locking pin fails to reach a ‘locked’ status on the first attempt, it attempts to lock again automatically. Only if this second attempt fails will the AZM400 report a fault. This helps to reduce the number of fault notifications and at the same time, protects the device from damage. ‘Protective doors must always reliably lock and unlock. At the same time, the safety technology must help to maximise plant availability. The AZM400 is, therefore, the optimal solution,’ explains Maicol Garavaldi, Safety Machinery Expert at Schmersal Italia.
Web:www.schmersal.in
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TECH TRENDS
Click & Ready!
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nterfaces in industrial applications are subject to higher demands. On the one hand, there are external factors such as moisture, dust, noxious gases or vibrations, which can impair or interfere with a connection. On the other hand, it is important to consider handling and ease-of-use by operating personnel. The protection of a connection has the highest priority
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The word plug comes from to plug in. Thatâ&#x20AC;&#x2122;s how easy it usually is to transfer data or power with household appliances or smartphones. Plug in and ready to go. In industry, however, the requirements are much higher and interfaces must be locked in order to ensure proper protection. To be able to connect data, signals and power more quickly and without tools in the future, HARTING is expanding its portfolio of PushPull plugs. Secure connections in a single hand movement. in order to prevent the worst case scenario of system failure or destruction. Nevertheless, plug operation must be easy and user-friendly. Over the years, different companies have developed such a diverse array of plug types and ensured their continued presence on the market. Plugs are usually sealed and made resistant against dirt or unintentional loosening through
vibration by means of a lock. This can be achieved using threaded connections, e.g. by screwing the connector itself, by levers, clips or many other systems. However, this approach often requires tools for assembly, as well as trained installation personnel to estimate the correct fit of the plug. Since the installation of systems and devices often takes places under far from
TECH TRENDS www.mtwmag.com
ideal conditions, i.e. with suitable tools and trained personnel, it was necessary to re-design the interface itself. The PushPull system has been a successful part of HARTING’s range for some time now. Types 4, 14 and Power L are classic rectangular connectors, which originate from the automotive industry and industrial device cabling. Factors such as durability and fast, but at the same time safe, installation remain in the forefront. Here, the saying “time is money” still applies. PushPull connectors enable all kinds of plug profiles to be securely connected in no time at all. An audible click informs the installer that the connection is now waterproof and closed. No tools, no torques, no special training for personnel. Various types of plug profile can be accommodated in the universal “containers” of the housing for types 4 and 14. Depending on the application, these can be RJ45, optical fibres in plastic or glass or even USB for the transmission of data. If signals are to be bundled and forwarded, users can choose between 10 and 20-pole plug profiles. However the power supply can be safeguarded using the tool-less interface up to 690 V at 16 A. Together, this provides device manufacturers with all necessary solutions from a single source as part of a uniform and standardized system. The newest member of the PushPull family came about due to the desires
and requirements of the market. The type 4 Mini DisplayPort interface serves the increased use of HMIs in the form of screens and keypads, which are fed video signals. In order to avoid additional conversion of video signals into Ethernet, the DisplayPort interface supports direct forwarding of video signals. Of course, in addition to all the rectangular elements of the PushPull system, it is important not to forget circular plug types. Rectangular and circular plugs The M12 is the most common representative in the field of metric circular plugs. It is a classic signal plug with a threaded connection for sensors and actuators. In recent years, this interface has increasingly become the go-to connector for D and X coding for Fast Ethernet and Gigabit Ethernet applications. However, they all feature threaded locking systems, which must be checked with a special torque wrench to ensure the specified IP 65/67 protection class. Obviously assembly takes a longer due to screwing and checking, and the packing density of interfaces on switches is rather limited as a certain amount of space for the tool is always required. Due to the increasing number of use cases for the M12, HARTING has already been offering it with the PushPull mechanism for a long time and deployed it initially within the railway
market. The requirements in the rail sector are among the highest available. If an interface can overcome demands here, it can be used in other application areas without raising concerns. Since feedback from railway manufacturers has been consistently positive and in general the trend in all industrial business sectors is towards increased modularity, HARTING has decided to supplement the PushPull connectors of all series with new types and, in future, to use printed circuit board connections for circular plugs within the PushPull system. This will not inconvenience previous users, because the interfaces are back-compatible and can still be used with conventional M12 screw locks. This means the switch to PushPull can be made gradually. The other alternatives in the M12 range are adapters that convert a standard M12 screw socket to a PushPull socket. Who benefits? PushPull’s time savings are particularly well received by users and represent an important purchasing criterion when selecting a device. PushPull can be positioned more compactly on housings, because users require less space for each individual interface when connecting without tools. This brings us to the main point and the actual target group: the user, in other words fitters, setters, service personnel or unskilled workers. The fact that tools are no longer required, together with the quick locking system, mean that, in the case of the M12 PushPull for example, assembly times can be reduced by as much as 70 % when compared to M12 screw types. Of course, this is most likely to become a decisive factor when connecting a large number of plugs, however the simplified operation also offers significantly more process reliability when employing unskilled personnel thanks to the system’s clear feedback and userfriendliness. For more information, Website: www.harting.com
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TECH TRENDS
Additive manufacturing – High productivity without compromise
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lobal engineering company Renishaw returns to Formnext in 2018 to showcase that it is possible to significantly increase additive manufacturing (AM) productivity without compromising on quality. Since the launch of its four-laser RenAM 500Q system, Renishaw has developed extensive expertise in multilaser applications in AM and established a deep understanding of how lasers interact with each other and the part. From the 13th to the 16th November, Renishaw can be found in Hall 3.1, Stand E68 at Messe Frankfurt, Germany. In 2017, Renishaw launched the RenAM 500Q, a pioneering four-laser system with precision dynamic focussing and a full-field view of the powder bed. This pioneering system transforms productivity in the most commonly used platform size, raising productivity and decreasing cost-per-part. Testing and analysis has now proven that multiple lasers can operate independently on separate parts or co-operate on a single, large component without diminishing the quality of the material produced. Multi-laser additive manufacturing has opened up new product design opportunities for a range of industries as the technology becomes more accessible. Ensuring users have the freedom to unlock all the benefits of multiple lasers
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requires file preparation and simulation tools to allow that freedom to be exploited without compromising quality. Renishaw will also demonstrate the latest version of its QuantAM build preparation software, with laser assignment tools that empower users to develop processing strategies in line with the quality and productivity demands of their applications. “When there are multiple lasers in close proximity, there is the potential that emissions from one laser could affect another,” explained Marc Saunders, Director of Global Solutions Centres at Renishaw. “This is dependent on their relative position within the machine’s inert gas flow. The first generation of multi-laser machines used zoning to avoid this issue, combined with either linear or divergent gas flow. “However, this strategy has several drawbacks including reduced productivity for non-symmetrical builds, discontinuities as a result of thermal drift in the optical systems and varying melting conditions as a result of divergent
gas flow,” added Saunders. “The design of Renishaw’s RenAM 500Q overcomes these drawbacks and enables efficient use of all four lasers. Renishaw is ensuring that its machine is as productive as possible, without any compromise on quality.” As well as offering attractive benefits, Renishaw has completed extensive testing to understand the potential of interaction between the lasers. The machine boasts melt-pool and laser power monitoring capabilities to provide evidence of melting behaviour in real-time. Building on its knowledge, Renishaw has ensured its machine performance is consistent and can offer guidelines to enable customers to produce high-integrity components in a productive and flexible way. At the show, Saunders is speaking on the TCT introducing stage on Tuesday November 13th from 11.30am to 11.45am. The session will cover how to radically improve productivity with multi-laser systems, without compromising on product quality. For more information, Website: www.renishaw.com
CASE STUDY
Vacuum casting technology facilitates record development cycles for Zumex
The food and beverage industry is a competitive sector where companies are always looking to reduce costs. The professional juicing machine manufacturer Zumex recently invested in a Renishaw 5/01 PLC vacuum casting machine, which allowed it to speed up its development cycle and cut third party costs
T
he Zumex Group is among the lead-
the peel. The company was the first to
ing designers and manufacturers
introduce automatic extraction in its pro-
of automatic juicers for the hotel,
fessional juicers and manufactures its ma-
catering and retail sectors, as well as
chines in an antibacterial silver polymer
industrial juicers. Headquartered in Spain,
that inhibits the growth of bacteria.
Zumex has a global presence in more than
Before approaching Renishaw, Zumex
100 countries and for the last 30 years, the
used computer aided design (CAD)
company’s innovative culture and avant-
software to create juicing system mod-
garde design has placed it at the forefront
els and sent the designs to a third party
of the industry.
vacuum casting company to be made. Due
An integral part of this ethos is Zumex’s
to exponential growth in recent years, the
continued dedication to research and
juicing machine manufacturer wanted to
development (R&D). The company con-
bring this capability in-house so it could
stantly adapts the design and manufacture
design, test and manufacture prototype
of its products to respond to market needs
parts quicker. Zumex got in touch with
and drive the industry forward. In 2014,
Renishaw to supply its manufacturing
when the firm decided to invest in a vac-
facility in Spain with a vacuum casting
uum casting system to produce prototype
machine suitable for producing parts for
cians needed to make slight changes to
parts for its juicing machines, Zumex got
its entire range of juicers.
designs, they would have to send the new
in touch with global engineering company
Challenge
ing company and wait several more weeks
The subcontracting of its vacuum casting
for the new prototypes to arrive. This
guarantees flavour and hygiene because
work meant Zumex had to wait several
proved to be a time-consuming exercise
there is no contact between the juice and
weeks before parts arrived. If the techni-
that was slowing down the company’s
Renishaw. Zumex’s unique juice extraction system
96
CAD files to the designated vacuum cast-
MACHINE TOOLS WORLD NOVEMBER 2018
CASE STUDY design and production processes. Zumex’s
PLC vacuum casting machine because of
proximately 90 per cent of the prototyping
main motive for purchasing a vacuum
its ability to produce small builds consist-
work we do is completely bespoke be-
casting machine was so it could produce a
ently. “The Renishaw 5/01 PLC vacuum
cause we want to test our juicing machines
small number of prototypes quickly, in its
casting machine has a smaller footprint
to the limits. We certainly found a vacuum
manufacturing facility in Spain, without
than other Renishaw units, so it was
casting machine that can cope with these
having to rely on external suppliers.
perfect for Zumex because the company
demands in the Renishaw 5/01.
Zumex wanted a machine capable of
needed it to produce low volumes of
“Since we purchased our vacuum cast-
producing the silicon moulds as well as
parts,” explained Iñigo Bereterbide, Ad-
ing machine, Zumex has significantly re-
the final prototype part made from resins.
ditive Manufacturing Product Manager at
duced production times for our prototype
The machine had to vacuum cast unique
Renishaw Ibérica. “When vacuum casting
parts. In-house vacuum casting capabili-
designs that would be fit for field-testing
a small number of parts, it is important
ties allow us to continue to be an innova-
in a food-safe environment.
that the final product is perfect the first
tor in our field, increasing our capacity to
time. The PLC controls and automation
design and manufacture new products,
Zumex vacuum casting machine
features of the Renishaw 5/01 machine
without having to rely on external suppli-
The level of service and support we
ensure consistent casting every time.”
ers. In this way, it has also allowed us to
received from Renishaw was outstanding;
Renishaw also supplies Zumex with
reduce costs.
the locality of Renishaw Ibérica means
specialist consumable materials on an
Zumex gets native speakers and short
ongoing basis, which allows Zumex to
received from Renishaw was outstand-
lead times. But by far the most impressive
test designs in true working conditions.
ing,” continued Codina. “The locality
aspect to me was the training. When you
Perhaps the most important part of the
of Renishaw Ibérica means Zumex gets
work with Renishaw, you benefit from a
service Renishaw supplied to Zumex was
native speakers and short lead times.
global knowledge bank, as demonstrated
the specialist training. Renishaw’s vacuum
But by far the most impressive aspect
by our two training sessions in the UK.
casting experts at its Additive Manufac-
to me was the training. When you work
turing Products Division (AMPD) in the
with Renishaw, you benefit from a global
Solution
United Kingdom delivered a tailored
knowledge bank, as demonstrated by our
“We approached Renishaw because of its
training programme for Zumex’s proto-
two training sessions in the UK. These
reputation in the prototyping technologies
typing technicians. This allowed the com-
were informative and allowed us to get
sector,” explained José Codina, Prototype
pany to get to grips with its new vacuum
hands-on experience so we could achieve
Technician at Zumex. “We were familiar
casting machine before it began producing
the most from our machine. Without the
with the company’s expertise in vacuum
prototype parts on its own.
comprehensive training, we would have
“The level of service and support we
wasted time, materials and money getting
casting, so when we made our decision to purchase a machine, we went straight to
Results
Renishaw.”
“Two of the most important values at
to grips with vacuum casting.” “The relationship between the two com-
Zumex are innovation and development
panies is such that Renishaw holds Zumex
cal subsidiary in Spain, Renishaw Ibérica,
and so in this sense, we demand a lot from
master parts and produces moulds to ship
which provided all the necessary informa-
our R&D department,” explained Codina.
to the juicing machine company when its
tion and support. After discussing what
“The machines we use have to be of the
production cannot handle the demand,”
Zumex required from a vacuum casting
highest standard, capable of producing
explained Bereterbide. “This is a testament
system, Renishaw recommended its 5/01
sleek and modern designs efficiently. Ap-
to our ability to understand our custom-
Zumex got in touch with Renishaw’s lo-
ers’ manufacturing challenges and our desire to provide solutions by whatever means possible.”
For more information, Zumex vacuum cast parts and feeder tube
98
MACHINE TOOLS WORLD NOVEMBER 2018
Juice extraction part and silicon moulds
Website: www.renishaw.com
Taming power quality is now child's play
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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
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A GLOBAL DISPLAY OF IN
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For More Details, Please contact: +91-98795 66567 SILVER SPONSORS
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Venue : NSIC Ground, 80 Feet Road, Aji Industrial Area, Rajkot, Gujarat 360003
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Last Day (1st December) Visitors Timing : 10.00 am to 04.30 pm
KMG BUSINESS TECHNOLOGY 207, 2nd Floor, Harmony Icon, Near Baghban Party Plot, Thaltej-Hebatpur Road, Thaltej, Ahmedabad-380059, Gujarat, India Telephone: +91 9909041613-18 | E-mail: kmg@kmgindia.com, info@kmgindia.com
www.rmtsindia.com
PRODUCTS SHOWCASE
PRODUCT SHOWCASE KING CUT PRO – The Large Gantry Type CNC Cutting Machine Ador’s KING CUT PRO is a CNC portal cutting machine which is very precise and reliable. The machine has one head for plasma sheet metal cutting and one head for flame cutting of sheet metal with a dual side longitudinal drive with AC motors. The standard equipment comes with a basic machine package with CNC controller, one torch, central gas diffusion with manometers and a remote flame ignition.
The following equipment are supplied as required by the customer: Additional Equipment: • Plasma power source KJELBERG with machine torch • Programming software MOST 2D • Support table for sheet metal with segment extraction system • Extraction-filter system • Laser position indicator for determining the cutting point Optional : • Extension of the longitudinal rail • Additional cutting head
The CNC Controller – Phantom: The Phantom brings you the performance of a
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
104
MACHINE TOOLS WORLD NOVEMBER 2018
cutting edge CNC that is built on more than 40 years of experience in the motion control and cutting industries. This controller is designed for multiple axis cutting machines and features the latest advances in CNC technology on a proven platform engineered to increase productivity, reduce costs and enhance profitability. The software provides flexibility, ease of operation and technologies that put Ador’s experience and expertise in your operator’s hands, resulting in extremely good cut quality and high productivity. The Phantom can operate any cutting machine and interface with virtually all plasma systems. Following are its standard features: Bright touch screen interface, Touch screen interactive display, Expandable shape library, True multi-tasking environment, Fast Dxt file conversion, Go to(Job interrupt), Quick plate alignment, and Monitor & track consumables. Advanced Plasma Process Control (Plasma Process Wizard) is available as optional extra. Ador offers cost-saving height control unit for simple plasma cutting applications. The KHC1 system provides all the essential functions that are needed for good cuts and optimum utilization of work-piece.
PRODUCTS SHOWCASE www.mtwmag.com
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
• 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.
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.
NOVEMBER 2018
MACHINE TOOLS WORLD
105
PRODUCTS SHOWCASE
Cross Linear Guideway-MSH Series Structure and Features Balls roll four rows of raceways precision-ground on a rail and a block, and endplates incorporated in the carriage allow the balls to circulate. Since retainer plates hold the balls, they do not fall o even if the rail is pulled out. This model is an integral type of linear guideway that squares an internal structure similar to other model, which has a proven track record and is highly reliable, with another and uses two rails in combination. It is machined with high precision. The two rails are also machined with high precision in relative straightness. As a result, extremely high accuracy in orthogonally is achieved. Since an orthogonal linear guideway system can be achieved with model MSH alone, a conventionally required saddle is no longer necessary, the structure for X-Y motion can be simplified and the whole system can be downsized.
Four-Way Equal Load The four trains of balls are allocated to a circular contact angle at 45°,thus each train of balls can take up an equal rated load in all four directions. Moreover, a suffi¬cient preload can be achieved to increase rigidity, and this makes it suitable for any kind of installation.
High Rigidity For Product Enquiry Contact Superslides & Ballscrews Co. India Pvt Ltd SUPERSLIDES HOUSE, A-774 T.T.C Industrial Estate, MIDC, Firebrigade Road, Off Thane- Belapur Road, Koparkhairne, Navimumbai-400 701 (INDIA) Tel.: 022-4935 5555 (40 Lines), Fax: 022-4935 5556 E-mail: sales@superslides.in / info@superslides.in Website: www.superslides.in
Since balls are arranged in four rows in a well-balanced manner, this model is stiff against a moment, and smooth straight motion is ensured even a preload is applied to increase the rigidity. The rigidity of the blocks is 50% higher than that of a combination of two carriages secured together back-to-back with bolts. Thus, MSH is an optimal linear guideway for building an X-Y table that requires high rigidity.
Applications Swiss-type lathe and Biaxial operation of the machine.
Load capacity meets manœuvrability
RE.F2-N Steel sheet bracket
RE.F2 Soft polyurethane wheels
RE.F2-H Steel sheet bracket for mediumheavy loads
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 info@elesaganter-india.com www.elesa-ganter.in
106
MACHINE TOOLS WORLD NOVEMBER 2018
Daily operations in industrial facilities often involve the manual or mechanical towing of trolleys or equipment even with heavy loads. In this case, the right rolling element can make the difference and significantly help the operator in his work. The brand new RE.F2 wheels have been recently introduced to meet these customers’ needs, providing a technical solution suitable to easily move trolleys. Wheel’s tread, in green soft polyurethane with high thickness, is characterised by good elasticity, load capacity and resistance to tear, thus guaranteeing the absorption of shocks and vibrations and, in addition, a less force required to push or tow trolleys. Soft polyurethane material is particularly resistant to wear and it is suitable in the presence of unfavourable atmospheric agents, alcohols and glycols. Thanks to these features, RE.F2 castors represent an ideal solution both for outdoor and indoor applications. The hub with ball bearings ensures an excellent rolling resistance improving manœuvrability for continuous moving, with heavy loads as well. RE.F2 wheels are supplied also with different types of bracket according to the application. The execution with electro-welded steel bracket is particularly suitable for loads up to 7000N and it is recommended for heavy industrial applications or in case of severe conditions of use, such as impacts and high speeds.
PRODUCTS SHOWCASE www.mtwmag.com
FARO SUPER 6DOF (6 DEGREES OF FREEDOM) TRACKARM The Most Versatile Portable 3D Measurement System The FARO Super 6DoF TrackArm is an extremely versatile portable 3D measurement system that brings together the long range and high accuracy capabilities of FARO’s Laser Tracker in combination with the flexibility and consistency of the FaroArm® or ScanArm®. The FARO Super 6DoF TrackArm combines the FARO Vantage platform (VantageS, VantageE, or legacy Vantage) with one or more FARO ScanArm® to provide a six-degrees-of-freedom probe. Switching between the Tracker and the Arm, users can reach hidden points – even around corners and inside hole features. Line of sight issues are eliminated. This solution enables users to inspect, reverse engineer or perform CAD-to-Part analysis with greater ease than ever before. The Super 6DoF TrackArm is available as a complete system consisting of the Laser Tracker, ScanArm and TrackArm Kit.
For Product Enquiry Contact FARO Technologies, Inc. Website: www.faro.com
URX Series Rotary Tables
For Product Enquiry Contact UCAM Pvt. Ltd. A-11 / 12, 1st Stage, 1st Cross, Peenya Industrial Area, Bengaluru - 560 058, INDIA Email : sales@ucamind.com Website: www.ucamind.com
The new URX Series Rotary Tables from the portfolio of UCAM rotary table products enables users to give higher cutting forces onto the components thus reducing the cycle time and increasing productivity. These Rotary Tables are with very high clamping torque generated by the new technology brake discs which are specially processed to generate higher frictional torque. Also the clamping area is increased to generate higher clamping forces. In URX 200 Rotary Table the clamping torque is 400 Nm (@ 5 bar Pneumatic input pressure) and 900 Nm (@ 30 bar hydraulic pressure) against 250 Nm & 500 Nm respectively in URH series. Due to this users can give higher cutting depths for his component or can go for one size smaller Rotary Table as compared to URH series (i.e. can work on URX-200 instead of URH-251 Rotary Table). In both cases users will be benefited by reduction in costs and improvement in productivity. Apart from the higher clamping torque, the URX series is with a specially molded FRP motor guard which has helped in reduction of overall weight of the Rotary Table by 6%. The URX series Rotary Table is available in four models: URX-180, URX-200, URX-250 and URX-320.
Looking for industrial Products for your plant/workshop ??? Connect to right manufacturers & suppliers http://www.mtwmag.com/category/products/ NOVEMBER 2018
MACHINE TOOLS WORLD
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MACHINE TOOLS WORLD NOVEMBER 2018
PRODUCT INDEX A
Drive Solutions
71
AC / DC Geared Motor
97
AC Linear Servo Motor
97
End Mills
Actuator
87
Energy Absorption
Actuator Line
79
& Vibration Isolation Products
Air Compressors
27
Alloy Wheel Machining Solutions
45
Aluminium Profiles
97
Angle Encoders
63
Angle Mill Heads
19
Automation Products
59
Motor Control Automation
71
E
FRONT GATEFOLD, 31 61
F
O
Oil/ Coolant Mist Cleaner
97
Oxy-Fuel CNC Cutting Machines
59
P
Flexible Couplings
97
G
Planetary Gear Boxes
74, 75
Plasma CNC Cutting Machines
59
Plunge Shaving Machine
51
Gas Flow Products
61
Position Displays
63
Gas Management
61
Power Conditioners
99
Gauge
41
Precision Air Moving Products
61
97
Gear Boxes
77
Precision Ball Screws
97
Ballscrews
87
Gears, Racks & Pinions
97
Pressure Control Solutions
61
Barfeeder
65
Grinding Machines
25
Project Engineering Solutions
59
Pump Solutions
73
B
Ball Transfer Units
Bevel Gear Boxes
74, 75
Brake Motors
77
C
Cables
H
Harmonic Filters
99
High Pressure Filtration
61
29
Horizontal Machining Center
Casting
81
Hydraulic Press
Clamps for Linear Guides
97
Hypid Gear Boxes
CNC Grinding Machines
47
CNC Horizontal Boring Machine
45
CNC Lathe
45
CNC Machines
7, BACK PAGE
22 - 23
Rotary Encoders
63
S
Screwiacks I
Inserts
FRONT GATEFOLD
Instrumentation Fittings & Valves
61
45
CNC Solutions
11
CNC Turning Center
17
Laser Scanners
49
CNC Vertical Machining Center
17
Lathe Machines
13
INNER IFC
99
95 74, 75
CNC Smart Mills
Coatings
R
Real Time Power Factor System
L
97
Slewing Ring
97
Stabilizers
99
Static Elimination Solutions
61
Stepper & BLDC Motor
97
Surface Cleaning
61
T
Length Gauges
63
Taps
Collet Holder
67
Light Energy Management Systems
99
Telescopic Line
Consumables
59
Linear Actuators
97
Threading & Grooving Solutions
Contouring Controls
63
Linear Encoders
63
Tool Holders
Curvic Coupling
97
Linear Guideway
87
Turning Solutions
Linear Line
79
Cycloidal Gear Boxes
74, 75
D
Linear Motion Guides
97
Lubricants
39
Deburring Tool Holder
21
Digital Inverter technology
15
Dimensional Measurement Systems
83
Machining Centers
Double Column Machining Centers
45
Mass Flow Controllers
61
Drill Tap Center
45
Metal Working Fluids
39
Drilling Solutions Drills
IFC FRONT GATEFOLD
57 IFC
FRONT GATEFOLD IFC
U
Ultra Isolation Transformers
99
Universal Machining Centers
43
M
9, 53
Milling Solutions
IFC
Motion Toolpaths
IBC
V
Vertical Machining Centers
45
W
Welding Equipments NOVEMBER 2018
59 MACHINE TOOLS WORLD
109
ADVERTISERS INDEX COMPANY NAME
PG. NO.
A ACE MICROMATIC GROUP
BACK PAGE
ADOR WELDING LIMITED
59
ANCA MACHINE TOOLS PRIVATE LTD
7
APEX PRECISION MECHATRONIX PVT. LTD.
97
COMPANY NAME
PG. NO.
COMPANY NAME
GLEASON WORKS (INDIA) PRIVATE LIMITED
51
P
GLOBE-TECH ENGINEERING EXPO - 2018
103
PARAGON MACHINERY CO. LTD.
47
GP PETROLEUMS LTD.
39
PRECISION MOTION INDUSTRIES, INC. ( PMI )
87
GROB MACHINE TOOLS INDIA PVT. LTD.
43
GRUNDFOS PUMPS INDIA PRIVATE LTD.
73
BIRLA PRECISION TECHNOLOGIES LIMITED
57
C CNC SOFTWARE, INC.
INSIDE BACK COVER
D
HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED
63
HOSABETTU HEAVY MACHINERY LLP
53
HYUNDAI WIA INDIA PVT. LTD.
9
I
DOWEL ENGINEERING WORKS
95
IMTOS - 2019
100
DUTCH TECH TOOLS PVT. LTD
31
INTEC - 2019
101
E
J
ELECTROTHERM (INDIA) LTD. ELGI EQUIPMENTS LTD.
15
JYOTI CNC AUTOMATION LTD.
Q QVI INDIA PVT. LTD.
83
R
H
B
PG. NO.
17
27
M
67
MARPOSS INDIA PVT. LTD.
55
MEERA CASTING
81
MGM-VARVEL POWER TRANSMISSION PVT LTD
77
RAJKOT MACHINE TOOLS SHOW - 2018
102
RENISHAW INDIA (PUNE)
41
ROLLON INDIA PVT. LTD. - INDIA
79
RR KABEL LIMITED
29
S SEW-EURODRIVE INDIA PRIVATE LIMITED
71
SHAVO TECHNOLOGIES PVT. LTD.
61
SUGINO MACHINE INDIA PVT. LTD.
21
T EMUGE-FRANKEN INDIA PVT. LTD. EPPINGER TOOLING ASIA PVT. LTD.
74 - 75
F FACCIN S. P. A.
37
FATTY TUNA INDIA PVT. LTD.
45
FENWICK AND RAVI
19, 65
FLIR SYSTEMS INDIA PVT. LTD.
85
G
49
MILLENIA TECHNOLOGIES
32 - 33
MITSUBISHI ELECTRIC INDIA PVT. LTD.
11
MMC HARDMETAL INDIA PVT. LTD.
INSIDE FRONT COVER
O
GEDEE WEILER PRIVATE LIMITED
110
MICRO-EPSILON INDIA PRIVATE LIMITED
13
MACHINE TOOLS WORLD NOVEMBER 2018
OERLIKON BALZERS COATING INDIA PVT. LTD.
INNER INSIDE FRONT COVER
TRUCUT PRECISION TOOLS PVT. LTD.
FALSE COVER
U UNITED GRINDING GMBH
25
UNITY CONTROLS PVT. LTD.
99
W WALCHANDNAGAR INDUSTRIES LTD.
69
Y YAMAZAKI MAZAK INDIA
22 - 23
YG-1 INDUSTRIES INDIA PVT. LTD.
FRONT GATEFOLD
THE FUTURE STARTS HERE
To see how Mastercam 2019 helps streamline your entire process, from job setup to job completion, visit Mastercam.com/2019.
Preparation/ Setup
Tool Support
CNC Programming
Validation
Job Management & Documentation
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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