Search june2013

Hyper-Competition Is Here To Stay

‘C

ustomer is the King’ is one of the over simplified and excessively used set of words that have the potential to decide the existence of a company and define the success formulae of winning companies. Companies intent on winning in the global marketplace ought to pay at least equal attention to external matters. They must look beyond themselves and initially, even beyond their customers, to comprehend the problems that customers need help to solve. Hyper-competition has rendered the old ‘make-and-sell’ model obsolete; this calls for probing into customers’ needs and to proactively look for ways to tackle them.

This customer-centric approach is also called the ‘Outside-in’ philosophy, which is nothing but a philosophy and management approach that places the interests of customers ahead of the organisation’s capabilities. Organisations that adopt an ‘Outside-in’ approach focus on satisfying their customers by efficiently and consistently delivering a combination of superior service experience and successful customer outcomes. This approach gains all the more criticality as during economically stressful times, management teams tend to focus almost entirely on internal processes—improving productivity, downsizing and so forth.

Decisions are made based on internal knowledge & instincts and it can cause you to lose touch with your customers.

In this age of customers, it is more than prudent to accept that nearly every business operates in a global hyper-competitive context. Your customers have more choice, are better informed about alternatives & substitutes and they can cross large areas of the planet to get a better deal, better service or a particular product or service.

It is important to understand why you are competing and to come to terms with the idea that competition is what makes a healthy industry. All things being equal in your industry, the business that knows the most about the market, the customers, the competition and the environment, within a defined budget, should have the competitive advantage over those businesses that choose be with the old schools of thought.

Companies, today, are expected to broaden their horizons and step out of their comfort zone by tapping into other industries. It is one of the best ways for businesses to maintain their competitive edge, to develop strategic partnerships with other firms across the board and leverage on each other’s competitive advantage to withstand competition & grow.

Today, as a result of technological evolution, which has levelled the playing field, we are suddenly thrust into a hypercompetitive business landscape where a company’s ability to innovate and stay ahead of the curve, regardless of size or experience, determines if they will still be around a year later.

We have seen giants of the global industry shaken to their core; their competitive advantages, once considered unassailable, have been ripped and torn apart by the fierce winds of competition.

Technological wonders appear overnight. Aggressive global competitors arrive on the scene. Organisations are restructured. Markets appear and fade. The weathered rule books and generic strategies once used to plot out strategies no longer work as well in this environment.

Welcome to the world of hyper-competition, where advantages are rapidly created and eroded. We, at SEARCH, are with you and are also gearing up to be your best source of strategies...good times or otherwise!

Archana Tiwari-Nayudu archana.nayudu@network18publishing.com

CONTENTS Special Focus: Electrical Equipment

CRGO in Transformers

Salvaging the r‘aw’struck industry

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Manufacturing is worst hit by the raw material crisis and the electrical equipment industry has also not been exempted. The `16,000-crore electrical transformer segment has been badly affected due to the serious supply gap of an imperative raw material called Coal Rolled Grain Oriented silicon steel (CRGO) for some time now. CRGO is a critical input for manufacturing transformers. Only five global steel makers have the technology to produce such steel and India imports around US$2 bn from them, annually. Additionally, the BIS regulation on raw CRGO import has created havoc in the transformer manufacturing segment. Industry bodies are searching for a quick solution to redress the issue.

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EDITORIAL Hyper-Competition Is Here To Stay

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NEWS, Views & Analysis Latest Happenings In The World Of Manufacturing

REPORT Hannover Messe 2013 Integrating Industry For Integrating Benefits

News analysis India Backbone Implementation Network Accelerating Implementation Of Reforms

TechNology & innovations Technology Update Cutting-edge Solutions

Strategy

‘The Indian Cable Segment Is Seeing A Lot Of Foreign Competition Coming In’

Cost-effective Manufacturing Methods Improving The Economics Of Manufacturing

Richard Lee, CEO – Asia Pacific, LAPP Group & Acting MD, LAPP India Pvt Ltd

Automation Trends Opinions & More ‘Industrial Automation Technologies Are Increasingly Becoming Not Only Intelligent But Also Intuitive’ Bhaskar Mandal, EVP & Head – Industry Automation Division, Industry Sector, Siemens Ltd

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Energy Management Opinions & More ‘We See India As A Long-term Sustainable Solar PV Market’ Sujoy Ghosh, Country Head, First Solar, India

Special Focus: Fluid Power l Insights & Outlook: Construction Equipment

CONTENTS SPECIALS IN THIS ISSUE

SPECIAL FOCUS Electrical Equipment

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Opinions & More ‘Substantially Augmenting Our Manufacturing Facilities From 220 KV To 1,200 KV Is A Quantum Leap For Us’ Harish Agarwal, MD & CEO, Supreme & Co Pvt Ltd

Electrical Equipment Trivia 8 Electrifying Facts Simulation Software Designing Fault-free Equipment

Insights & Outlook Welding

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SF6 Utility A Double-edged Sword?

Manpower Shortage Upgrade Technical Education, Beat The Crisis

Green Electrical Equipment Matching The Environmental Matrix Wires & Cables’ Safety Encountering The Electrical Impendence

Tips & Tricks Stick Welding Techniques CLAMS Formula For Greater Success!

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Opinions & More ‘Indian Manufacturers Compare Relatively Well To Global Producers And Are Quite Competitive’ Abhinav Sood, Sales Leader, Hypertherm India

Speciality Welds Forging Special Bonds

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Metal Inert Gas Welding A Metal-friendly Welding Option

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Plasma Cutters & Blowtorches Cutting-edge Technologies To The Rescue Weld Metal How To Avert Porosity?

Robotic Automation Solution To The Manpower Shortage Riddle

Event report BLECH India 2013 ‘Forming’ The Growth Ladder For The Sheet Metal Working Industry

100 Tenders

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PRODUCT UPDATE Electrical Equipment Latest Products In Electrical Equipment

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Welding Latest Products In Welding

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General Products Rolling Out The Best In Class

138 events’ list

Product UPDATE

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Product Index

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Advertisers’ list

Alphabetical Listing Of Products Presented In The Issue

Advertisers’ List In Chronological Order

Cover Design: Sanjay Dalvi

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NEWS, Views & Analysis L a t e s t

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March IIP grows at 2.5% compared to 0.6% in February

Showing signs of recovery, industrial growth has bounced back to 2.5% in March on better performance of manufacturing and power sectors coupled with higher output of capital goods.

Industrial production had seen a reduction of 2.8% in March last year.

According to Chandrajit Banerjee, Director General, CII, “A 2.5% growth over a negative base of -2.8% in March last year indicates that a robust and broad-based growth is elusive for the sector. What is creating concern is the growth of the mining sector, which continues to be in the negative terrain. Similarly, the negative growth of consumer durables indicates subdued

demand conditions, reinforcing our view that the sector continues to be stymied by the high interest rates prevailing in the economy.” However, the factory output measured in terms of Index of Industrial Production (IIP) grew by 1% in 2012–13 compared to a growth of 2.9% in the previous fiscal, according to official data recently released.

Growth in the industrial output for February has been slightly revised downwards to 0.46% from the provisional estimates of 0.6% last month. Manufacturing, which constitutes over 75% of the index, grew by 3.2% in March as against a decline in output by 3.6% in the same month

L&T’s subsidiary Tamco Switchgear bags $85 million order

Larsen & Toubro (L&T) recently announced that its Malaysian subsidiary Tamco Switchgear bagged a contract worth $85 million from Qatar General Electricity and Water Corporation. Tamco will manufacture and supply 11 kV Vacuum Circuit Breakers (VCBs) over a two-year period to distribution stations across Qatar, the company said in a statement.

Tamco has supplied switchgear panels to many projects and national assets in Qatar including Lusail utility tunnels, Lekhwiya sports stadium, Khalifa stadium, Khalifa sports city ASEAN Games Village, Qatar Foundation and Doha west sewage water treatment plant, the release said.

High Fly: The book ‘First to the Last: 50 years of MiG -21 with the IAF’ was recently released at a function in New Delhi to commemorate the Golden Jubilee of MiG 21’s historic association with the Indian Air Force. Air Chief Marshal NAK Browne, appreciated HAL for its contribution pointing out that of the 874 aircraft, 264 are still flying. The aircraft always has had an aggressive edge and has even served the country during 1971, Kargil conflict; it is safe in many ways, he added.

The book published by the Society for Aerospace Studies, New Delhi, is compiled by Air Marshal Philip Rajkumar (retd) and M Pushpinder Singh.

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of 2012. But 2012–13, the growth in output of the key sector remained low at 1.2% as against 3% in 2011–12. Power generation grew by 3.5% in March 2013 compared to a growth of 2.7% in the same month last year. During 2012–13, electricity generation also rose by 4% against 8.2% in 2011–12.

Overall, 10 of the 22 industry groups in manufacturing have shown positive growth during March. The mining output in March 2013 reduced by 2.9%, compared to a decline of 1.1% in the same month a year ago. During 2012–13, the production in the sector showed a decline of 2.5%, against a contraction of 1.9% in 2011–12.

Investment proposals worth `1,000 cr cleared to boost electronics manufacturing The government has cleared investment proposals worth around `1,000 crore under a scheme to promote manufacturing of electronic products & components in India.

The Department of Information Technology has, so far, received investment proposals worth `2,000 crore under the Modified Special Incentive Package Scheme (M-SIPS), Telecom Minister Kapil Sibal recently said on the sidelines of a round table with companies and ambassadors of leading Electronic System Design and Manufacturing (EDSM) countries.

Under M-SIPS, the government will provide up to `10,000 crore in benefits to the industry during the 12th Plan for promoting domestic production of electronics products & components.The scheme provides subsidy for investments in capital expenditure with a limit of 20% for investments in Special Economic Zones (SEZs) and 25% in nonSEZs. The incentives will be given to investment made in a project within 10 years from the date of approval.

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JCB to invest `500 crore on new manufacturing plant in India

UK-based construction equipment maker JC Bamford Excavators (JCB) has recently announced that it will invest `500 crore in India over the next five years to set up its fourth manufacturing facility here. The company’s wholly-owned subsidiary JCB India will set up the plant on a 115-acre area here.

The plant, to be constructed at Mahindra World City SEZ, will be operational by second quarter of 2014 and will start with fabrication work.

The company will hire 1,300–1,500 people for the new plant over the next 4–5 years. JCB has three operational manufacturing facilities in India—one at Ballabgarh, Haryana and two at Pune, Maharashtra.

Lighting up Lives: Sachin Tendulkar and Schneider Electric India have come together for ‘Spreading Happiness’, a non profit organisation, to provide access to energy (rural electrification) by installing solar home lighting systems for the benefit of over 25,000 villagers in India in the initial phase. The initiative has already rolled out a pilot project in Velunje, Nashik in Maharashtra and is currently impacting over 1,000 villagers. It is expected to light up the lives of many more in the next couple of years.

US-based high-performance adhesives manufacturer establishes facility in Vadodara, gujarat

US-based, Parson Adhesives Inc and India-based, Uttam Technologies Pvt Ltd, have collaborated to form a new venture to produce, package and distribute high-performance engineering adhesives in India.

The new company, named Parson Adhesives India Pvt Ltd, will be headquartered in Vadodara, Gujarat.

Operations at the company’s facility in Vadodara will commence from May 1, 2013. Parson Adhesives is a leading manufacturer of a wide range of industrial adhesives such as Anaerobic Adhesives, Cyanoacrylate Adhesives, Epoxy & Polyurethane

Adhesives, Methacrylate Adhesives and UV Curable Adhesives, among others.

Parson products are well established in more than 48 countries around the world backed by highly accredited certifications such as SGS, DVGW, NSF, ABS, ISO, SKZ, among others.

Parson supplies these highperformance adhesives to many of the leading companies in the world such as Bombardier, Harley Davidson, SRG Global, Indiana Marine, Cooper Standard, Yulin Engine, Wibo Engine, Tata, Kemrock, Inox and Godrej, among others.

Crompton Greaves to set up switchgear plant in Indonesia

Crompton Greaves (CG) recently signed a joint venture agreement with PLNE, an Indonesian company, to manufacture and market high voltage and extra high voltage switchgears in Indonesia. CG will own 51% stake in the company.

The JV terms includes a technology

transfer by CG over a period of five years for the production of the entire range of switchgears for the network.

The products will be manufactured in CG’s new manufacturing base in Indonesia. Production is expected to commence in 24 months, the company recently announced in a statement.

Tata Power to set up 28.8 MW solar plant in Maharashtra Tata Power plans to set up a 28.8 MW solar plant near Satara, Maharashtra, this fiscal, as a part of its strategy to meet its clean energy capacity target. This will be its second solar plant in Maharashtra where the company would be spending over `230 crore this fiscal for setting up the project.

Currently, the company has a 3-MW project at Mulshi, Maharashtra and a 25-MW solar Photovoltaic (PV) project at Mithapur, Gujarat.

Besides, its subsidiary, Tata Power Delhi Distribution Ltd, has also commissioned a 1-MW grid connected rooftop solar power plant in Delhi. Tata Power has also partnered with Australia’s Sunengy to build the first floating solar plant at Mulshi. Also, Tata Power has set a target of generating 26,000 MW by 2020 and intends to have a 20–25% contribution from clean power sources.

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Deepesh Nanda to lead TPGS and DP for GE South Asia GE India recently announced the appointment of Deepesh Nanda as Region General Manager, Power & Water. In his new role, Nanda will lead GE’s Thermal Power Generation & Services (TPGS) and Distributed Power (DP) efforts in India, Bangladesh and Sri Lanka. He will be focused on sales and commercial for gas turbines, steam turbines, gas engines and aero derivative-based power generating solutions for clients spread across the wide spectrum of power, infrastructure, oil & gas, chemicals, metals and other process-oriented industries.

Prior to this new role, Nanda headed the sales for GE’s Power Generation Services business in India. He joined GE in 2010 from Tyco Sanmar Ltd, where he was VP and the Head of business for India. He is an energy industry veteran with 18 years of rich experience of having worked with companies like Flowserve and Tyco, where he held managerial roles.

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Valvoline Cummins LTD opens new India manufacturing and packaging facility for automotive lubricants near Mumbai

Valvoline Cummins Ltd, a joint venture formed in 1998 between Ashland Inc and Cummins India Ltd, recently announced the opening of a new manufacturing and packaging plant in Ambernath Industrial Area near Mumbai. The new facility will produce Valvoline automotive lubricants for consumers, industries and heavy-duty markets.

Built on 10 acre, the new $30 mn plant will expand Valvoline brand’s in-house production capabilities. It will also enhance the brand’s ability to deliver fast, localised technical services to customers in India, South Asia and other nearby countries.

“Western India is a manufacturing hub that has the largest consumption of industrial lubricants among all regions. We are excited about the growth opportunities provided by this new manufacturing and packaging facility. We believe that investing in technology and innovation helps

deliver what our customers need—a competitive advantage in a growing market,” said Sam Mitchell, President, Ashland Consumer Markets, a commercial unit of Ashland Inc. and the producer of Valvoline branded products.

To this, Naveen Gupta, MD, Valvoline Cummins Ltd, added, “Our new manufacturing facility will expand our in-house, local production capabilities to meet the growing needs of regional customers.”

Thrilled about the new facility opening, Sandeep Kalia, CEO, Valvoline Cummins Ltd, said, “We are looking forward to our continued growth in the Indian market. The new plant will enable us to provide our customers with additional innovative solutions and products to improve business results. Through this project, Cummins and Valvoline are once again partnering to provide valuable solutions for our customers.”

Photo By Devyani P Korgaonkar

India is A preferred option for Japanese companies

Leadership of Thought: Mumbai’s business community recently gathered at KC College Auditorium to draw inspiration of growth from Narendra Modi, the ‘CEO of Gujarat’ (as addressed by IMC President Niranjan Hiranandani). His speech featured the usual theories pertaining to Gujarat as a model for inclusive growth (be it as an energy surplus state, having Asia’s largest solar park or becoming an auto & steel hub) that the rest of the country should adopt. He invited the business fraternity to his state for setting up businesses there saying, “Come to Gujarat, I am constructing a city, Dholera, six times the size of Shanghai.” Advocating the public private partnership model across all sectors, he initiated the community to adopt his unique mantra ‘Skill, Scale & Speed’.

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India is set to overtake China as the preferred destination for investment.

The gap between China and India in attracting Japanese manufacturing companies has reduced significantly in the last couple of years.

According to a latest survey

by Japan Bank of International Cooperation (JBIC) on overseas investment by Japanese manufacturing companies, India ranked as the second most preferred investment destination after China. However, Japanese firms have been steadily reducing investment in China. JBIC conducts an annual survey of Japanese companies’ preferred investment destination every August.

India’s demographic advantage and increasing buying power is said to be motivating more Japanese firms to set up units here.

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Global Edge Software Ltd acquires Dearborn Electronics

Global Edge Software, an embedded software solutions and services company focused on wireless, telecom and IP networking technologies, recently signed a definitive agreement to acquire 100% stake in Dearborn Electronics (India) Pvt Ltd, an unlisted entity specialising in automotive and automation control, communication and information solutions space. This acquisition will strengthen Global Edge’s focus on automotive electronics and industrial automotion embedded systems. Dearborn will continue to remain a separate entity as a wholly owned subsidiary of Global Edge Software.

GlobalEdge has been a leader in delivering solutions and services, particularly in wireless, platform, multimedia and embedded domains, to customers world wide.

GlobalEdge’s customers list includes

leading semiconductor vendors, CPE device makers, Consumer Electronics Companies, Communications OEMs etc. Dearborn Electronics India caters to large Original Equipment Manufacturers (OEMs) and Tier I suppliers providing embedded software solutions and services focusing on diagnostics, ECU software systems and control systems for the automotive & industrial automation segments.

“This acquisition supports GlobalEdge’s current strategy to enter vertical sectors and expand its portfolio in global and domestic markets.

With this acquisition, GlobalEdge will be well placed to tap into newer segments like automotive electronics and industrial automation providing enhanced value to customers,” said MP Kumar, Chairman & CEO, GlobalEdge Software Ltd. Srinivas Prasad, MD, Dearborn

Sustainability is not a Destination, it is a Journey: Frost & Sullivan

Frost & Sullivan concluded its 4th edition of the ‘Green Manufacturing Excellence Summit and Awards (GMEA), on May 3, 2013. Its mission through the GMEA is to educate organisations about the need for ‘Sustainable Development’, to assist in their sustainability journey and motivate those who have inched ahead of others by recognising their efforts. Frost & Sullivan, through its year-round assessments, feedback, benchmarking and sharing of best practices, believes that “Sustainability is not a Destination, it is a Journey!”

The summit provided a platform for showcasing some of the best practices in sustainable manufacturing from diverse manufacturing industries that Frost & Sullivan assessed for Green Manufacturing Excellence Awards.

The focus was on the strategic aspects related to sustainability as well as the mechanism for implementing the green strategy. Commendable work

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being done by companies in various facets that take the ‘Green’ and ‘Sustainable’ mission forward, like biodiversity, energy management, water management, logistics, among others, were brought to the fore with a clear focus on business benefits. The summit also highlighted a few innovative technologies in the renewable energy.

The evening concluded with celebrating the best in the industry through Green Manufacturing Excellence Awards. Pradeep Banerjee, Executive Director – Supply Chain, Hindustan Unilever Ltd graced the occasion as the esteemed Chief Guest.

Banerjee said, “We need to look at new models of growth that will decouple our growth from environmental impact.

It makes immense business sense.

Becoming green does not add costs.

The pursuit of sustainable growth will enable us to find new models of growth, which will not only be sustainable but will also deliver savings.”

Electronics (India) Pvt Ltd said, “We are excited to join GlobalEdge Software. The synergy with GlobalEdge Software provides sector expertise, embedded domain knowledge and quality processes.”

Anand Mutalik, CEO, Dearborn Electronics (India) Pvt Ltd, said, “We are excited about this partnership that will add greater value to our clients. We are confident that Dearborn, which has strong presence in automotive and industrial automation, will reach greater heights with GlobalEdge.”

Prasad will continue to be on the Board of Dearborn India and Mutalik will continue as CEO, Dearborn India post acquisition. Mutalik brings in three decades of experience in IT industry and had been one of the core promoters of Kshema Technologies, which was acquired by Mphasis.

Essar Steel launches high-end branded steel plate products Essar Steel has joined the ranks of international steel producers who manufacture extra wide plates.

The 4 Hi Rolling mill has a roll separating force of 10,000 metric tonnes and can produce plates with a width of up to 5 metres. Other facilities include normalising, accelerated cooling/direct quenching, hot & cold levelling and quenching & tempering. Set up at a cost of approximately `2,000 crore, the plant at Hazira, Surat, has an annual production capacity of 1.5 MT and has the capability to produce up to 5 metre wide steel plates. Looking at the opportunity and the growing need in the shipbuilding sector, Essar Steel has introduced ‘Essar Shipor’—a range of hi-tech steel plate products that have been designed to support this surge in demand in the sector.

Hannover Messe 2013

Integrating Industry For Integrating Benefits With the theme ‘Integrated Industry’, Hannover Messe 2013 clearly showcased core technologies and services that enable industrial production, innovation and efficiency. The exhibition has been valued by companies and organisations around the globe as the world’s premier industrial technology showcase. A report…

Nishant Kashyap

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annover Messe, the Mecca of all trade exhibitions, proved to be the meeting ground of the who’s who of the manufacturing sector. Organised in 27 halls with around 9,000 exhibitors, Hannover Messe 2013 was inaugurated by HE Vladimir Putin, President, Russian Federation; Dr Angela Merkel, Chancellor, Federal Republic of Germany; Prof Dr Johanna Wanka, Federal Minister, Education and Research; Stephan Weil, Prime Minister, Lower Saxony and Friedhelm Loh, President, German Electrical and Electronic Manufacturers’ Association.

The world’s biggest showcase for industrial technology was organised in Hannover from 8–12 April, 2013.

Hannover Messe united 11 flagship fairs under a single umbrella. These included Industrial Automation,

Motion, Drive & Automation, Energy, Wind, Mobilitec, Digital Factory, Comvac, Industrial Supply, Surface Technology, Industrial Greentec, Research & Technology.

Integrated Industry

The main theme of Hannover Messe was ‘Integrated Industry’. Herein, in an attempt to provide a brilliant showcase for this theme, approximately 6,550 exhibitors highlighted innovative products and technology solutions.

Commenting on the theme ‘Integrated Industry’, Friedhelm Loh, President, German Electrical and Electronic Manufacturers’ Association (ZVEI), said, “Hannover Messe showed us what ‘Integrated Industry’ was capable of delivering, and the kind of groundbreaking developments that can be expected. The show has taken place at a very exciting time—a time of

revolution in industrial processes.

Industry, science and research are gearing up for the next stage in the development of integrated intelligent process structures.”

The show’s five core topics— industrial automation & IT, energy and environmental technology, fluid power & power transmission, industrial subcontracting, manufacturing technology & services and R&D— generated a huge interest among the exhibitors and visitors alike.

Partner Country Russia

Every year, Hannover Messe features one of its major exhibiting nations as a Partner Country. Its 2013 edition’s Partner Country was the Russian Federation—one of the biggest consumers of German machines.

Russia is the fourth biggest consumer of German machinery, around 22%

Photos By Nishant Kashyap

Major German companies such as Schaeffler, KUKA, Siemens, Rittal, Schunk and Dürr Ecoclean, among others, not only launched a few products during the trade show but also showcased their latest solutions. For instance, KUKA showcased a concept at Hannover Messe featuring an industrial robot flexibly and autonomously processing XXL work pieces.

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Photo By Nishant Kashyap

Hannover Messe 2013

The five core topics—industrial automation & IT, energy and environmental technology, fluid power & power transmission, industrial subcontracting, manufacturing technology & services and R&D—of Hannover Messe 2013 generated a huge interest among the exhibitors and visitors alike.

of all imported machines comes from Germany. Elaborating further, Hannes Hesse, Executive Director, VDMA, informed, “With export to Russia reaching a volume of about €8 billion in 2012, the country ranked fourth as a trading partner after China, the US and France.”

As Partner Country, the Russian Federation focused on energy, industrial automation and new materials. More than 100 Russian companies occupied a total display area of 4,500 sqm at Hannover Messe 2013. The list of participants included big players such as Gazprom, Rosnano, Russian Railway, Rosneft, Transnest, UralVagonZavod, RAO UES of Russia, Vnesheconombank, TMKGroup and Metalloinvest.

Technology Showcase

Hannover Messe is literally the launching ground for many companies!

Many companies eagerly await the perfect platform that Hannover Messe provides to launch their latest innovations. And this year’s Hannover Messe was no exception. Major German companies such as Schaeffler, KUKA, Siemens, Rittal, Schunk and Dürr Ecoclean, among others, not only launched a few products during the trade show but also showcased their

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latest solutions. For instance, KUKA showcased a concept at Hannover Messe featuring an industrial robot flexibly and autonomously processing XXL workpieces. “Hannover Messe is one of the most important shows for us. In this show, we meet many overseas buyers and our existing customers. As the Asian countries are creating huge opportunities for us, the show becomes very important as there are many visitors and exhibitors from China, India, South Korea, Indonesia, among others,” informed Helmut Treffer, VP – Sector Management Industrial OEM, Schaeffler Technologies AG & Co KG.

India @ Hannover

To optimise the advantages of this mega trade show, many Indian companies had also participated in the Hannover Messe. Despite the ongoing Eurozone crisis, Indian companies were confident about the business opportunities in the region. During the exhibition, Raj Singh Rathee, MD, KUKA Robotics (India) Pvt Ltd (an Indian subsidiary of KUKA Roboter GmbH), expressed, “This is one of the most important trade fairs for almost everyone who is associated with the engineering sector. It is undoubtedly one of the best places to showcase your capabilities to the world, as there are

many overseas visitors and exhibitors.”

There was also an Indian pavilion with many Indian exhibitors that was supported by Engineering Export Promotion Council (EEPC). “This is one of the most important events for Indian companies. Every year, we support many of them to showcase their capabilities at the biggest trade show. This provides Indian companies a fair opportunity to understand the market demands in the European region,” noted Gurvinder Singh, Joint Director - Exhibition, EEPC INDIA. While most exhibitors were confident of generating good business enquiries during the show, visitors from India too made the most of it at Hannover Messe 2013 and were mainly looking for new markets, latest technologies and business tie up opportunities.

Gaurav Sarup, Director, Marshall Machines (P) Ltd, who visited Hannover Messe 2013 was keen to know about the latest technologies.

“I did not want to miss a chance to witness one of the biggest industry exhibitions. Hannover Messe is the biggest platform to observe the new happenings in the industry and understand the latest technologies,” he opined.

Looking forward to hannover messe 2014

‘Integrated Industry’, at Hannover Messe 2013, not only could be defined in terms of technical and electronic integration but also in terms of the challenge faced by all areas of industry as they seek to cooperate across corporate and sector boundaries. Integration would shorten communication channels and make collaboration more efficient. In line with this theme, Hannover Messe 2013 has left participants and visitors eager to be a part of Hannover Messe 2014, which will be held during April 7–11, 2014, in Hannover. nishant.kashyap@network18publishing.com

India Backbone Implementation Network

Accelerating implementation of reforms

With an aim to improve the implementation of policies, programmes and projects in India, the Planning Commission and India@75 have launched ‘India Backbone Implementation Network’ (IBIN). Modeled on the successful Total Quality Movement implemented in Japan, IBIN will disseminate techniques and skills for collaboration, coordination and better planning through a network of agencies in the country.

Arindam Ghosh

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agree on what really needs to be done.

Company Ltd, informs that the move resently, India is one This process will take some time. The will not only play a key role in sustaining of the fastest growing need of hour is to harmonise different India’s economic progress but will also economies in the world. In industry perspectives pouring in from look into issues of ‘implementation, and a bid to further accelerate various business verticals.” rationalisation’. The initiative aims at its inclusive growth Establishing such an ecosystem will bringing in transparency “….on what strategy, the Planning Commission and lead to the formation of guidelines, needs to be done to build efficiency and India@75 initiated the India Backbone which will create a favourable ensure higher productivity,” he says.

Implementation Network (IBIN). atmosphere for both the government The programme is aimed at ensuring and the industry to take forward timely implementation of policies, Modalities of the move the growth of India in a sustainable programmes and projects. According IBIN has been modeled on the very manner he adds. to Arun Maira, Member, Planning successful Total Quality Movement An analysis of projects and schemes Commission, in the 12th Five Year (TQM) in Japan, which, in the 1960s has revealed that the major causes of and 70s, transformed the capability of Plan, timely execution is a necessity for bottlenecks in its implementation are Japanese organisations in the private accelerating India’s inclusive growth. contention among stakeholders, and and public sectors to deliver results.

“This institutionalised ‘backbone’ poor coordination among agencies.

TQM provided techniques and capability will provide the ‘tools and These bottlenecks exist at many levels tools to teams within organisations techniques’ to different stakeholders in the system, at the Centre, in the with which they could make rapid to ensure effective & efficient states, and in districts and coordination, design and IBIN will disseminate techniques and skills for collaboration, cities too. They require implementation,” he says. coordination and better planning through a network of collaborative action of Speaking at the launch agencies in the country. The partners in the network include stakeholders and agencies of the programme, Montek institutions such as the Administrative Staff College of India, at multiple points. With Singh Ahluwalia, Deputy the Indian School of Business, SEWA, WISCOMP, UNDP, GIZ, respect to coordination he Chairman, Planning the World Bank, FISME and other business associations. informs, “It is all interCommission, said that they related.” With the establishment have introduced several innovations in improvements in processes, resulting of harmonisation, an effective the 12th Plan to improve planning, in higher efficiency and productivity. and efficient coordination will be According to Maira, the network communication and implementation. strengthened. will form around nodes. The functions These include the use of techniques of of a node will be to bring together ‘scenario planning’ for the first time, providers of the skills and techniques use of social media for communications Develop a joint roadmap and the agencies that need them, and with youth and the concept of IBIN. It is important to develop or design to continuously distil good practices S Gopalakrishnan, Co-Chairman, a roadmap, which is jointly done by and disseminate them widely. In Infosys & Chairman, Apex Council both the industry and the government. addition, India@75 will also help of India@75, added that the objective The main challenge lies in developing expand IBIN. of India@75 is to assist collaborative a compatible regulatory ecosystem movements of change to achieve in sync with the industry needs. To national goals in important sectors. develop such a process, the industry Harmonisation & Co-ordination: The organisation is already engaged in and the government have to work very Major challenges expanding skill development. closely under an ecosystem favouring Speaking on the initiatives required harmonisation, Godrej concludes. to make the move a success, Godrej Offering an industry perspective, explains, “The government and Jamshyd N Godrej, Chairman & industry need to collaborate and jointly MD, Godrej & Boyce Manufacturing arindam.ghosh@network18publishing.com

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CUTTING-EDGE SOLUTIONS

Higher Performance Through Profinet Interface For Motion Control

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ere is a new fieldbus interface that increases the communications flexibility of the system for machine builders and end users, enabling application performance. With an addition of Profinet interface option availed by motion control specialist Heason Technology, Kollmorgen has expanded its Kollmorgen Automation Suite (KAS) motion control platform. The interface is also available for existing users and is of further benefit when used with Kollmorgen’s AKD PDMM programmable servo drive as the multiaxis master-based system is integrated with KAS. The automation platform is tailored specifically for high-performance applications where complex motion sequences and automation processes must be perfectly synchronised. KAS provides high-performance PLC and motion control functionality with

choice programming environments.

Its intuitive Pipe Network graphical programming environment features drag-and-drop functionality.

USPs

• This is a high performance application.

• The intuitive Pipe Network graphical programming environment has drag-anddrop functionality.

Alternatively, KAS supports the fivestandard IEC 61131 programming languages for motion control as well as a PLC open standard library with numerous motion control function blocks. The advanced control algorithms and high-speed control loops integrated into KAS make operation possible with higher bandwidth and provide greater throughput.

New ‘Mobile Robots’ inspired by the biological visual functioning of a ‘Locust’

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cientists from the University of Lincoln and Newcastle University have created a computerised system, which permits autonomous navigation of mobile robots based on the locust’s unique visual system. The work could provide a blueprint for the development of highly accurate vehicle collision sensors and surveillance technology.

Locusts have an incredibly powerful data processing systems built into its biology, which can, in theory, be recreated in robotics.

USPs

• It is a Visually Stimulated Motor Control (VSMC) system.

• It is inspired by the anatomy, responses and developments of circuits in a locust’s brain.

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Inspired by the visual processing power built into these insects’ biology, Professor Shigang Yue of University of Lincoln’s School of Computer Science and Dr Claire Rind of Newcastle University’s Institute of Neuroscience created the computerised system.

The research started by understanding the anatomy, responses and development of the circuits in a locust’s brain that allow it to detect approaching objects and avoid them when in flight or on the ground.

A Visually Stimulated Motor Control (VSMC) system—consisting of two movement detector types and a simple motor command generator— was then created.

Each detector processes images and extracts relevant visual clues, which are then converted into motor commands.

Solar cell technology based on nanowires get a real boost

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cientists from the NanoScience Centre at the Niels Bohr Institute, Denmark and the Ecole Polytechnique Fédérale de Lausanne, Switzerland, have proved that a single nanowire can concentrate sunlight up to 15 times of the normal sunlight intensity. Due to some unique physical light absorption properties of nanowires, the limit of energy one can use from sunrays is higher than previously believed. These results show the great potential of development of nanowire-based solar cells.

USPs

• The diameter of a nanowire crystal is smaller than the wavelength of the light coming from the sun.

• The limit of energy that can be utilised from the sunrays is higher than previously believed.

During recent years, research groups have studied ways to develop and improve the quality of nanowire crystals with a cylindrical structure having a diameter of about 10,000 part of a human hair. Nanowires are predicted to have great potential in the development of not only solar cells but also future quantum computers and other electronic products.

Also, nanowires naturally concentrate the sun’s rays into a very small area in the crystal by up to a factor 15. As the diameter of a nanowire crystal is smaller than the wavelength of the light coming from the sun, it can cause resonances in the intensity of light in and around nanowires. Thus, the resonances can give a concentrated sunlight, where the energy is converted, which can be used to give a higher conversion efficiency of the sun’s energy.

CUTTING-EDGE SOLUTIONS

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WD AND SANDISK CREATE INNOVATIVE SOLID STATE HYBRID DRIVES D, a Western Digital USPs company, and Sandisk

Corporation, a global leader in flash memory storage solutions, have collaborated to introduce a hybrid storage device that features best-inclass flash memory technology from SanDisk and best-in-class hard drive technology from WD. SanDisk is supplying a SanDisk iSSD™ storage device for the WD Black™ solid state hybrid drive (SSHD), the world’s thinnest 2.5-inch SSHD solution, which utilises both WD proprietary hybrid technology and industry standard SATA IO technology. The SanDisk iSSD brings an elegant balance of performance, low power consumption, cost, reliability, and a compact form factor to this SSHD, which will offer ample storage to meet consumers’ growing appetite for digital content as well as flashenabled speed, data throughput and responsiveness—all within ultra-slim form factors.

WD Black SSHDs use WD hybrid

• The device consumes less power & is cost effective.

• It provides highest performance level.

• The device is built on most advanced 19 nm process technology.

technology that blends responsive, intelligent flash memory technology from SanDisk with high capacity hard drives from WD. This enables both high capacity and a higher level of performance than traditional hard disk drives, including increased speed, instant-on and faster application launching.

The low-profile of the solid state hybrid drive is complemented by the extremely small form factor of the SanDisk iSSD, which is built on 19 nanometre (nm) process technology—the world’s smallest and most advanced semiconductor manufacturing process.

SEA TURTLES AND FLIPPER-DRIVEN ROBOT REVEAL PRINCIPLES OF MOVING ON SAND

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robot mimicking the way sea turtle hatchlings move over sand has shed light on the principles of locomotion on granular surfaces. For sea turtle hatchlings struggling to reach the ocean, research has shown success may depend on

USPs

• The robot has two flippers driven by servo motors.

• It has flexible wrists.

having flexible wrists that allow them to move without disturbing too much sand.

The recently published research describes how a similar wrist also helps a robot known as ‘FlipperBot’, designed

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by researchers at the School of Physics at the Georgia Institute of Technology, move through a test bed.

This latest research could help robot designers better understand locomotion on complex surfaces and lead biologists to a clearer picture of how sea turtles and other animals like mudskippers use their flippers. The research could also help explain how animals evolved limbs—including flippers—for walking on land.

The 19-cm robot has two flippers driven by servo-motors and, like the turtles, the robot has flexible wrists that allow variations in its movement as it moves through a track bed filled with poppy seeds that simulate sand.

NEW BATTERY DESIGN COULD HELP SOLAR AND WIND POWER THE GRID

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esearchers from the US Department of Energy’s (DOE) SLAC National Accelerator Laboratory and Stanford University have designed a low-cost, long-life battery that could enable solar and wind energy to become major suppliers to the electrical grid.

For solar and wind power to be used in a significant way, there is a need for a battery made of economical materials that are easy to scale and still efficient. Currently, the electrical grid cannot tolerate large and sudden power fluctuations caused by wide swings in sunlight and wind. As solar and wind’s combined contributions to an electrical grid approach 20%, energy storage systems must be available to

USPs

• The battery is low cost, but has a long life.

• The flow batteries pump two different liquids through an interaction chamber.

smooth out the peaks and valleys of this ‘intermittent’ power—storing excess energy and discharging when input drops.

Among the most promising batteries for intermittent grid storage today are ‘flow’ batteries, because it is relatively simple to scale their tanks, pumps and pipes to the sizes needed to handle large capacities of energy.

Today’s flow batteries pump two different liquids through an interaction chamber where dissolved molecules undergo chemical reactions that store or give up energy. The chamber contains a membrane that only allows ions not involved in reactions to pass between the liquids while keeping the active ions physically separated.

Compiled by Devyani P Korgaonkar

Richard Lee

“Global players are eyeing the market and the competition has got tougher. Quality, reliability & speed help us stay ahead of others,” avers Richard Lee, CEO – Asia Pacific, LAPP Group & Acting MD, LAPP India Pvt Ltd, during a tête-à-tête with Prateek Sur. Excerpts…

Why India?

The Lapp Brothers had come to India in the 80s. Over time, they got familiar with the culture of India; this motivated them to expand their reach in the Indian market. India is an English speaking, democratic country; they had foreseen great potential in the Indian market. Additionally, the highly talented resource, scope of evaluating innovations and global connectivity were some of the key driving factors that proved favourable for the business. Besides, strong focus on quality management, application of high-end innovations and global best practices are some of the significant

The Indian cable segment is seeing a lot of foreign competition coming in factors that Indian companies can leverage from global companies.

Strength Lapp Group brings to Lapp India and the local market

We are a very strong brand. Lapp products are well recognised overseas, especially in Europe, for its excellent German quality. As a manufacturer, we have acquired rich skills and knowledge of the cables segment, which we have been successful in passing over to Lapp India as well. Talking of the local market, I would say that we have defined the benchmark for safety standards and product quality in the market. So, I would consider that as

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Richard Lee

the greatest strength that we have brought in. The tremendous success that we have witnessed in India helps us gauge our performance to a great extent; it helps us understand how well we are performing. Lapp India is our second largest company; our growth in India has set an example for our business in other countries worldwide.

Position of Lapp India globally, including exports

Lapp cables are globally certified; most of our cables are in conformity with the global VDE and IEC Standards.

Our products reflect the international standards in the Indian market. The customer who buys our products here in India will be absolutely assured that he is purchasing an internationally accredited product. For a global customer, buying a Lapp cable from Lapp India is no different from buying cables from Lapp Germany because we adhere to all the quality requirements.

Accessing the international market for exports is the next big leap that Lapp India has potential in to take a leadership position.

continent. However, the cable products going into Europe or America are challenging as it has to be harmonised.

To sell products in Europe or America, it has to be VDE or UL certified, respectively. Even if you have the VDE certification, it does not necessarily mean it is harmonised as it has to be made in Europe. Similarly, for the US, cables have to be harmonised for exports. Hence, the biggest challenge for Indian manufacturers is addressing issues of harmonisation, particularly for the European and American markets.

Demand differences between MNCs and SMEs

SMEs are generally new, growing or in a dormant stage struggling with brand recognition. When they use our products, they benefit from our brand equity. Besides, it adds a competitive edge to their services in the market.

We have a wide range of around 40,000 products in different verticals that cater to individual requirements

Mantra of the company

The cable segment in India is extremely competitive; the mantras that help us maintain a competitive edge are our unbeatable quality, reliability and speed. To ensure unbeatable quality, we use pure copper. Thus, there are no compromises made in terms of raw material inputs. Apart from quality, reliability—in terms of services, products performance and assurance of a long-term presence—is the key that helps us distinguish ourselves from our competitors in the market. Speed also plays an important role in determining excellence at customer service; we believe that we should be able to serve our customers for 24 hours.

Demand for Indian products

Cables manufactured in India are sold in many parts of the world, particularly in the Middle East and the African

Up close & personal Your passion?

I have a tremendous passion for building brands and building strong teams. Besides, I spend a lot of time understanding the market.

Your hobbies?

I am an avid golfer, which takes me away from work. Moreover, I also enjoy watching English football and listening to music.

Your mentor?

First PM of Republic of Singapore Lee Kuan Yew. He is a visionary; he is ethical and a great leader.

in the industry. MNCs, on the other hand, have greater scale and resources. They are protocol driven and consequently, sluggish with a bureaucratic environment, they also suffer from benchmark issues. SMEs are flexible and cater to niche segments of the market.

Safety & environmental concerns

Being a responsible corporate organisation, our business practices are compliant with OSHA Standards.

Ensuring safety has been of utmost importance in our company values and we never compromise with it. Also, concern and care for the environment has always been a strong focus for us across all our manufacturing units, we adhere to all the necessary standards related to pollution control. We understand the need for incorporating green thinking into the company culture; hence, we have a widespread green space in our units. Additionally, our organisation is responsible enough to incorporate environmental qualities in our products worldwide. We encourage recycling of PVC, copper and other products from our industrial waste on a regular basis. Moreover, we have installed solar lights wherever possible to reduce the intake of energy.

In line with Lapp’s commitment to environmental sustainability, we ensure that all our employees understand environmentally sound practices and try to incorporate the same in Lapp’s solutions for various industries. Here, I would like to talk of the automobile industry, where there is a large need to reduce dependence on fossil fuels, electric vehicles is definitely one of the successful ways to help counter this dependence. At Lapp, we are promoting environmental sustainability through brilliant technological offerings such as Lapp Helix, which is a patented charging solution for the automotive industry.

Trends & emerging opportunities

The GDP of India is approximately

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Richard Lee

5%. While it is still good, operating Challenges in adoption the most integral area of focus at 5% GDP v/s operating at 8% GDP when it comes to developing new Adoption is not a challenge for us growth is surely a different experience. technologies. Developing compounds as we are well equipped to keep up As far as trends in the industry are that are capable of surviving extreme pace with the changes undergoing concerned, businesses are becoming conditions, last longer. Compounds in the industry. Lapp India, being more efficient and highly productive that are easily available, reusable, part of the global conglomerate, has offering high value additions and cheaper is of utmost importance to our the privilege of relying on the parent high product development. Our focus R&D unit. In addition, we are working company, Lapp Group, for its R&D is on finding ways to partner this very hard on the PVC material. requirements. The German efficiency progress as we strongly believe in value and quality of our products is well engineering. Infrastructure continues acknowledged, thereby giving us an Indian Wires and Cables market to be a major thrust area and stands edge over the others’ products and has in the next 5–10 years as the backbone of the economy. We worked to our advantage. We are a In India, we are planning to are closely observing the sectors—be research-centric company that is at grow higher than 25% in sales. it rail, energy or utility, on the basis of the helm of innovation and always Nationally, in terms of what we can which we develop or procure products focused on creating new applications do, we have less than 3–5% share that can serve the needs of respective that cater to newer markets. Our R&D currently. Globally, the markets have sectors. As per the current market and innovation centres back in Europe been extremely tough. Germany, as a outlook, the Indian cable segment is have been developing new compounds, country, went into negative last month seeing a lot of foreign competition deploying new raw materials and are in terms of GDP. Internationally, our coming in. Global players are eyeing looking at generating more efficient long-term goal is to double our size the market and the competition has and advanced ways of transmitting by 2020. And our global vision is to got tougher. energy. In fact, even in case of our dominate the control cable business existing product portfolio, we are and lead the Indian market as the The emerging opportunities can be focusing at expanding our parameters.

No. 1 player in the control cables outlined as infrastructure and energy— Lapp believes in creating products segment. the two significant sectors that have that cater to the real needs of customers.

The wires and cables market is immense potential and will emerge as We understand that not all customers quite fragmented and is dominated one of the highest contributing sectors by some big local players. of the economy in future.

This year, in terms of The need for electrical The primary challenge faced by companies is the issues vehicles and the growing pertaining to mindset and culture. Cable is an old segment; it profits, some of the players are suffering, especially focus on implementing is essential to bring in energetic, fresh minds with a dynamic approach towards work to build up the momentum. We are the smaller ones. I do renewable energy sources focusing on constant training, performance management, expect some consolidation like solar energy and wind recruitment and retention programme to emphasise on the to take place in this energy in the recent years three parameters—speed, reliability and quality. segment. Considering have seen a considerable the commodity cable rise. Furthermore, when will like to pay a high premium, so we market, we can expect Mergers and we talk of the emerging opportunities are looking at manufacturing products Acquisitions (M&As) between few of in infrastructure, the housing in the application where we do not over these players as the market is going sector/building and connectivity engineer, thus avoiding higher cost through a difficult phase. solutions contribute to a major portion factor. Our latest launch ÖLFLEX® If the country is successful in of the demand. Intelligent cabling Classic 110 and Smart 108 promise improving the infrastructure facilities, solutions for buildings in terms of fire greater versatility, performance and the cables segment will definitely safety and fire survivability is the need efficiency. Unlike its predecessor, witness aggressive growth in the of the hour. the latest ÖLFLEX® Classic 110 coming years. As far as the cables There is an increased growth in has an expanded temperature range segment is concerned, we can expect awareness in the market to differentiate stretching from -15°C to 70°C, and the market to grow between 5% and between good quality and cheap can even withstand up to -40°C when 10% in the next 2–3 years. However, I products. Besides, improved lifestyle permanently laid. do hope that beyond the 2–3 years, the affluence, demand for improved market grows by 15–20%. quality, better designed products and understanding of safety standards have Latest technologies made the customer expectations clear.

Compound research has occupied prateek.sur@network18publishing.com

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opinions & more

Opinions & More ‘Substantially Augmenting Our Manufacturing Facilities From 220 KV To 1,200 KV Is A Quantum Leap For Us’ Harish Agarwal, MD & CEO, Supreme & Co Pvt Ltd .......................................................................52 Electrical Equipment trivia: 8 Electrifying Facts .................................................................54 Simulation Software: Designing Fault-free Equipment ..........................................................56 SF6 Utility: A Double-edged Sword? .............................................................................................58 Manpower Shortage: Upgrade Technical Education, Beat The Crisis .....................................60 CRGO in Transformers: Salvaging The R‘aw’struck Industry ...................................................62 Green Electrical Equipment: Matching The Environmental Matrix .....................................66 Wires & Cables’ Safety: Encountering The Electrical Impendence ............................................68

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opinions & more

Substantially augmenting our manufacturing facilities from 220 KV to 1,200 KV is a quantum leap for us Though the electrical equipment manufacturing industry is witnessing negative growth, performances of few companies have surprised us. Quality growth of such companies is an indicator that the Indian manufacturing sector is quickly reviving. Harish Agarwal, MD & CEO, Supreme & Co Pvt Ltd, an exemplary upcoming company, talks to Devyani P Korgaonkar about the company’s achievements, strategies and contributions to the growth of India. Excerpts…

Tell us about the MoU Supreme has signed with PGCIL for the 1,200 KV transmission line system

Supreme has signed two MoUs with PGCIL. One MoU was signed about 6–7 years back for developing hardware and conductor accessories for the 1,200 KV transmission line. Here, we had supplied most of the insulator hardware, conductor accessories and clamps & connectors; they are all working on the line, quite satisfactorily. This is the highest system voltage used in the world, so far, and is a very prestigious project. Supreme is very actively

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involved and the business model of this will emerge after the trial is completed.

Even at 765 KV, there were very few Indian manufacturers qualified when it was brought into India, for this test station;all the product and equipment used are indigenous.

The second MoU was signed with PGCIL last year for their pilot smart grid project in Puducherry, where we have been providing services like advance metering infrastructure, system configuration and GIS services. They are willing to provide their own grid for trial. So, once this pilot is completed, it

will be our significant contribution to a national project because cutting down AT&C losses is the primary concern of the Indian power sector. Moreover, the current AT&C losses are unaffordable for any power sector.

What difficulties did you initially faced while manufacturing the 1,200 KV equipment?

There were a lot of challenges; we were not even in the power grid’s approved list for 400/765 KV hardware and fittings. So, it was a quantum leap for us from 220 KV to 1,200 KV.

opinions & more

We had to substantially augment our manufacturing facilities only for the sake of supplies to the non-commercial test station. We invested very heavily into dies, tools and testing facilities.

We installed a 200 tonne test bench, which would only be needed for a 1,200 KV quad tension strings. A large range of dies were developed; all these supplies were done non-commercially.

And non-commercially is only a matter of expression because when we send our materials for performance testing outside India, we not only supply without payment but we also have to pay them very hefty charges for using their test bench for testing. In this case, the test station was made available to us without any extra charge. So, the new technology that has been developed is a quantum leap in transmission.

Having said this, the challenges in development of new facilities, new test abilities, new dies were not engineering alone but also required commitment of such significant investment in noncommercial supplies.

what’s the response to the products?

The commercial response to the 1,200 KV system will come only after the trial period is over. There is a world wide interest as the world has, for the first time, looked towards India with expectations because now the country has something to showcase in T&D.

Are you looking for some Joint Ventures (JVs) globally?

We are not looking for any particular JV for technical development because most JVs in our trade have not been for very specific technical inputs.

They have been more for the purpose of getting the validated designs for which there is no need to spend for type testing again. We have pursued a different strategy. We would rather invest in our own type testing rather than opt for the softer option of bringing in collaboration. Thus, we have more freedom and there are no restrictions on marketing our products.

What are the key steps for the company in the coming years?

The key will be continuously climbing up the value chain. We cannot take any market both in terms of product range or geography for granted. In today’s business world, all hegemonies have a very short shelf life. Hence, the key would be continuous research and innovation, climbing up the value chain and trying to provide all possible end-to-end solutions to the customers.

In the total mix of products, solutions and services, the ‘solution’ component is to keep getting higher and higher weightage.

Which are the growing markets internationally?

In the power segment, the growing markets are Latin America and Africa as a whole. South East Asia is also seeing qualitative improvement in power distribution; the Middle East is one big option. Talking about India’s neighbours, the opportunities, threats and the problems over there are not the same as in India. This is because distribution is in a much bigger mess in India than in neighbouring countries.

Talking about smart metering in India, do you see the right kind of momentum going on?

No, the right type of momentum is lacking. This is because while the thought processes at the top level, there is a huge resistance among consumers primarily coming out of non-understanding. The customer is not paying the true cost of electricity.

Eventually, at some stage, the various renewables will have to become a much bigger part of the overall energy supply, both in terms of meeting the energy demand as well as for addressing energy security concerns.

The issues of renewables can only be addressed if there is a proper smart grid; smart meter is a very important step in the smart grid. Concepts like timeof-the-day metering, peak demand, bridging the gap between the invoiced

demand and peak demand need to be addressed. Further, there is a huge need for smart meters. Ultimately, consumers will have to understand that they will have to pay the right price of electricity; they need to reduce their peak time consumption by shifting the use of some of the power guzzling devices to off peak hours. Smart meter is an enabling tool for this exercise.

We have already reached a situation where discoms do not want to supply 24 hours of electricity because every unit supplied means additional losses.

What are Supreme’S short-term goals?

In three years, the trial period for 1,200 KV national test station will be complete along with the pilot for the smart grid.

The smart grid technology will have matured with people concerned having a better understanding of smart grid applications. In the three-year period, our qualification level would also be at par with any manufacturer anywhere in India and abroad for our range of products in the T&D segment By next year, we will complete the threeyear period of satisfactorily installation of 400 KV hardware and connectors to qualify for 765 KV. We will be automatic qualifiers for the 1,200 KV line. Also, we will have already had experience of a smart city pilot.

Further, we are also adding to our range of products. We have also set up a facility for polymer insulators and are in the process of adding a very large range of products like fittings for high-temperature low-sag conductors, which is entirely a new generation of conductors. We also offer end-toend solutions for installation of fibre optic cables and integrate it with the passive network including live line retrofitting OPGW. We are working in close co-ordination with PGCIL, RAILTEL & BSNL—the three nodal agencies for implementing National Optical Fibre Network. devyani.korgaonkar@network18publishing.com

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Electrical Equipment trivia

8

El ctrifying Facts

Electrical equipment is one of the most vibrant industries. It has been in the spotlight since the past couple of years.

The reason: no sector creates more economic value or supports additional jobs than electrical manufacturing. But, apart from business, have you ever thought where the first transformer was used, when was the generator invented or the history behind circuit breakers…No? Here’s taking a look at some such interesting facts…

In the 19th century, Michael Faraday, a British physicist, invented the first electrical generator known as the Dynamo.

The first electric motor capable of moving machinery was constructed

by William Sturgeon in 1832. However, in 1888, Nikola Tesla invented the first practicable AC motor and with it the polyphase power transmission system.

Thomas Alva Edison invented more than 2,000 new products, including switches, fuses, sockets and meters. The first central power plant, Pearl Street Station in Lower Manhattan, built by Edison began generating electricity on September 4, 1882. Edison developed the idea of a circuit breaker in 1879, sketched different concepts in his scientific journals and patented the idea in the same year. Circuit breakers equip every electrical system today, more than 120 years after being invented.

In 1898, at the L Street Station of the Boston Electric Light Company, the first circuit breaker featured an oil tank and upward-breaking contacts manually activated. The oil was used to dampen the heat generated from the arc forming between the two open contacts.

Cutter Manufacturing Company manufactured the first circuit breakers in Philadelphia in 1904. The product became very successful under the name of Inverse Time Element (ITE) breaker. The electrical catalogs today feature different types of ITE breakers.

India’s first manufacturer of light bulbs and electrical equipment was Bengal Lamps, Calcutta, in 1933.

Ottó Bláthy, Miksa Déri, Károly Zipernowsky of the Austro-Hungarian Empire first designed and used the transformer in both experimental and commercial systems. Later on, Lucien Gaulard, Sebstian Ferranti, and William Stanley perfected the design.

The first AC power system that used the modern transformer was in Great Barrington, Massachusetts, in 1886. Earlier forms of the transformer were used in Austro-Hungary 1878–1880s and 1882 onward in England. Lucien Gaulard (a Frenchman) used his AC system for the revolutionary Lanzo to Turin electrical exposition in 1884 (in Northern Italy). In 1891, mastermind Mikhail Dobrovsky designed and demonstrated his 3-phase transformers in the Electro-Technical Exposition at Frankfurt, Germany.

Compiled by Nishi Rath

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Simulation Software

Designing fault-free equipment

The electrical equipment market in India is huge. Only allied equipment like switchgears, capacitors and energy meters, among others, are growing at a CAGR of approximately 12%. The electrical equipment manufacturing industry contributes more than 10% to the manufacturing sector in India. This huge industry cannot afford faults; so it has opted to use simulation software that enables complicated computations and elimination of faults during the designing phase. It also helps accelerate product development, thereby benefitting the industry at large.

Nishi Rath

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anufacturing simulation and digital engineering tools & procedures have had a positive impact on the manufacturing sector. In the last few years, there has been considerable interest in having simulation software that is easier to use, which largely means reducing the amount of programming required to build a model. This has given rise to a manufacturing-oriented simulator, which is a simulation package designed to model a manufacturing system in a specific class of systems. These kinds of software generally have two main characteristics; normally the orientation is towards manufacturing and little or no programming is required to build a model.

Better and faster

Simulation is a very helpful and valuable work tool when it comes to

electrical equipment manufacturing. It can be used in the industrial field, thus allowing the user to understand and test the system’s behaviour. Simulation software also provides a low cost, secure and fast analysis tool; its benefits can be reaped with many different system configurations.

According to experts, simulation technology holds tremendous promise for reducing costs, improving quality and shortening the time-to-market for manufactured goods. “With the use of simulation software, possible errors in the design of electric equipment are eliminated at the design phase itself. The software simplifies complicated computations and virtual prototyping, thus, accelerating product development. At Eaton, a Dynamic Simulation analysis is performed in conjunction with Eaton’s design of alternative energy and battery storage systems. Results are used to modify

Simulation Software Offerings 20-sim: 20-sim (Controllab products) is a relatively new software used for

blocks modeling system for continuous systems. It is a modeling and simulation programme that runs under Windows. With 20-sim, one can simulate the behaviour of dynamic systems, such as electrical, mechanical and hydraulic systems or any combination of these systems.

Automod: This software provides true to scale 3D virtual reality animation, making simulation models easy to understand. It provides advanced features to allow users to simulate complex movement, such as kinematics and velocity of equipment like robots, machine tools, transfer lines and special machinery, among others.

Prosolvia: This software brings reality to virtual manufacturing. It allows the user to view the product in a variety of views and situations. End user interaction and functional testing in the early concept stages of the product development process means that important design and manufacturing decisions can be made earlier on in the process.

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control parameters and to enhance system design,” said Nitin Chalke, MD, Eaton India. Potential simulation impact areas are closely intertwined with strategic manufacturing. Yet, a number of factors are currently holding back the use of simulation technology in the manufacturing sector.

“Simulation has gained a lot of importance in the past few years and allows designers to come up with new systems, thus enabling them to both calculate and observe the equipment behaviour. Additionally, simulation software can be used to study and compare alternative designs or to troubleshoot existing systems, thus saving on costs and lead times,” said a designer on condition of anonymity.

Selection of simulation software

Most organisations use a commercial simulation software product, rather than a general-purpose programming language. The two common criteria for selecting simulation software are modeling flexibility and ease of use.

In the short term, the software helps designers pick the best components for the job. In the long run, it aims to automate more of the design process. Electrical equipment manufacturing involves the design, development, assembly and testing of electronic components, parts & tools.

The model-based-design approach lets users model the entire structure and control system in sufficient detail to get a realistic idea of the electrical equipment. nisi.rath@network18publishing.com

SF6 Utility

A double-edged sword?

Sulphur hexafluoride (SF6) is widely used in the electric utility industry for insulating circuit breakers, substations and switchgears in electric power transmission and distribution. SF6 presents a double-edged sword—it is indispensable for the safe transmission of electrical power; yet due to its global warming potential, it represents a longer-term problem if used carelessly. Here’s taking a look at the pros and cons of SF6…

Nishi Rath

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ulphur Hexafluoride (SF6) has a much higher specific global warming potential than Carbon Dioxide (CO2) and an atmospheric lifetime of approximately 3,600 years as compared to roughly 100 years in the case of CO2. Unlike CO2, which has numerous significant natural sources, SF6 is exclusively a man-made gas. Apart from its status as a greenhouse gas and its long atmospheric lifetime, SF6 is generally appreciated for its complete inertness, its lack of acute or chronic toxicity and its excellent dielectric and quenching properties. It is used in various products and industrial processes such as in electrical equipment, as a cover gas for magnesium die-casting, in degassing of aluminium, in semiconductor manufacturing and in sound-insulating glazing, among others.

According to Manish Walia, Senior Director – Industrial Automation, Delta India, “SF6 is widely used in utility electrical transmission and distribution equipment—especially gas-insulated switchgears and circuit breakers. Several discussions have been held in the international arena to reduce SF6 emission and various actions have been advocated for SF6 reduction measures. The domestic industry needs to concentrate more on new technologies and innovations for environmental sustainability and energy security. The government on its part has also initiated the efficiency

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criteria in terms of maximum allowed heat rates for various unit sizes.”

The SF6 Emission Reduction Partnership for Electric Power Systems is a collaborative effort between EPA and the electric power industry to identify and implement cost-effective solutions to reduce SF6 emissions. It is a highly potent greenhouse gas used in the industry for insulation and current interruption in electric transmission and distribution equipment.

SF6 Advantages

The electric power industry has been using SF6 gas as a dielectric and insulating material for years. Its popularity is mainly due to its unique physical and electrical properties like: Dielectric strength twice that of air Nontoxic and noncorrosive Chemically stable with high breakdown strength. SF6 molecules provide excellent arc extinction during electrical operations, which minimises contact wear and maintenance Excellent thermal conductivity; high heat transfer permits lower operating temperatures Readily available in many commercial locations.

Cutting down on SF6 emissions

The electrical equipment industry uses a significant percentage of the SF6 produced worldwide each year. Under ideal operating conditions, SF6 would remain entirely contained within the

T&D equipment. However, during real-world equipment operation, maintenance and SF6 recycling activities, gas is emitted into the atmosphere. Fugitive emissions of SF6 can escape from gas-insulated substations and switchgear through seals, especially from older equipment.

It can also be released during equipment installation and when the equipment is opened for servicing.

This can be put to a stop by taking a few remedial steps like: Equipment Upgrades and Maintenance: Older circuit breakers generally contain 800–2,000 pounds of SF6 and have the potential for leakage. Also, damaged equipment like worn bushings, seals, tubing and manifolds can create leaks.

Having a system in place to identify equipment that needs replacement or repair can have a significant impact on overall emissions.

Recycling: Before the greenhouse properties of SF6 were assessed, used gas was commonly returned to cylinders and stored or simply vented into the atmosphere. But today, SF6 can be recycled and reused, offering a socially responsible solution. Used gas can be recycled through processing using gas carts or by removing it to offsite processing facilities.

Employee Education: Creating awareness among employees about the impact of SF6 on the environment and proper handling procedures is

SF6 Utility

Avoiding use of fluorinated greenhouse gases is the best way to limit emissions “During the last 15 years, the manufacturing processes of many global electrical equipment manufacturers have significantly improved in terms of reducing SF6 emissions,” informs Nitin Chalke, MD, India, Eaton, during an interaction with Nishi Rath. Excerpts…

SF6 emissions reduction from electrical equipment manufacturing

SF6 is the most potent of the six main groups of greenhouse gases. The best way to limit emissions is avoid use of any fluorinated greenhouse gases. The Global Warming Potential (GWP) of SF6 is 23.900 CO2 equivalents; it is one of the substances that have been banned for almost all applications, except for high voltage and medium voltage switchgears. The reason for this exception is that there would be no alternatives available.

During the last 15 years, the manufacturing processes of many global electrical equipment manufacturers have significantly improved in reducing SF6 emissions. Eaton has developed very compact and environment-friendly MV switchgear, called Xiria, which is based on vacuum technology and solid insulation for voltages up to 24 kV. With this green solution, utilities can choose a sustainable alternative and therefore, reduce the use and emission of SF6 in their distribution networks.

Manpower shortage in the industry

Shortage of skilled manpower is a challenge confronted by organisations across industries. It is not specific to a particular industry or segment. The reasons for this phenomenon can be many, but I believe that our technical training institutions and polytechnics can play a key role in bridging this gap by producing technically superior innovative technicians capable of understanding and working in critical functions such as R&D, design and consultancy. Eaton, as an organisation, envisions great value in partnering with technical training institutions; thus, contributing towards building an industry-ready talent pool through appropriate learning inputs and interventions.

Green equipment

At Eaton, ‘Doing Business Right’ has been central to our vision and our work for more than a century. As a diversified important. A training programme that includes environmental awareness training for employees regarding the greenhouse potential of SF6 should be made a must. Awareness regarding the

power management company, protecting and improving the environment are among Eaton’s highest priorities. Eaton is not only reducing its own emissions, energy & water consumption, and waste production, but has also been partnering with the industry to offer more efficient power management solutions to customers globally. Eaton’s green solutions are products, systems or solutions that represent Eaton’s benchmarks for environmental performance.

Though all of Eaton’s products and solutions are designed to meet or exceed applicable government standards related to protecting the environment, our ‘green leaf’ symbol is our promise that the solution has been reviewed and documented as offering exceptional, industry-leading environmental benefits to customers, consumers and the communities. Eaton green solutions help our environment in diverse ways. To cite a few examples: SF6-Free Medium Voltage Switchgear uses environmentfriendly choices for insulation, avoiding sulphur hexafluoride, an extremely harmful greenhouse gas.

Green Building Solutions monitor, control and reduce electricity consumption in LEED-certified buildings.

Power Xpert Software manages power system at a component, device and system level and allows identification of energy saving opportunities.

BladeUPS reduces electricity consumption for blade servers, data centres, networking applications, storage devices and critical IT equipment.

9395 UPS System reduces electricity consumption in large datacentres.

Effect of economic crisis

These have indeed been challenging times for the global economy. However, our integrated diversification strategy has paid off; it has helped us and is helping us deliver good results during troubled times. We have diversified across three key dimensions—product portfolio balance, geographic balance and balance through the economic cycle.

safe handling of cylinders to ensure safety while handling high-pressure cylinders can also work wonders.

Through greater awareness and improved gas management techniques,

electric companies can not only reduce their emissions but also save money in the process. nisi.rath@network18publishing.com

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Illustration By Sanjay Dalvi

Manpower Shortage

Upgrade Technical Education,

beat The crisis

The electrical equipment industry plays a prominent role in the infrastructure development of the power sector. In the past, the sector made use of low-cost labour as well as strong manpower base to strengthen its presence in the global markets. But now, as India is reeling under the pressure of global economic meltdown, acute manpower shortage has started to haunt the Indian electrical equipment industry.

Nishi Rath

T

he Indian electrical equipment industry is among the fastest growing industries in India. Although the industry is highly fragmented, the Small and Medium Enterprises (SMEs) enjoy a fair share of the market. Analysts believe that over 90% of the electrical equipment manufacturers in India are SMEs. With regard to the overall output, around 30% contribution is accounted

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for by SMEs in this sector. As per the government figures, the electrical equipment industry offers direct employment to around 5 lakh people and indirect employment to more than 10 lakh people. But the industry has been facing various challenges, fluctuating raw material prices, poor investment in R&D and the growing shortage of skilled manpower.

According to the Ministry of Heavy Industry and Public Enterprises, the rising problem of skilled manpower is

impacting various key functions of the electrical equipment industry such as R&D, design and detailed engineering work. In a statement last year, the Ministry said that the technical education system in the country does not promote innovative thinking, training being provided in the ITIs is outdated and the students are not able to meet the aspirations of the industry. “Even qualified supervisors and engineers are not available. Those who are qualified are not well trained to meet the technical needs of the industry. Because of the above factors, the labour productivity is far less than the labour productivity in China and Korea,” the statement added.

The technical education system does not promote innovative thinking; training provided in the industrial institutes does not match the current requirements. It is one of the most important reasons why students are not able to fulfill the industry aspirations. Furthermore, various engineering graduates are of the opinion that the electrical equipment industry lacks considerable growth prospects, leading to limited career options and insufficient salaries. It is leading the new-age students to opt for other high paying sectors. It is believed that this demand-supply mismatch can be solved by upgrading the present curriculum followed by the engineering colleges across India.

Manpower crisis impacting industry’s growth

According to reports, the skilled manpower crisis has started to impact productivity in a large way; the rate of skilled manpower has gone down as compared to countries like China and Korea. It can also be said that it is one of the possible reasons for making the industry non-competitive in nature in the recent times. As per the Indian Electrical and Electronics Manufacturers’ Association (IEEMA), the growth of India’s electrical equipment industry slipped to 6.6%

Manpower Shortage

components, etc. during 2011–12 as According to the Ministry of Heavy Industry and Public “Further, domestic compared to 13.7% during Enterprises, the rising problem of skilled manpower is companies are slow when the previous financial year impacting various key functions of the electrical it comes to absorbing new equipment industry.

2010–11. Reports say that technology. According to the growth in capacitor, an estimate, less than 1% of the annual teaching staff in these colleges to spend switchgear and transmission line turnover of the industry is invested in a few months directly working in the segments portrayed negative growth R&D. The main focus of the SMEs industry. This will prove beneficial during 2011–12. Though, the industry remains with the cutting costs and for the continuous upgradation that is is sailing in rough waters, the future is not on innovative technologies,” says much needed today. Apart from this, likely to brighten up soon. According to Walia. various measures can be taken, such as: IEEMA, the industry expects exports Despite the importance of this to witness a six-fold jump to reach Students should be given hands-on growing industry, it has failed to grab $25 billion within a decade. It has also training at industries that house the attention of policy makers. The been holding regular interactions with improved R&D centres, latest Indian electrical equipment industry the Department of Heavy Industry technologies and products continues to face severe shortage of and the National Skill Development Developing exchange programmes skilled manpower—a problem that Corporation (NSDC) to establish skill for students and teachers across cannot be ignored. councils for the ailing sector. technical institutes Some of the main reasons why “There is a dearth of skilled and The government should allot funds students do not possess the necessary employable manpower in the electrical and other facilities to technical skill set can be attributed to various equipment manufacturing industry. institutes. This will help them reasons like outdated syllabus, lack Besides, the variation in demand and upgrade the facilities and adopt new of practical training, non-exposure to supply is affecting critical functions like technology, among others.

R&D, design and other engineering work. This has resulted in the Indian Indian Electrical Equipment Industry overview industry becoming non-competitive as compared to other Asian countries India’s electrical equipment industry is highly diverse and manufactures a wide like China, Taiwan or Korea,” explains range of high and low technology products. The industry directly employs around Manish Walia, Senior Director – half million persons and provides indirect employment to another one million people. The industry can be broadly classified into two sectors—generation Industrial Automation, Delta India. equipment and T&D equipment. For 2011–12, the industry size is estimated at “The academic courses imparted `1.20 lakh crore, of which generation equipment segment consisting of Boilers, at the technical institutes failed to Turbines and Generators (BTG) contributed `31,000 crore, while the major T&D produce competent students who can equipment segment of transformers, cables, transmission lines, switchgears, take on the changing scenario and capacitors, energy meters, etc., provided the larger share of `64,235 crore. Other aspirants of the industry. Further, a electrical equipment, including instrument transformers, surge arrestors, stamping large number of students are switching and lamination, insulators, insulating material, industrial electronics, indicating to IT/ITeS for better career options, instruments, winding wires, etc., contributed to `25,000 crore. the electrical industry too needs to attract students with considerable growth prospects along with scope for products and limited awareness about Miles to walk… better R&D facilities,” Walia adds. the industry. Apart from this, there The recent global economic crisis is a need to change the mindset of and continuous interest rate hikes to many young engineers who believe control high inflation has adversely Fighting the manpower crisis the electrical equipment industry to be affected the pace of manufacturing Opening more technical institutes slow moving, entailing limited career growth. A fresh spurt of growth is the very first step to fight the options and inadequate salaries. can only come from encouraging manpower shortage affecting the A proper government initiative is investor sentiments, both domestic industry. “By investing in good and required to boost the growth of this and overseas. The domestic electrical well equipped engineering colleges and sector, which is impossible without equipment manufacturing industry ITIs, we hope the manpower shortage participation from the industry suffers a cost disadvantage due to in one of the most technical fields representatives. higher financing cost, lack of quality can be met,” said an industry expert infrastructure, dependence on foreign on condition of anonymity. Taking it sources for critical raw material and further, it should be mandatory for the nisi.rath@network18publishing.com

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CRGO in Transformers

Devyani P Korgaonkar

G

Salvaging the

r‘aw’struck industry

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Courtesy: www.diytrade.com

rowth of the transformer industry generally depends upon the planned capacity addition to the power generation, transmission & distribution network in India. The installed power generation, in the country is approximately 2,00,000 MW as on March 2012; capacity addition of approximately 85,000 MW is planned in the 12th Five Year Plan by 2017. Thus, there is a huge requirement for power transformation capacity. Also, most transformers, which have completed more than 20–25 years in the field, will need to be Manufacturing is worst hit by the raw material crisis and the electrical equipment replaced by new transformers in industry has also not been exempted. The `16,000-crore electrical transformer segment has been badly affected due to the serious supply gap of an imperative the near future.

The combined installed raw material called Coal Rolled Grain Oriented silicon steel (CRGO) for some time capacity of the Indian transformer now. CRGO is a critical input for manufacturing transformers. Only five global segment in the organised and steel makers have the technology to produce such steel and India imports around unorganised sectors is about US$2 bn from them, annually. Additionally, the BIS regulation on raw CRGO import 4,00,000 MVA (transformers has created havoc in the transformer manufacturing segment. Industry bodies are ranging from 5 KVA to 500 searching for a quick solution to redress the issue.

MVA and voltage ranging from 1.1 KV to 1200 KV). Recently, Korea & China, thereby making the a 1,200 KV technology has been Addressing the issue developed and absorbed by the Indian industry march towards sickness,” Indian Electrical and Electronics industry. In fact, 1,200 KV single phase opines B Lal, Director General, Manufacturers Association (IEEMA) transformers have been manufactured Indian Transformer Manufacturing has been actively addressing the and are currently installed/being Association.

CRGO issue with various ministries. installed at the 1,200 KV BINA The association has requested that Elaborating further, Aaditya R sub-station managed by Power Grid the local transformer industry be Dhoot, MD, IMP Powers Ltd, Corporation of India Ltd (PGCIL). provided with a level playing field as informs, “One of the biggest challenges, CRGO contained in the imported which has emerged is the BIS Second transformers does not currently fall Steel Quality Control Order for The CRGO Crisis under the purview of this order and CRGO Steel. Herein, all CRGO Cold Rolled Grain Oriented laminated hence, is not BIS certified. silicon steel or CRGO steel used by steel which is imported into the country According to Lal, “There are the electrical transformer industry will have to necessarily conform to about 9–10 mills across the world used to be made by Steel Authority IS:3024 Standards. Currently, there having 15 plants to produce about of India Ltd (SAIL). The state-run are 14 mills manufacturing CRGO 25 lakh tonne of electrical steel steel firm has stopped production of steel across the world; all CRGO (CRGO) per year. India’s requirement this vital raw material. “For the past steels are imported, as there is no is about 12–13%, which may be couple of years, electrical equipment manufacturing facility in India as increased to 15% in the 12th Plan has faced negative growth. The of now. We are not against this domestic demand of equipment is certification, but its present form does period. It is a known fact that CRGO reducing because of upswing in the not cover transformers imported (from is not produced in India and we import of goods, especially from China, Korea, etc.).” have to totally depend on the import

Courtesy: supremeco.wordpress.com

CRGO in Transformers

The 1200 kV transformer

of this crucial raw material for the transformer industry.”

Further, IEEMA has also requested the government to keep the order in abeyance till at least 10 steel mills get the required BIS certification. This will ensure ready availability of CRGO at competitive prices. If not, it will impact the transformer production in the country delaying power programme and help countries like China and Korea gain at the cost of Indian manufacturers.

With an aim to improve the scenario for India, Dhoot states, “We are in active communication with the government and are always ready to help. Extension for the implementation of Steel Quality Control Second Order deadline has been a temporary respite for the industry. Implementation of this order on September 12, 2012, would have disrupted the supply of CRGO Electrical Steel, fully imported raw material and a critical input for transformer manufacture.

Short/no supply (only 3 of 14 mills are presently BIS certified) would have derailed the entire power production.”

role of CRGO in causing

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meet demands of the power sector is set to take off soon on a public private partnership with Tata Steel. A source from the Steel Ministry informs that the plan to produce CRGO has been with the Ministry for quite some time.

National Metallurgical Laboratory and Tata Steel’s proposal for development of CRGO steel in the country will take off soon. However, the Steel Ministry’s Empowered Committee (EC) for R&D, headed by the Secretary, said that the joint ventures undertaken by Indian steel firms cannot ensure total technology transfer.

To this, Lal adds, “The manufacturing technology though unavailable in India, is available with Indian-owned companies in their subsidiaries overseas. Tata Steel has the technology available transformer failures in Corus in the UK. Also, Arcelor Investigations on the transformer Mittal manufactures CRGO in failures conducted by the world their European and Brazilian plants. renowned CIGRE clearly indicate that Further, Posco is already considering the magnetic circuit of transformers, setting up CRGO steel manufacturing which also includes CRGO as one of at its greenfield venture in Odisha and the components, may be responsible for JFE is in discussion with JSW for the 3–4% of transformer failures, that too manufacturing of CRGO in India and if the magnetic circuit is not properly transfer of technology.” earthed or is damaged during transit, “However, the history of indigenous development Currently, there are 14 mills manufacturing CRGO steel across the world; all CRGO steels are of CRGO has not been imported, as there is no manufacturing facility in very successful. SAIL India as of now. laboured and ventured Aaditya R Dhoot, MD, IMP Powers Ltd for many years to achieve success in commercially producing CRGO at its Rourkela etc. “Studies have shown that CRGO Steel Plant; finally, the exercise was is not the prime reason for transformer abandoned in 1990s. Similar is the case failures; it may contribute to only 3–4% with Raymond Steel at Nashik; the of such failures. We have requested the plant was ultimately sold to TKES, a Ministry of Power to further investigate German steel company,” he elaborates. and validate this on top priority by instituting an independent Third Party Indigenous manufacturing of study by CIGRE (India) or CEA to CRGO in India will help the Indian find a lasting & permanent solution,” electrical industry to avail raw materials at an affordable price.

Dhoot adds.

Besides, its dependence on imports will dramatically reduce and develop The utmost solution further scope for the export market to A silver lining for transformer grow and flourish. manufacturers is another recent report, which says that India’s plans to produce CRGO steel indigenously to devyani.korgaonkar@network18publishing.com

Green Electrical Equipment

Devyani P Korgaonkar

ching t a M t

h

Manufacturing mandates

The manufacturing process of electrical equipment can play a crucial role in making the equipment green. A multitude of case studies

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in manufacturing. Where and how the product was made is just as important as how the product performs.

Citing an example, Kumar states, “Many products such as circuit breakers use SF6 gas. Proper safeguards can prevent the leakage of this greenhouse gas.

There are mandates, particularly in European countries, to capture, reuse and safely dispose of this gas.

Also, the Government of India has made it mandatory for IT equipment to be recyclable or disposed of in an environmentally safe manner.”

“Similarly, Department of Telecommunications has released its green procurement guidelines in 2012 that have established guidelines for the telecom sector for purchasing telecom equipment having reduced environmental impact,” Kumar continues.

“Coming to the manufacturing process, many factories use packaging that utilise recycled paper or plastics— the crates or boxes use one-third less wood than what is typically found in the industry. In particular, our factory in Hyderabad also recycles water and has a rainwater harvesting system in place. Our factory in Bengaluru, which was inaugurated in 2012, is a green building, and has been awarded a Gold rating by the Indian Green Building Council. This building itself uses less energy, water and also provides an excellent working environment for workers. This, in turn, improves the productivity and leads to less wastage.

Last, but not the least, many of our facilities in India, have obtained or are in the process of procuring an ISO

a al m trix nt

H

onouring the environmental needs, leading electrical equipment manufacturers are focusing on products that have minimal adverse impact on the environment. A green product that is able to reduce the energy consumption has become the need of the hour. Moreover, such products are easy to dispose of or even recycle, thereby achieving more eco-friendly brownie points like reducing carbon emissions and using fewer resources. Engineering in the realm of electric product development can be used to contain a major portion of environmental impact by the way in which systems and products are designed, manufactured and used.

According to Dr Satish Kumar, Energy Efficiency Ambassador and VP, Schneider Electric India, “Green electrical equipment provide higher efficiency as compared to traditional equipment. Bureau of Energy Efficiency has introduced ‘Star Labeling’ for various household and commercial products in India, such as refrigerators, air-conditioners, and geysers etc. It is mandatory for these products to be rated on a five-point or ‘star’ scale. A five-star rated appliance consumes much less electricity as compared to say a two or a three starrated product. Efforts are underway to introduce similar rating systems for other equipment.”

Courtesy: www.voting2point0

In a world where ‘energy preservation’ is a major challenge, few conglomerates have taken futuristic steps and are creating principles of sustainable development that present tremendous opportunities for growth and differentiation. Showing respect to the environment, these firms are positioning themselves for new kinds of markets—all of which will lead to growth in the coming years. One such pioneer of green electric product manufacturing, Schneider Electric India offers an understanding of the present scenario of green electrical equipment in the country. indicates huge potential for ‘green electric components’ manufactured through better process and systems engineering. The complete lifecycle of products impacts the environment and its users. Better engineered products can lessen the impact through consumption of fewer resources in designing and more resource-efficiency

Green Electrical Equipment

50001 certification, which is a global standard in energy management. For our customers, Schneider Electric’s IT Business unit (formerly APC) has a robust e-waste management programme, which includes recycling of batteries and UPS,” he elaborates.

Product Range & Implementations

Is India adopting green electrical equipment?

Several projects in India make use of such energy-efficient products and solutions. Schneider Electric India has collaborated with various organisations and helps them achieve energy efficiency in their operations. “One of the projects we carried out was with Assam State Electricity Board, where the scope of the project included design, engineering, supply, installation, testing and commissioning of 330 KV and 11 KV equipment, power and auxiliary, remote commissioning.

The application of green electrical equipment has been successful in India and is increasingly being used

There are hundreds of energy efficiency and energy management products, which cater to different sectors like buildings and power, among others.

Kumar informs, “We have lighting and HVAC control systems, which optimise energy consumption in these areas. Our energy management system can monitor and control operations within a commercial building as well as in A five-star rated appliance consumes industrial buildings. much less electricity as compared to In utilities, we have say a two or a three star-rated products like power factor product. Efforts are underway to introduce similar rating systems for improvement panels, other equipment. demand controllers, Dr Satish Kumar, Energy Efficiency Ambassador and VP, capacitor banks, etc. For Schneider Electric India the industrial sector, we have products like motor and conveyer system optimisers, by companies in various sectors. Our compressed air generation optimisers, experience has shown that awareness DG load management, blower about environment-friendly products controllers, etc.” has increased; people are willing to The products named above and pitch a little more to buy energymany more are used in a large number efficient products and equipment.” of sectors of an economy. Schneider However, there are still a few Electric, in particular, focuses on five financial as well as technological sectors, viz., energy and infrastructure, obstacles that need to be overcome. The industry, data centres and networks, financial problems include expectations buildings and residential. of quick returns on investment, high These products contribute to energy interest rates and high product costs. efficiency in these varied sectors in The technology barriers, on the other different ways. Kumar explains, “Our hand, include lack of infrastructure and dimmers reduce artificial lighting low quality technologies that are already when there is sufficient daylight installed and are being used. With in a space. Occupancy sensors various government schemes (such as control HVAC, lighting and other BEE Star Labeling, Perform Achieve equipment in offices. Variable speed Trade (PAT), etc., and rating systems drives increase the efficiency of a such as LEED and GRIHA) now motor. Other than these devices, coming into the picture, the demand is which directly contribute to energy set to increase in the long run. efficiency, we have energy management solutions that monitor and control a R&D on green electric products facility.”

Schneider Electric has more than

1,000 R&D staff in Bengaluru catering to products and solutions for Indian as well as global markets. It devotes 4–5% of revenues to R&D. “We have recently introduced Struxureware®, which is an integrated system that assists in better automation and connectivity everywhere for profitable business. Struxureware system architecture enables the convergence of five key domains of our expertise— management of power, process & machine, IT room, building, and security,” Kumar highlights. “It acts as a solution ecosystem, delivering guaranteed compatibility across key application areas. It is a simplified way to save money and reduce waste by enabling guaranteed compatibility between the management of power, white space, process & machines, building control, and security,” Kumar adds.

An agent of ‘energy efficiency’

Energy efficiency is the key indicator to achieve sustainable development. Schneider Electric wants to build sustainability through its energy-efficient solutions. “The fact is we have to cut the world’s CO2 emissions in half by 2050. However, energy demand—a major source of CO2 emissions—will double by that date.Investing in renewable energy resources are the logical way forward, but not enough to change the energy mix. By implementing integrated energy management solutions in industrial, commercial or residential buildings today, we can save up to 30% of three quarters of the world’s final energy consumption,” Kumar points out. As energy demands escalate from all aspects of our global society, the most acute pain point is that for every three units of energy created at the power plant, only one makes it to the point of use at the plug. devyani.korgaonkar@network18publishing.com

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Wires & Cables’ Safety

W

ires & cables, which constitute the largest segment of the electrical industry, have witnessed a severe downturn.

According to an IEEMA report, the segment has seen a negative growth of 35%.

Slowdown in number of projects

The electrical industry’s fortunes are linked to that of the power sector, which are interlinked to the plans and policies of the government. The power projects are stuck due to issues

have run into huge losses. What’s worse? There is no government funding to recover these losses owing to which they have become cash starved.”

“Besides, the wires and cables segment, which constitutes more than 27% of the electrical industry, is seeing a negative growth considering that the electrical industry is witnessing a negative growth with the production and sales slumping by almost 35%,” adds Karia.

Policies to blame?

The wires & cables segment has

given access to capital, cheaper finances to set up plants and incentives to work on R&D. Today, in India, we are still working on specifications, which are almost 50 years old,” Karia opines.

“Asymmetrical policies of the Indian Government are the root cause. The government has only 2.5% differential duty between raw material and finished goods. Moreover, the fluctuating prices of raw materials are not giving the sector any chance to recover,” he adds. The rate of import on copper is 5%, while for copper cables, it is 7.5

Encountering The Electrical Impendence

The Indian electrical industry is going through tough times and the wires & cables segment is no exception. There is a need to survive, but at what cost? Does surviving mean compromising on quality? Such questions are being raised with the mounting fire-related accidents that are tarnishing the image of the segment. Besides, poor government policies on imports have severely jeopardised the interest of the local players; this segment seeks an immediate survival strategy. Vijay Karia, CMD, Ravin Cables, addresses the issue and shares his valuable opinions with Devyani P Korgaonkar on the same. pertaining to coal supply, linkages, increase in coal prices and dollar rates.

These, in turn, have led to an increase in the per unit cost of electricity—the main cause of negative growth seen in the wires and cables segment.

Elaborating on the same, Vijay Karia, CMD, Ravin Cables, one of the largest exporters of cables from India, explains, “Due to a slowdown in projects, all the state electricity boards

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also been suffering due to the wrong import policies. Imports from China have indeed posed a threat to this segment. “The Indian Government could be held responsible for not protecting the local industry. In order to deal with this threat, you have to protect the local industry by offering them incentives and giving them a chance to grow.”

“This implies that they need to be

%; the differential of 2.5% protection that the local industry is getting is eaten up by high infrastructure cost and high local taxes. This makes it extremely difficult for the segment to survive.

Unorganised sector challenges

Many unregistered organisations, which manufacture wires and cables, have mushroomed in the nooks and

Wires & Cables’ Safety

would get out-priced in the market. corners of India. According to reports, Moreover, only a miniscule set of units more than 30% of wires and cables deal in the consumer segment.” come from the unorganised sector, which employ unskilled manpower.

This gives more reason to worry about Safety standards the safety standards of such products.

Wires & cables are a big source of However, Karia disagrees. “I honestly fires; as many as 20–25 fires a day only feel that around 10% of the wire in Mumbai are attributed to Defective segment falls under the unorganised Electrical Circuit (DEC). The two sector,” he emphasises.

“Besides, the The Indian Government could be government has made held responsible for not protecting it mandatory that all the local industry. In order to deal Polyvinyl Chloride with this threat, you have to protect the local industry by offering them (PVC)-insulated cables incentives and giving them a chance to grow. bear an ISI mark. Such Vijay Karia, CMD, Ravin Cables a stipulation mandates many other specifications like factory registration, excise & sales major reasons for DEC are poor quality tax and factory licences to be in place. of cables and poor installation. “I had Thus, there are a huge number of units personally advocated to the industry to already registered under the Bureau start an awareness programme, which of Indian Standards. So, we cannot was Indian Approved Cables Institute really claim that they fall under the (IACI). This was basically meant for unorganised sector,” he says. bringing together the manufacturers, He adds, “Though specifically, the government, stakeholders, PWD, BIS, wire segment may be facing a problem BEE and various fire departments to of stealing on duties & taxes, the cable prescribe norms for the finished cables segment is not facing any such problem. to comply with,” Karia informs.

This is because its major customers are “This would result in manufacturers government utilities and industries, taking responsibility to manufacture which rarely deal in cash. Also, I cables matching these norms and do not see such stealing becoming a standards. We would have tied up with rampant trend as it would mean that ERDA & CPRI who will conduct these players will not get their excise independent testing of these products. and sales tax refund. Additionally, they Manufacturers not meeting these testing standards would be blacklisted,” he adds.

“It is easy to comply with safety standards and specifications if one uses the correct quantity and quality of raw materials. However, “in a bid to be the lowest bidder, companies have started compromising on quality. Thus, there is a need for strict policing”, expresses Karia.

The current economic scenario is

a paradox where our electrical losses are among the highest in the world; power tariff is the highest in the world, whereas telecom tariff is the lowest.

“Such an anomaly is due to the fact that we are facing more than 30% of T&D losses each year, i.e., 70,000– 75,000 MW is lost. This is more than what Germany generates in a year (50,000–55,000 MW),” remarks Karia, adding, “This is due to the fact that we continue to use ageold equipment, especially wires & cables, which are not only derived from old specifications but are also physically redundant and, on an average, at least 50 years old. They are not able to cater to the ever increasing consumption patterns due to technological advancements like air conditioners, mobiles, laptops and iPads in every household. Such overload causes the wires & cables to heat up and as conductor resistance is inversely proportional to temperature, their efficiency keeps on reducing.

Besides, as the temperature of the conductor rises your losses increase.”

What’s the solution?

“Only good safety standards will solve such a problem of high electrical losses, which, in a way, causes danger to life & property,” avers Karia. The Bureau of Indian Standards has very stringent quality standards; even adhering to these standards is enough to meet the safety requirements. “We need to be true to our commitment. What we certify we need to adhere to,” he believes. The industries, government and regulatory authorities need to work in tandem to formulate strict quality standards as lives are at stake.

More so, consumers also have a role to play in demanding safety. Until and unless consumers are not alert, aware and demanding, the focus will not shift to safety standards. devyani.korgaonkar@network18publishing.com

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Opinions & More

Opinions & More ‘Indian Manufacturers Compare Relatively Well To Global Producers And Are Quite Competitive’ Abhinav Sood, Sales Leader, Hypertherm India.................................................................................72 Speciality Welds: Forging Special Bonds ....................................................................................74 Metal Inert Gas Welding: A Metal-friendly Welding Option ..................................................78 Plasma Cutters & Blowtorches: Cutting-edge Technologies To The Rescue .....................80 Weld Metal: How To Avert Porosity? ...........................................................................................82 Robotic Automation: Solution To The Manpower Shortage Riddle........................................86

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Opinions & More

Indian manufacturers compare relatively well to global producers and are

quite competitive

“India is considered by many MNCs as an ideal location for setting up their regional production base. In addition, the generally lower cost of operations makes the country even more attractive,” points out Abhinav Sood, Sales Leader, Hypertherm India, during a tête-à-tête with Prateek Sur. Excerpts…

Recent Initiatives & Latest Technologies

To cater to the demands of our everexpanding customer base in India, Hypertherm recently enlarged its local set-up in 2012. The new premise houses our first-ever Cutting Technology Centre (CTC) in the country. This CTC serves as a gathering point where sales and service personnel from channel partners can train their sales expertise and technical skills to enhance their capabilities when introducing Hypertherm products to end users. Such training sessions are important because Original Equipment Manufacturers (OEMs), system integrators and distributors, are usually our end users’ main point of contact. We also conduct demonstrations at our CTC to allow potential end users to understand the benefits of our technologies.

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Technological Trends

Welding and cutting industries continuously adopt the latest innovations that improve productivity, lower operating costs and reduce downtime.

Hypertherm always focuses on end user needs to develop solutions that bring maximum benefit to customers.

Demands, Challenges & Emerging Opportunities

Over the past few years, Hypertherm has seen strong growth within the construction, infrastructure, railway, vessel manufacturing and shipbuilding industries. These have continued to exhibit great developments, which is why Hypertherm has maintained its focus on these areas, and supported each industry with technology upgrades and new product offerings. Although we have witnessed some slowdown in

manufacturing in the recent months, Hypertherm continues to invest in enlarging our local infrastructure, as part of our long-term commitment to India market.

Benefits for SMEs

For SMEs, as with any other business, it is important to maximise productivity and returns on any investment. At Hypertherm, our engineers strive to lower the cost of cutting metals with all our innovations without compromising on cut quality and efficiency. By adopting our solutions, SMEs can be confident of enhancing their metal cutting processes and optimising operating costs.

Demand Differences between MNCs and SMEs

Hypertherm’s customer base in India

Opinions & More

is split evenly between SMEs and large corporations. Based on our experience, the bigger companies tend to invest in top of the line technologies, such as our HyPerformance® Xtreme Definition (HPRXD) systems and integrated cutting solution, because they usually have greater purchasing power. On the other hand, SME end users purchase a mix of entry-level air plasma systems and high-end solutions.

Indian manufacturers vs. global counterparts

Indian manufacturers compare relatively well to global producers and are quite competitive. Hence, India is considered by many MNCs as an ideal location for setting up their regional production base. In addition, the generally lower cost of operations makes the country even more attractive. At present, the export levels of machinery manufactured in India are not that high, which means that there is a lot of opportunities in this area. Also, as plasma becomes more widely adopted, more international plasma CNC table manufacturers will most likely set up their regional production centres in India.

cutting technologies. As a company, Hypertherm recently celebrated its 100th plasma technology patent. Our emphasis on R&D has allowed us to create leading-edge solutions that uphold our mission to ‘cut the cost of cutting metal’ while improving cut quality. This has truly set us apart from local and international competition.

In addition, we work closely with our channel partners to ensure that their employees are well-trained in both technical and sales skills, in order to assist end-users in their troubleshooting and maintenance needs.

Safety & Environmental concerns

A way in which Hypertherm protects the environment is by adhering to local and national environmental regulations.

The Restriction of Hazardous Substances (RoHS) Directive from the EU restricts the use of hazardous materials in electronics products, and we pride ourselves in exceeding the compliance obligations on a global basis. Hypertherm also observes rules set out by the Waste Electrical and

Benefits for Hypertherm in India

As a company, we believe in providing global technology coupled with local expertise. Having an India office allows us to provide professional assistance in a direct and efficient manner. At the same time, local associates are able to gather insights into the specific needs and demands of end users in India, which we take into consideration when designing upcoming plasma and fibre laser systems and technologies.

Company Mantra

Hypertherm enjoys a dominant leadership position in India market and continues to be the world plasma leader with local expertise. In essence, this means that Hypertherm provides local channel partners with capable after-sales support, and world-class

Up close & personal Most ambitious project so far...

At present, Hypertherm is looking into different means to strive to further strengthen our leadership position in the plasma cutting market in India.

Tips to scale up business for SMEs To stay ahead of competition, businesses should always consider investing in advanced technologies that minimise operating costs, while allowing them to receive RoI in a shorter time span.

Electronic Equipment (WEEE) directive and REACH regulation, thus ensuring that our products are both eco-friendly and safe.

In the development of new products, we believe in the idea of ‘doing more with less’. Newer technologies have been able to cut thicker and faster with the same or lower amperage. Also, the cutting quality achieved today is vastly superior, thus virtually eliminating the need for secondary operations that require additional electricity and time.

Hypertherm also accomplishes more with less by reducing the number of parts within our cutting systems. As a result, fewer components need to be purchased, transported and recycled.

Electrical efficiency of systems is another area of innovation that has reduced the environmental impact of operating Hypertherm’s products. Our newest mechanised power supplies have total efficiency ratings of well over 90%, which compares quite well to efficiencies of less than 70% in many of the older systems.

Market size of products and Future Growth

In spite of the various cutting technologies that are available in India, oxyfuel remains the most widely adopted thermal cutting tool. Many end users are resistant to switching over to more advanced cutting solutions because of the high initial capital cost and limited awareness about the technologies. Year-on-year, we have seen a growth in the local plasma install base, as more manufacturers have begun to adopt plasma for their thermal cutting needs. This is driven mainly by the enhanced productivity, advanced technology and reduced cost of cutting that plasma offers.

5–10 years down the line…

As global companies continue to invest in India and set up manufacturing base here, we foresee that the local welding and plasma cutting market will continue to witness growth.

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Speciality Welds

Forging special bonds

Welding is a process, which finds applicability in almost every aspect of manufacturing—be it among small SMEs or big MNCs. While welding is a common process, there are many exceptional cases, which require more precision than normal welding can offer, to meet the needs of specific applications. Thus, came to the fore the need to have speciality welds.

PRATEEK SUR

Percussion Welding

Percussion welding is a form of resistance welding that unifies dissimilar metals as one.

It produces a high temperature arc that is created from a short quick electrical discharge.

Instantly, subsequent to the electrical discharge, pressure is applied, which, in turn, forges the materials collectively. This kind of joining brings the materials together in a percussive manner. Percussion welding is analogous to flash welding and upset welding, but is usually considered to be more multifarious. It is considered to be more intricate as it applies an electric discharge at

the joint, followed by pressure being applied to join the materials together. Percussion welding is used to join dissimilar metals together, or used when flash is not required at the joint. This type of welding is limited to the materials having the same sectional areas and geometries. Additionally, percussion welding is used on materials that have small cross sectional areas. The advantages of using percussion welding types include a shallow heat affected zone. Besides, the time cycle involved is very short; typical times can be found to be less than 16 milliseconds.

Cold Welding

Cold welding, i.e., the joining of materials without the use of heat, can be accomplished simply by pressing them together.

To achieve this, surfaces have to be well prepared and pressure has to be sufficient to produce 35–90% deformation at the joint, depending on the material. Lapped joints in sheets and cold-butt welding of wires constitute the major applications of this technique. Pressure can be applied by

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punch presses, rolling stands or pneumatic tooling. Pressures of 1,400,000–2,800,000 kilopascals (200,000–400,000 pounds per square inch) are needed to produce a joint in aluminium; almost all other metals need higher pressures.

Cold or contact welding is a solid-state welding process in which joining takes place without fusion/heating at the interface of the two parts to be welded. Unlike in the fusion-

Speciality Welds

vacuum. The newly discovered micro- and nano-scale cold welding has already shown great potential in the latest nanofabrication processes. Its applications include wire stock and electrical connections (such as insulation-displacement connectors).

welding processes, no liquid or molten phase is present in the joint. Cold welding was first recognised as a general materials phenomenon in the 1940s. It was then discovered that two clean, flat surfaces of similar metal would strongly adhere if brought into contact under

Ultrasonic Welding

Ultrasonic welding is an industrial technique whereby highfrequency ultrasonic acoustic vibrations are locally applied to workpieces being held together under pressure to create a solid-state weld. It is commonly used for plastics, and especially for joining dissimilar materials. In ultrasonic welding, there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the materials together.

Ultrasonic joining is achieved by clamping the two pieces to be welded between an anvil and a vibrating probe or sonotrode. The vibration raises the temperature at the interface and produces the weld. The main variables are the clamping force, power input and welding time. A weld can be made in 0.005 second on thin wires and up to 1 second with material 1.3 mm (0.05 inch) thick.

Spot welds and continuous seam welds are made with good reliability. Its applications include extensive use on lead bonding to integrated circuitry, transistor canning and

aluminium can bodies.

The applications of ultrasonic welding are extensive and are found in many industries, including electrical and computer, automotive & aerospace, medical, and packaging.

Whether two items can be ultrasonically welded is determined by their thickness.

If they are too thick, this process will not join them. This is the main obstacle in the welding of metals. However, wires, microcircuit connections, sheet metal, foils, ribbons and meshes are often joined using ultrasonic welding. Ultrasonic welding is a very popular technique for bonding thermoplastics. It is fast and easily automated with weld times often below one second and there is no ventilation system required to remove heat or exhaust.

This type of welding is often used to build assemblies that are too small, too complex, or too delicate for more common welding techniques.

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Speciality Welds

Spin Welding

Spin welding is a friction welding technique used on thermoplastic materials, in which the parts to be welded are heated by friction.

The heat may be generated by turning on a lathe, a drill press, or a milling machine, where one part is driven by the chuck and the other is held stationary with the spinning part driven against it. This is continued until the heat of friction between the parts reaches a sufficient level for the parts to weld. The stationary part is then released to spin as well, while pressure is applied along the axis of rotation, holding the parts together as they cool.

Spin welding is a process by which two different parts are fused together through the use of heat generated by the force of friction. The friction is created by one of the pieces being held in place, while the other piece is held against it and revolved in a spinning motion, which, in turn, generates friction. The friction then results in an intense heat that allows the two pieces to begin fusing or joining together. When the two pieces join, the stationary piece is then released from the vice. The second piece is then allowed to spin along with the first until the created seam in the two pieces cools. The final result is that the two pieces are joined as one.

For the two pieces to be properly fused together, the correct amount of pressure must be applied at the point of

axis in the piece’s rotation the moment the pieces are allowed to spin. The pressure must hold the two pieces together until the seam is cooled and the two pieces are fused. Applying proper pressure to the right point is crucial, because the amount of pressure applied to the two pieces can either help create a strong fusion or can shift the two pieces if the pressure is uneven, making the pieces fuse unevenly or even breaking the seam. There are only a limited number of materials conducive to spin or friction welding. Soft plastics cannot withstand the force created by spin welding, nor can they handle the heat generated by the creation of friction.

Metals are not conducive to the process either, as the process does not generate enough heat to efficiently create the friction needed to fuse the two pieces securely.

Any high-speed machine that functions by using one stationary piece along with one spinning piece may be used as an agent in the process of spin welding. Lathes, drill presses, or specialised spin welding apparatuses may be used to effectively fuse two thermoplastic pieces together.

In order for this to be successful, however, the user must first have knowledge of any materials that are used and the machines used to complete the process. The user must also be thoroughly trained in the spin welding process to be successful.

Atomic Hydrogen Welding

Atomic hydrogen welding is an arc welding process that uses an arc between two metal tungsten electrodes in a shielding atmosphere of hydrogen. The process was invented by Irving Langmuir in the course of his studies of atomic hydrogen. The electric arc efficiently breaks up the hydrogen molecules, which later recombine with tremendous release of heat, reaching temperatures from 3,400–4,000°C. Without the arc, an oxyhydrogen torch can only reach 2,800°C. This is the third hottest flame after cyanogen at 4,525°C and dicyanoacetylene at 4,987°C. An acetylene torch merely reaches 3,300°C. This device may be called an atomic hydrogen torch, nascent hydrogen torch or Langmuir torch.

The process was also known as arc-atom welding.

The heat produced by this torch is sufficient to weld tungsten (3,422°C), the most refractory metal. The presence of hydrogen also acts as a gas shield and protects metals from contamination by carbon, nitrogen, or oxygen, which can severely damage the properties of many metals. It eliminates the need of flux for this purpose.

The arc is maintained independently of the workpiece or parts being welded.

The hydrogen gas is normally diatomic (H2), but in cases where the temperatures are over 600°C (1,100°F) near the arc, the hydrogen breaks down into its atomic form, simultaneously absorbing a large amount of heat from the arc. When the hydrogen strikes a relatively cold surface (i.e., the weld zone), it recombines into its diatomic form releasing the energy associated with the formation of that bond. The energy in atomic hydrogen welding can be varied easily by changing the distance between the arc stream and the work piece surface. This process is being replaced by shielded metal-arc welding, mainly because of the availability of inexpensive inert gases. In atomic hydrogen welding, filler metal may or may not be used. In this process, the arc is maintained entirely independent of the work or parts being welded. The work is a part of the electrical circuit only to the extent that a portion of the arc comes in contact with the work, at which time a voltage exists between the work and each electrode. prateek.sur@network18publishing.com

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Metal Inert Gas Welding

A metal-friendly welding option Metal Inert Gas (MIG) welding, as the majority of us are aware, is a semi-automatic arc welding process in which a constant, consumable wire electrode and a shielding gas are fed through a welding gun. At the end of the weld gun, there is a contact tip, which passes electricity to the wire. Both the wire and shielding gas are activated to create the weld when the operator depresses the trigger of the gun. One of the most important forms of welding, MIG has a lot of benefits but it also has some shortcomings.

PRATEEK SUR

G

as Metal Arc Welding (GMAW), now and then, is referred to as Metal Inert Gas (MIG) welding or Metal Active Gas (MAG) welding, which are its subtypes. It is a welding process in which an electric arc forms between a consumable wire electrode and the workpiece metals. Therefore, it heats the workpiece metals and causes them to melt & join. Along with the wire electrode, a shielding gas feeds through the welding gun, which shields the process from contaminants in the air. MIG welding has many distinct properties and corresponding advantages and limitations.

The Pros

MIG welding is fairly accepted as it is simple to learn and calls for no extraordinary skills. Even a firsttime operator will be able to attain a good weld with the least amount of practice. Welders favour MIG welding as it is faster than stick welding and saves time. Thus, the operating cost of MIG welding is lower than that of stick welding because of this crucial factor, i.e., it saves time. Also, MIG adjusts to limited electrode length, which allows for longer welds with fewer interruptions.

Besides, there is also no waste of filler metals. Generally speaking, thinner materials can be welded far more easily with MIG than with stick welding. Another reason why MIG welding is favoured is because MIG welding is a tidy process and does not

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require chipping slag as in the case of stick welding. MIG certainly makes for very convenient weld tacking and fitting of parts; there is very scant stub loss due to the continuous spool of filler metal.

MIG welding is versatile and capable of a variety of applications, including trailer hitches, auto body repair and restoration, farm/ranch equipment, household projects, repairing wheel barrows, bicycles, etc.

This type of welding demands lesser time as compared to other types of welding processes.

The Cons

The preliminary cost of MIG set up is high in view of the regulators and shielding gas—though some MIG welding may be done with a selfshielding flux core and without gas or

a regulator. It is a fact that all types of material can be welded with an MIG machine. However, in the MIG process, different materials require different wire and gases. For instance, mild steel can be welded with either a self-shielded wire or with CO2 or a CO2 mixed gas, but aluminium material requires the use of argon gas.

Also, it is inadvisable to weld through dirty materials using MIG machines. It is said one should always weld on the cleanest possible material; so for best results, scrape off paint, rust or other debris where the weld is being made. There is no denying that MIG welding equipment is more complex, expensive and less portable.

Besides, the welding gun is difficult to manoeuvre. Filler metal can get tangled within the wire feeder, which will not only annoy the operator but also add to the downtime. The welder has to patiently keep leads and liners in a straight position to allow for proper feeding of filler metal.

Finishing Touches

When an electrically charged wire is fed into the welding arc, then it is called MIG welding. MIG is commonly preferred because the welding leads are very easy to perform. As a matter of fact, it is said that even robots can be utilised to get the mechanical job done.

MIG welder is capable of working with almost all kinds of metals, though aluminium and mild steel are the most popular ones. prateek.sur@network18publishing.com

Plasma Cutters & Blowtorches

PRATEEK SUR

P

resently, all industries depend on the handling of heavy metal and alloys.

Companies need metals to build the tools and transportation essential for everyday business. For example, companies

build cranes, cars, skyscrapers, robots and suspension bridges out of accurately shaped metal components.

The reason for using metal is evident— metals are tremendously strong and durable, and so, they are the rational selection for most things that require

Every manufacturing process needs to have a welding process in place so that it can function. But the processes of welding have remained the same since a considerably long time. In this new millennium, there has been slow but steady evolution of new forms of welding, which are more energy efficient, more environmentally friendly and, above all, easily affordable. Plasma cutters and blowtorches are two such new-age evolutions of the welding process, which have slowly crept into the hands of every welder. Let’s see why...

Cutting-edge Technologies

to the rescue

to be particularly big, principally sturdy, or both. Strangely, a metal’s strength is also its weakness! Because metal is so good at opposing damage,­ it is very hard to manoeuvre and form into dedicated pieces. So, the question that arises here is: how will companies precisely cut and manipulate the metals to build something as huge and as strong as an airplane wing? Also, what will companies do in order to curb the usage of electricity and opt for environmentally friendly processes?

Let’s find out…

Plasma Cutters

Plasma cutters is a widespread tool that has been around in small spurts and braces since World War II. Theoretically, a plasma cutter is exceptionally simple. It gets the job

Commonplace Plasma Roughly 99% of all substances in the universe are plasma. It is not common on Earth because of its extremely high temperatures; but somewhere like the sun, it is the norm. On Earth, it is found in lightning, among other places.

Plasma cutters are not the only devices to harness the power of plasma. Neon signs, fluorescent lighting and plasma displays, to name a few, rely on it to get the job done. These devices use ‘cool’ plasma. Though cool plasma cannot be used to cut metals, it has tonne of other useful applications. done by harnessing one of the rifest states of matter in the evident universe.

Nowadays, companies are cutting through the mystery surrounding the plasma cutter and seeing how one of the most enthralling tools is shaping the world.

Blowtorches

A blowtorch is one of the most charming and appealing welding

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Plasma Cutters & Blowtorches

Welders Scarce In the present day, there is a vast and growing need for welders. During the past 20 years or so, welding has become an unpopular career choice.

The ‘Wall Street Journal’ suggests that young people entering the workforce are deferring to more white-collar, less dangerous professions. This means that knowing how to weld pays big bucks in the current market. equipment to watch. The showers of illuminate sparks that are discharged from a blowtorch at work are persuasive. These fireworks are easy to attract attention, but the welder should not let the pyrotechnics draw him/her too close as these sparks are actually small pieces of molten metal that spit off during cutting and welding.

What is Plasma?

If a gas is boosted to extremely high temperatures, plasma is formed. The energy instigates to break apart the gas molecules, and the atoms begin to split.

Normal atoms are made up of protons and neutrons in the nucleus, bordered by a cloud of electrons. In plasma, the electrons break up from the nucleus.

Once the energy of heat liberates the electrons from the atom, the electrons start to move around rapidly. The electrons are negatively charged, and leave behind their positively charged nuclei known as ions. When the fastmoving electrons collide with other electrons and ions, they release vast amounts of energy. This energy is what gives plasma its exclusive status and incredible cutting power.

Plasma cutters @ work

Plasma cutters are now a staple of the industry. They are used principally in conventional auto shops as well as by car manufacturers to tailor-make and produce chassis and frames.

Construction companies use plasma cutters in large-scale projects to cut

and fabricate huge beams or metal sheet goods. Locksmiths use plasma cutters to bore into safes and vaults when customers have been locked out.

Blowtorch on the job

Blowtorches produce an exceptionally hot flame and harness that heat to mould and cut metal. It does this by using highly combustible gases in the right proportions, which means that it is also a dangerous tool. Improper pressures, mishandling of the equipment, excessive sparks and messy workshops can all lead to fires, or even fatal explosions. The invention of the blowtorch in the late 19th century thrilled pyromaniacs everywhere and revolutionised the process of welding.

The earliest known evidence of welding, or connecting metal pieces by applying heat, dates back to more than 3,000 years. By the middle ages, the process was significantly developed, and blacksmithing was a common profession. A blowtorch made it easy to cut and weld metal more precisely by focusing a high temperature on a small point. Welders and plumbers are not the only ones who use these firebreathing machines. Regular folks may keep them around the house for various tasks including lighting cigars, mending jewellery and even cooking.

Inside a Plasma Cutter

Plasma cutters come in all shapes and sizes. There are monstrous plasma cutters that use robotic arms to make precise incisions and there are compact, handheld units that you might find in a handyman’s shop. Regardless of size, all plasma cutters function on the same principle and are constructed around roughly the same design.

Plasma cutters work by sending a pressurised gas, such as nitrogen, argon, or oxygen, through a small channel. In the centre of this channel, a negatively charged electrode is present. When power is applied to the negative electrode, and the tip of the nozzle to the metal is touched,

the connection creates a circuit. A powerful spark is generated between the electrode and the metal. As the inert gas passes through the channel, the spark heats the gas until it reaches the fourth state of matter. This reaction creates a stream of directed plasma, approximately 30,000⁰F (16,649⁰C) and moving at 20,000 feet per second (6,096 m/sec) that reduces metal to molten slag.

The plasma itself conducts electrical current. The cycle of creating the arc is continuous as long as power is supplied to the electrode and the plasma stays in contact with the metal

Welding Growing Pains The atoms in a solid object are far from stationary—they constantly vibrate. In fact, they vibrate more intensely as their temperature rises.

When this happens, the repulsion between the atoms outweighs their attraction, which means that they spread farther apart and the solid expands in volume. This effect, called thermal expansion, makes it easier to open the lid to a bottle after it has been run under hot water.

However, this process inevitably causes problems for welders. When only one side of a piece of metal is heated and then cooled, the whole thing becomes warped and misshapen. That is why welders make sure that they heat the entire piece of metal uniformly before they begin. that is being cut. In order to ensure this contact, the welder should protect the cut from oxidation and regulate the unpredictable nature of plasma; the cutter nozzle has a second set of channels. These channels release a constant flow of shielding gas around the cutting area. The pressure of this gas flow effectively controls the radius of the plasma beam. prateek.sur@network18publishing.com With inputs from Abhinav Sood, Sales Leader, Hypertherm India

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Weld Metal

How to avert Porosity?

Porosity is a weld defect that is quite widespread, but reasonably simple to fix. There are several factors that contribute to weld porosity. Here’s enlisting some of these factors that would give a welder a fairly good idea of what could be the root cause of the problem and how he could use gas flow, material conditions & consumables to avert the defect...

PRATEEK SUR

W

eld metal porosity may often feature in a weld bead, but it is not really a welcome sight. Porosity is weld metal infectivity, which is caused due to the trapped gas in the weld. Shielding gases and many other gases are released when the weld torch is applied to treated metal. These gases are absorbed into the molten metal and then released.

All this happens during the process of solidification. In other cases, the shielding gas does not wholly arrive at the weld pool. In this case, the atmospheric air unfavourably has an effect on the weld bead. Substantiation of porosity comes in the shape of rounded holes called spherical porosity.

The imperfection might be called wormholes or piping, if the holes are extended. Porosity is, at times, called a serious defect, because many-a-time the porosity level is fairly acceptable.

Porosity becomes a cause of weld reject, if the welding code or standard is not maintained. Fortunately, porosity is an imperfection that has a fairly accurate

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90% prevention rate.

If some common tips are rigorously followed, then many of the possible causes of porosity would automatically turn from being rejected parts to becoming accepted weldments under most of the common welding codes of conduct.

Likely Porosity-associated Problems

From the commonest to the slightest, some of the reasons of porosity in welds are: The cylinder is out of gas—a common occurrence.

Air or a draft of some kind disturbs the delivery of the shielding gas during the welding process.

Overhead or floor fans even as far as 25 feet away can wreak havoc on the gas delivery. Welders also need to be aware of open doors and air being discharged from machinery.

These drafts, if more than 4–5 miles per hour, can affect Shielded Metal Arc Welding (SMAW) and Flux-Cored Arc Welding

(FCAW) operations.

The presence of moisture can lead to problems. It might be simple water or morning dew, but also could be condensation from welding on heavy plate and lap joints, which might occur particularly when temperatures reach below 50oF. The easy fix is to preheat the metal to 200o–220oF to evaporate the moisture.

Plugged or restricted Gas Metal Arc Welding (GMAW) gun nozzles— typically from weld spatter—impede the delivery of shielding gas. To rectify this obstacle, the welder needs to look at the nozzle opening before starting a weld. This doublecheck might prevent weld spatter from falling into the weld.

The weld nozzle is held too far from the weld puddle. The volume of shielding gas reaching the weld is diminished, and dilution of the shielding gas with the atmosphere severely affects the weld.

The GMAW gun is laid at an angle that will spread the gas flow

Weld Metal

Advice for Welders What type of welding machine works best for allround use?

Any welding machine with an AC/DC output works well. It can either be an electric arc machine or a gas engine drive. DC welding offers advantages over AC for most stick applications. Some of them are: easier starts; fewer arc outages & sticking; less spatter/better looking welds; easier vertical up & overhead welding; a smoother arc and, also, easier to learn ‘how to weld’.

DC reverse polarity (electrode positive) provides about 10% more penetration at any given amperage than AC, while DC straight polarity (electrode negative) welds thinner metals better.

Does an AC output have any advantages?

Yes, if the individual needs to weld on material that has becomes magnetised from friction. A very common example could be the rubbing of hay/feed/ water constantly against any steel part of the product.

A DC output will not work because of ‘arc blow’. In this, the magnetic field blows the molten filler metal out of the weld puddle. On the other hand, an AC output alternates between polarities, therefore, it enables the user to weld magnetised parts.

How big a welding machine is considered necessary?

A 225–300 ampere machine can handle just about anything that an average user may come across. Most of the stick welding processes require 200 amperes or less. In order to weld material, which is thicker than 3/8 inches, it is advisable to simply make numerous passes.

Most professionals also prefer this even while welding on 1-inch thick structural steel.

The words ‘duty cycle’ appears on most product specification sheets? What does it mean?

In a 10-minute cycle, the number of minutes a user can operate is the ‘duty cycle’. For example, if a welding machine creates a 200 ampere DC output at 20% duty cycle, it means it can weld constantly at 200 amperes for two minutes. Hence, it needs to cool down for 8 minutes in order to prevent overheating. Duty cycle and amperage are inversely proportional in the new-age welding machine, which was not a norm in

the past. For example, a welding machine operating at 90 amperes and 100% duty cycle means that the user can weld without stopping. This inversely proportional rule is still not applicable to all welding machines.

What type of rod should an individual use for hard facing?

Hard facing rods are endowed with impact resistance, abrasion resistance or both depending on the usage, function and application. The type of rod requisite for any welding depends on the type of soil or aggregate in that area. So, it is advisable to contact local welding supply distributors and ask for their expert opinion.

What type of rod should an individual use for general work on steel?

Universally used electrodes for wide-ranging applications include 6010, 6011, 6013, 7018 and 7024, each of which has specific properties; for instance, 6010 electrodes penetrate deeply, while 6013 electrodes penetrate less. For better bead appearance and work on higher strength steels (say for a hitch), the individual should use a 7018 rod. For better penetration on thick material, it is advisable to grind the joint to a 30⁰ bevel (a nickelwidth land on the bottom of the groove should be left) and make multiple passes. On the other hand, make the first pass with a 6010 rod, and then make a ‘cap’ with a 7018.

The 7024 rod is possibly the simplest to use and most trouble free. This is more commonly known as a ‘drag rod’. This electrode’s thick flux involuntarily maintains the correct arc length, and therefore, allows the individual to drag the rod directly along the workpiece.

Is it necessary to remove rust or oil before welding?

Welding is more pardoning on dirty conditions, but it never hurts to clean parts with a wire brush or grind off excess rust. If the user prepares well and has an average welding ability, then the individual would make a sound weld. However, even immense welding skills cannot prevail over poor groundwork. Poor preparation can lead to cracking, lack of fusion and slag inclusions.

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particular is like a sponge. Once the Cleaning solid wire and flux-cored out and actually suck in the container is opened, the welder wire with wire wipes and GTAW atmosphere from the back side, should store the package according fillers with steel wool is a good idea. opposite the nozzle direction. A to the manufacturer’s directions.

5o–15o angle, perpendicular to the Contaminated GMAW gun liners joint, is an acceptable angle for can introduce unwanted elements The gas flow is too high. Gas flow of forehand or backhand methods to the weld pool. All the grease, 50-60 Cubic Feet Per Hour (CFH) with GMAW or FCAW guns and oil, dust, and dirt found in the at the GMAW nozzle and 20–30 SMAW electrodes. shop environment collects on the CFH at the GTAW torch should wire and ends up in the guns whip be sufficient. If not, then it is a Paint, grease, oil, glue and liner.

Stainless steel and questionable doubt. Wide-open gas sweat release large volumes of gas high-nickel-alloy wires are especially flow at the nozzle actually creates when exposed to arc welding susceptible to attracting these turbulence and can pull outside air temperatures. This is especially true contaminants. into the weld zone. Additionally, it with solid-wire GMAW and Gas is a terrible waste of gas and adds Tungsten Arc Welding (GTAW), GMAW right on the edge of an outside unnecessary cost to the project. The but FCAW and SMAW processes corner joint might create problems only exception might be if the are vulnerable as well. The flux given the awkward position of the shielding gas contains more than makeup was not designed to handle nozzle. The nozzle often does not 50% helium. such contamination. cover the joint properly, causes turbulence and draws in outside air When mill scale and rust are welded A pinched or smashed gas hose does into the weld joint. over, decomposition gases are not deliver the shielding gas formed, and oxidation begins, properly. If the gas hose is more If the weld joint is open at the root, it which can involve the will suck in air from the presence of moisture. back side. Unprotected In one real-world example, a hose was grabbed from a The strong possibility of liquid metal can absorb air storeroom to repair a cut hose that was attached to the wire cold lapping and lack of easily. feeder. Unfortunately, a bug had built a nest in the hose fusion at the weld toe

The welding gas while it was sitting undisturbed in the storeroom. In another also exists. When a itself could be contaminated. example, an air hose that was previously used as an air line metal oxidises, it is no If the welding gas is for a tool on a line with an oil lube system on it was quickly longer truly a metal and a suspect, the shop needs connected to the welding equipment only to find out later cannot be expected to that the hose was full of air tool oil. the gas supplier to certify respond to welding the that the gas has the correct same as a metal, especially when dew point. than 20 feet long, the possibility of welding flux is not used. it kinking is good.

A contaminated gas hose could be a culprit, in particular, hoses Plating compounds with zinc, such as Improper use of anti-spatter that have been used for other in the galvanisation process, can compounds, sprays, or gels can be a activities prior to being used in a create a problem. Zinc melts at major contributor to porosity. welding application. approximately 420oF. At welding When used in excess, the antispatter material becomes a temperatures far in excess of Damaged O-ring seals on the GMAW contaminant, boiling into a gas 2,000oF, zinc changes from a solid gun whip where it plugs into the when exposed to the high wire feeder or the GTAW torch to a gas in a fraction of a temperatures of the welding arc. cap where it screws into the torch second. Also, zinc dust is a Also, jamming the GMAW gun could introduce unwanted air into byproduct of the welding process. into a container of anti-spatter gel the welding process.

The release of both gases and dust can result in the gel dripping back make welding galvanised metal an Cut or burnt hose anywhere from the into the weld puddle. However, an unpleasant experience. regulator flowmeter to the operator should use the anti-spatter connection at the feeder could SMAW electrodes, FCAW electrodes material properly. create issues. and Submerged Arc Welding (SAW) flux absorb moisture in an Weld filler metals contaminated with A defective gas solenoid at the wire unprotected environment. To paint, grease, oil, tape and glue can feeder or the GTAW machine is a address moisture in the welding release gases when exposed to the possible contributor to conditions process, codes are pretty clear about very hot welding arc. Even dirty that create porosity. the use of dryers and ovens to store gloves used during GTAW can these materials. SAW flux in contaminate the consumables. prateek.sur@network18publishing.com

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Robotic Automation

Devyani P Korgaonkar

I

ndia, a populous country, has been facing a major crisis of skilled welders and the manufacturing fraternity is struggling to find a fitting solution. If we look back 20 years down the line, India remained underdeveloped till 1992. And by the time the country adopted new ways & liberalisation policies, it was too late for the nation to become a manufacturing economy, especially as compared to China—a country, which is ahead of us by 15–20 years, owing to its quick decision making ability. Elaborating further on the same, VS Agwan, Regional Director, Indian Institute of Welding (IIW), comments, “Indian enterprises engaged in manufacturing activity were formally driven by ‘import substitution’. However, a small

minority section of engineers could not cope up with the new environment.

The bigger industries survived and thrived to some extent, while the skilled engineers in India took up IT jobs for better salaries, freedom and comfort of working.”

Over the last 20-year period, i.e., since 1993, most engineers from different disciplines, who were supposed to help the nation marching towards progress on all the fronts and fields of the economy, remained unavailable to the manufacturing sector. Agwan explains why. According to him, “Today, everybody complains about the unavailability of employable engineering skills at all levels. However, one needs to understand here is that the situation would have been different had we, as a nation, advocated systematic building

up of these skills sets. The cumulative result is in front of us as a crisis of tremendous shortage of employable skills and talents everywhere. Fortunately, the Government of India has woken up to the situation. It has announced a `75,000 crore fund for the National Skills Development Programme, an established cell in Prime Minister’s Office, to be headed by S Ramadorai, Adviser to the Prime Minister of India in the National Council on Skill Development.”

Why Opt For Robotic Automation Welding?

Mechanisation, automation & robotisation are the three needs of the industry during this crisis hour.

There are 103 welding techniques, but the manufacturing sector seems

Solution to the

manpower shortage riddle

Courtesy -www.fabricatingandmetalworking.com

The entire manufacturing sector across the world is reeling under tremendous dearth of skilled welders and welding engineers. Major projects across India have either been delayed or are in a stagnant stage as professional welders are hard to find & employ. India currently needs more than two lakh welding engineers to run some of the vital projects nationally. However, it is not possible to churn out such a huge number of workers overnight. As a solution to this grave problem, the welding industry explores whether robots designed and programmed by leading automation companies can work as an alternative!

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Robotic Automation

an automobile manufacturing plant extremely enthusiastic about robotic automation in the welding industry adopting Global Body Line for its welding automation. Commenting would be at 100% per annum if not manufacturing plants across the world. on the utmost utility of robotic more, remarks Sinha. “The profitability When the volumes are low, Indian automation, Akshat Sinha, Executive of the business at this time for a robot plants follow the similar practices Director, ATE Welding Engineering, user is primarily non-tangible from the followed by the West, i.e., they use Robotics & Automation Pvt Ltd, time it is functional at his premises. As human operators at the station where avers, “Advanced welding processes far as the monetary aspect is concerned, robots are being used. But when the offer superior welds for specific joints typically, the break-even for highproduction volumes grow and reach a and independent applications. The use productivity products can be as low as critical mass, the unskilled workers will of a robot, on the other hand, allows 12–15 months and may go up to 24 surely be replaced by robots.” the user to tightly control various months for low productivity products. parameters required for a good welding.

In specific cases, customers invest in These include very complex features robotic automation even if the breakRobotic automation to the rescue such as weld geometry monitoring, even point is ahead of 24 months (in Robotic automation can solve the correction of weld parameters in real cases where they have specific interests skilled worker shortage; limited to time and varying weld specifications including the creation of a world-class specific product areas. “But this rule dynamically, among others. While it setup to attract foreign investors, quality cannot be generalised across products is not possible to entirely replace the certifications, simplifying product and product lines,” believes Sinha. hand-eye coordination that engineering process, etc.),” a human welding operator Sinha continues.

Mechanisation, automation & robotisation are the three can offer, the use of a robot “The time is not far needs of the industry during this crisis hour. There are 103 welding techniques, but the manufacturing sector seems comes remarkably close to when we will be able extremely enthusiastic about robotic welding automation. this application.” to make affordable Robotic automation robots having cameras offers scalability and flexibility— According to him, in cases where to facilitate hand-eye coordination. the advanced utilities that are rarely high productivity with repetitive While something remarkably close to available with other independent welding application is required, robotic this technology is available even now, advanced welding processes. To automation can contribute extensively the price of such products becomes a this, Sinha adds, “With increasing considering that a welding robot does deterrent to over 90% of customers. shortage of skilled manpower and its not get tired, never loses efficiency and With technology becoming cheaper availability becoming a constant threat, never takes a day off. “However, where and more affordable, the welding the demand for this technology in the extreme skill is required and limited robot will soon find its place Indian welding industry is experiencing to variable product lines, sizes or among most SMEs across India,” a sharp increase. The influx of inquiries product geometry, it may be difficult Sinha adds. is quite high now and we are unable to to replace the human skill with robotic We have reached our present stage cope with the demand in the market.” automation,” Sinha opines. Agwan, owing to the cumulative and collective who, on the other hand has a different human actions that have taken place take on this, avers, “Today, in complex over a period of time. Likewise, the But do we have the manufacturing operations, the robot is corrective actions will also evolve over infrastructure? earmarked and deployed at a point. a period of time out of cumulative Though robotic automation is the The alternate job is planned for that and collective human actions. need of the hour, most Indian manpower to become tutors and Agwan concludes, “There cannot manufacturing companies do not monitors for robots. All these high be a simple answer to this problem have the infrastructure to install levels of instrumented automated of large unemployed population, and handle the function efficiently. production setups require similar levels but one cannot ignore the fact “The investment costs of the robot of efficient supporting services and that a large number of labours, or any automation adopted by the logistical help of that calibre—from lacking the technical knowledge industry is of very high standards. the infrastructure and resources. In are non-employable. All we need The system is not economically isolation, automation cannot work for is good governance that implies justified when it comes to volumes of any industry.” reduction of corruption in all walks production either in terms of quality of life.” or quantity,” Agwan says. Citing an instance, Agwan narrates, “A suitable What we really need is… example of a robot application can be The demand trend of robotic devyani.korgaonkar@network18publishing.com

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Cost-effective manufacturing methods

Arindam Ghosh

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terms of its resource base, rich pool of talented people and demographic advantage.”

However, “what we need is a political consensus among the government, civil society and industry to strive towards a policy and regulatory regime that is progrowth and an enabling environment that can attract more investments”, he points out. Further, referring to the low wage cost regime that India has, in

Illustration By Sanjay Dalvi

iven the level of competition that exists in the market today, manufacturing companies are constantly formulating strategies to remain competitive in their production process. It ensures stability, credibility and sustainability in the market. “By adopting cost-effective methods, India can manage its resources optimally,

Currently, scenarios like the Eurozone crisis, economic turmoil in the US (like the fiscal cliff) coupled with the lower cost competitiveness of China (due to rising wages and appreciating Yuan) and increased competition in the low-cost manufacturing segment is immensely impacting the global manufacturing landscape. Such a situation has created an opportunity for India to emerge as a global manufacturing powerhouse. However, for the country to make most of this scenario, the Indian manufacturing fraternity needs to opt for various cost-effective manufacturing methods like automation & robotics solutions, green technologies, digitisation along with autonomation. Adopting these will not only enhance their quality, productivity, safety but also ensure sustainability under the long-term horizon. focus on quality and price and look forward to capturing its legitimate share of the global market,” opines Ajay Shankar, Member Secretary, National Manufacturing Competitiveness Council (NMCC). Further referring to a recent report on Perception Analysis of CEOs developed by Deloitte on India, Shankar informs, “In terms of manufacturing capacity, India ranked fourth after the US, Germany and China. India has the capacity to emerge as the second best destination for manufacturing in the world in

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comparison to other major economies, Shankar informs that this is an advantage which “we should leverage for proliferating business ventures and attracting more investments”.

Additionally, Jayant Davar, Deputy Chairman, CII Northern Region and VC & MD, Sandhar Technologies Ltd, avers, “We have to focus on quality, price competitiveness and a clean environment. Automation, other than reducing the drudgery, can reduce emission of pollutants and get India to the desired position in manufacturing.”

Cost-effective manufacturing methods

According to Deep Kapuria, Chairman, AutoMach 2013; Chairman National MSME Council & Central Europe Committee, CII and Chairman, Hi-Tech Gears Ltd, to enhance the technological capabilities, green, clean and lean manufacturing is the order of the day for the Indian industry. Some of the important ways to ensure costeffective manufacturing include: Automation & Robotics Manufacturing has to be competitive

Cost-effective manufacturing methods

to survive in an increasingly global world. And automation is one of the critical inputs. Automation need not be restricted to only manufacturing but can be extended to transfer of material, accounting, logistics, etc.

However, we need to develop ‘India specific’ solutions “India can achieve 14% growth in manufacturing on a sustained basis, if we adopt automation to raise productivity and reduce costs,” informs Shankar. Emphasing on the role of automation he says, “Adopting automation and cost effectiveness is critical for Indian manufacturing to survive, grow and compete globally.

Today, cost effectiveness and the best use of energy is not just an option but a dire need because all markets and economies are open now.

Competitiveness along with price and quality are critical for the sustained growth of manufacturing.” Kapuria adds, “India’s target of raising the contribution of manufacturing to the GDP to 25% can only be achieved if we adopt automation, innovation, enable R&D linkages, enhance productivity, reduce costs, develop skilled labour and raise quality standards. Automation and robotics provides the much needed speed, reliability, safety, cost effectiveness & adequate use of energy and scarce resources.” Davar agrees, “Implementation of automation and robotics leads to higher precision, quality, safety and consistency.”

Green Technologies Today, sustainability and energy efficiency are emerging as the new mantras for a company to achieve competitiveness in manufacturing.

Over time, there has been a transformation in the thought process of the manufacturing fraternity for gaining competitiveness—opting for green equipment over its conventional forms. “These technologies may not have an immediate impact but they will have an impact under the longterm time frame. These solutions not only reduce your dependence on fossil fuels and bring down the level

of carbon footprint but also save the world for future generations,” Davar explains. In addition, it is increasingly becoming an integral part in most of the companies as they are realising the importance to do so, he adds.

Autonomation & Digitisation Highlighting the latest trend to remain competitive, Rajendra G Abhange, Technical Director, Gabriel India Ltd, informs, “There is a new concept called Autonomation, which is nothing but integrating of man and machines, which means automation with a human touch. Under the concept, you transfer the skills, which a man can do easily to the machine and keep with the man the intelligent part, i.e., the decision making ability.

If you combine them, it results in the formation of autonomation. Apart from autonomation, digitisation too can play an important role in helping manufacturers attain cost efficiency.

Giving a perspective on the same, Rajiv Bajaj, Head – MFG Solutions India & SAARC, Autodesk India Pvt Ltd, avers, “It is important to digitise the data that is available and then move towards automation. This will play a key role in making the process competitive.” Explaining the concept, he adds, “For instance, in terms of factory design through digitisation, we are able to design, visualise & simulate an entire factory and bring in changes or modify according to the requirements.”

Leveled & syncronised manufacturing Pointing out to another major concept, which is expected to gain popularity in the coming years, Abhange says that one of the biggest areas where companies are working is on, “leveled and syncronised manufacturing.” This is one technique, which the companies are practicing. It can reduce inventories, work in progress, scrap levels and reduce all the wastage happening in the complete value chain, and “I think that is going to be one of the major initiatives, which will be undertaken after automation,” he informs.

Lean manufacturing methods There is a programme launched by the government for the MSMEs: Lean Manufacturing Competitiveness Scheme (LMCS), which involves application of various new techniques—Lean Techniques (e.g. Total Productive Maintenance (TPM), 5S, Visual control, Standard Operation Procedures, Just in Time, Kanban System, Cellular Layout, Poka Yoke, TPM, etc.) to identify and eliminate waste, reduce manufacturing costs and be more productive.

Policy initiatives supporting competitiveness

The government has taken a lot of initiatives to make manufacturing competitive. Last year, the Union Cabinet approved the proposal to offer financial support for the development of Electronics Manufacturing Clusters (EMCs), which would aid the growth of the Electronics Systems Design and Manufacturing (ESDM) sector and thus help develop an entrepreneurial ecosystem, drive innovation and catalyse the economic growth of the region.

According to Chandrajit Banerjee, Director General, CII, “EMCs have potential advantages like increased productivity of the companies in the cluster, driving innovation, cutting down unproductive costs and reduction of costs through shared resources.”

Further, taking a strong step towards rolling out the National Manufacturing Policy in India, is developing the Technology Acquisition and Development Fund. The scheme is meant for acquisition of appropriate technologies including environmentfriendly technologies; creation of a patent pool; and development of domestic manufacturing of equipment used for controlling pollution and reducing energy consumption. This speaks volumes about the high level of awareness of the policy regulators towards improving competitiveness, thus ensuring a bright future for Indian manufacturing.

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Opinions & More

New-age automations

Automation technology was mainly being used in industries till the recent past to ensure quality consistency, increase efficiency & reduce overall production cost. Going beyond conventional use, today, the trend is to integrate manufacturing processes with IT by way of Manufacturing Execution System (MES) and Product Lifecycle Management (PLM), so that efficiency improvement is extended beyond the manufacturing process to the organisation’s complete value chain. Industrial automation is assuming greater importance in today’s world; its realm is no longer limited to the control of machines, energy or environment. For example, we were proudly associated with NASA in launching the latest Mars Rover ‘Curiosity’—designed by NASA’s Jet Propulsion Laboratory (JPL) using Siemens’ software—as a tangible example of how modern software technology is being employed to enhance competitiveness in aerospace.

Industrial automation technologies are increasingly becoming not only intelligent but also intuitive “At the heart of the development of new age automation is the desire to strike an optimum balance to ensure increased productivity, enhanced flexibility and improved efficiency,” explains Bhaskar Mandal, EVP & Head – Industry Automation Division, Industry Sector, Siemens Ltd, during a tête-à-tête with Prateek Sur. Excerpts…

The NASA team used Siemens’ PLM software throughout the development process to digitally design, simulate and assemble the Rover before any physical prototypes were built. The software ensured that all the components would fit together perfectly, operate well and withstand the environmental conditions during the mission.

Need-gaps

Improving productivity is a major challenge for manufacturers.

The automation level in India

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is approximately 50% lower as compared to the automation level in the developed economies and approximately 30% lower as compared to China. In developing markets, such as India, it has been observed that while well-known companies in the market are keen to implement automation technologies, the smaller players consider it to be expenditure and not investment.

To benefit from industrial automation, it is essential to develop a holistic view of implementing

automation in the entire production process rather than merely implementing it for a single purpose, such as energy efficiency or environmental regulations. Siemens’ has always focused on optimising lifecycle costs and drawing customers’ attention towards ‘total cost of ownership’. This will help customers decide on investments in automation.

So far, we are the only suppliers that can help customers cut time-to-market for certain products in half by using software and automation technology,

Opinions & More

while significantly reducing the costs associated with energy.

Challenges encountered

One of the challenges is integration of various automation platforms in a manufacturing environment to avoid ‘automation islands’. Siemens has always supported & promoted the concept of ‘Totally Integrated Automation’ (TIA). All Siemens’ automation solutions are based on TIA with a common engineering & open communication platform, which facilitate effective integration.

Another challenge for automation players is to understand customers’ processes and requirements and offer/ execute optimum solutions to meet these. Siemens extensively follows a vertical market approach by having market-specific products & solutions for focused industries like automotive, chemicals, food & beverages, glass, minerals, marine & shipbuilding, pharma and pulp & paper, among others. These industry verticals are handled by a team of competent sales/execution engineers having extensive application knowledge of that particular vertical. With an unmatched combination of automation technology, industrial control technology and industrial software, Siemens supports the entire value chain of our customers—from product design to production & services.

This results in the implementation of optimum solutions, leading to customer satisfaction.

Bhaskar Mandal is the Executive VP & Head of Industry Automation Division of Industry Sector, Siemens. He is primarily responsible for business development, sales & factory of control components, industrial automation systems, sensors and communication. He joined Siemens in 1992 prior to which he headed the marketing & R&D activities of an Indian IT company. Back then, he spearheaded Siemens’ entry into the Indian telecommunications market and played a key role in setting up the Telecommunication Factory at Salt Lake, Kolkata. In 1996, he was selected to join the Regional Strategies Department of CDS, Siemens AG in Munich.

In 1999, Mandal returned to Siemens India to head the Strategic Planning Department. Here, he was involved in various initiatives in strategy development, M&A activities, standardising business processes and designing customer satisfactions surveys. He was also instrumental in developing and implementing the shared services concept and e-business strategy for Siemens in India. In 2003, he moved to the erstwhile Automation & Drives Division in India as Head of the Channel Management Project. He has been heading the Industrial Automation Division since January 2009.

Known for coming up with creative solutions, Mandal has a participative management style with a propensity for taking firm decisions on critical business issues. Mandal is a member of the Executive Council of the Indian chapter of the Alumni Association of IMD, Switzerland, as well as a member of the Alumni association of ISB, Hyderabad, India. He also regularly participates as a guest lecturer and project evaluator in the management learning programmes for Siemens’ business managers. provides an online overview of the automation devices’ operational status.

The exchange of communication ensures maximum availability and reliability of plants & machines. Such easy-to-manage, real-time, analytical tools can be utilised by industry professionals that, in turn, enable them to optimise the usage of resources and increase productivity.

Global growth

Nowadays, automation technologies are increasingly becoming not only intelligent but also intuitive. To create an efficient production process, it is essential that all the devices used during the production process are seamlessly connected. The Siemens TIA Portal has a powerful graphical engineering framework, which acts as a single software with one common user interface. The TIA portal always

These innovations are not restricted to only one area of automation. The electrical systems like motor control centres are also getting integrated into automation systems with the help of automation capable devices like SIMOCODE, Sirius Innovations, etc.

Sirius Innovations, for example, offer a unique and comprehensive portfolio for every industrial control application occupying a smaller footprint, which translates into less energy consumption, higher productivity and time-saving offering CAx data for plug and play. This illustrates that product innovations at all ends of the manufacturing spectrum enable customers to manage complexities more productively and efficiently.

Opportunities & Trends

Up close & personal Your hobby?

Cooking You are passionate about?

Music & travelling

Today, the opportunities available for automation in India across various verticals are growing multifold due to various factors. Increasing population, present lower per capita consumption and increasing purchasing power are driving the demand upwards across

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Opinions & More

various verticals. On one hand, the opportunities are on account of additional capacities being put in place to meet the growing demand. On the other hand, the level of automation, which is relatively low in India as compared to global standards, itself, is being redefined upwards.

Additionally, new automation technologies & concepts are widening the coverage of automation into more & more applications and more & more verticals under the umbrella of automation. At the same time, existing facilities also need support for expansion, modernisation & optimisation. All in all, the environment is encouraging for automation industry players in India.

From a technology perspective, we look at automation systems with enhanced diagnostics, which, in turn, help reduce downtime. New motor management systems introduced by Siemens have enhanced diagnostic features to reduce downtime and improve productivity. Also, the

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convergence of Internet with automation systems is shaping a new range of Internet-compatible automation systems that help monitor KPI of production facilities across the world from a single location, further reducing complexities in optimising productivity.

Impact on the manufacturing sector

Today, the manufacturing sector has to launch new products featuring top quality on global markets in ever shorter time periods and at attractive prices. The only way to ensure success throughout the entire production lifecycle is the application of highly efficient PLM. Seamless interaction with the factory lifecycle management represents a further decisive success factor.

Therefore today, ‘digital factory’ and ‘digital engineering’ are increasingly being focused on globally; automation is at the heart of this

technology. Optimisation of the production process is being realised by simulating the processes in ‘digital factory’, whereas ‘digital engineering’ software facilitates the seamless transfer of the digital factory into the real production factory and thus sets new automation standards in terms of machine and factory engineering.

This is one of the most significant trends, which will seamlessly integrate processes from product design to production, thereby making the entire lifecycle highly efficient.

Automation can help the Indian manufacturing sector to become competitive by improving productivity, quality consistency and flexibility of the manufacturing process, reducing time-to-market and also helping manufacturers meet safety & compliance requirements. Automation, in short, is a great enabler to achieve operational excellence. prateek.sur@network18publishing.com

Opinions & More

Role of solar in the long term

Solar energy has a definite role to play in the energy mix of India; there are a few reasons for this. First is the decline in the prices of solar PV equipment and the resultant levelised cost of energy from the grid connected solar projects.

Today, developers are willing to sign up for levelised power tariffs in the range of `6.45/kwh to `8/kwh in various Indian states, thereby significantly reducing the gap in pricing with other modes of generation. Moreover, India has an excellent solar resource.

Secondly, the low gestation period of solar Photovoltaic (PV) projects, which are typically one year as compared to four years for a coal-based power project, gives developers the benefit on time to market the power.

Thirdly, the demand-supply gap on domestic coal has increased; today we have a 25% shortfall in supply of coal for power generation. The availability of domestic natural gas has sharply declined creating stranded assets.

Overall, the dependence on imported fuel for fossil power generation has gone up steeply. Finally, is the steep escalation and volatility in prices of imported fossil fuel. In the past three

We see India as a long-term sustainable

solar PV market

“The Indian market has a unique combination of good solar irradiation, high energy demand and good policies, which would incentivise renewable energy to be deployed on the grid via Renewable Purchase Obligations (RPOs) and Generation Based Incentives (GBI),” informs Sujoy Ghosh, Country Head, First Solar, India, during an interaction with Arindam Ghosh. Excerpts… years, we have witnessed over 100% rise in prices of imported coal, and an even higher rise in the pricing of imported natural gas, significantly increasing the dispatch risk of projects using imported fuel. Further, with other options like hydro and nuclear having very long gestation periods and permitting risks, solar energy has a role

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to play as a mainstream power solution in the energy mix of India.

Experience in Indian market

Our experience in India has been very positive. The Indian market has a unique combination of good solar irradiation, high energy demand and good policies, which would incentivise

renewable energy to be deployed on the grid via Renewable Purchase Obligations (RPOs) and Generation Based Incentives (GBI). These factors combined with the country’s need for energy security makes solar energy a natural choice for the energy mix for India. Hence, we see India as a longterm sustainable solar PV market.

Opinions & More

Distinguishing features

Our key differentiator is the proven ability to maximise customer value through advanced technology solutions and minimise investment risk by offering a bouquet of services around the technology offering with a single point ownership. Our integrated power plant solutions deliver an economically attractive alternative to fossil fuel electricity generation today.

With vertically integrated capabilities improving every aspect of the solar value chain, First Solar provides PV energy solutions to address contemporary energy needs. Our PV energy solutions include utility-scale generation, industrial power and fuel displacement solutions.

With over 7 GW installed worldwide, and capabilities spanning the entire solar value chain—including project development and finance, grid integration and plant yield, module manufacturing, balance of systems technologies, engineering & construction, and operations & maintenance—we provide the most comprehensive PV energy solutions to our customers, which ensure that power plants deliver the desired energy profile & cost structure and are optimised for project-specific economics. By applying our knowledge, experience and technical excellence, we maximise value and mitigate risk for our customers.

Technological advancements

We are working to continuously improve reliability, availability and maintainability of utility scale solar PV plants. We have an ongoing programme to enhance efficiency and reliability of our PV modules and also simultaneously work on complementing the enhancements on modules with matching innovations on the BOS design and components to offer more reliable and efficient power plants.

On the modules, we have set a new world record for Cadmium-Telluride (CdTe) PV module conversion efficiency, achieving a record 16.1%

total area module efficiency in tests confirmed by the US Department of Energy’s National Renewable Energy Laboratory (NREL). The new record is a substantial increase over the prior record of 14.4% efficiency, which the company had set in January 2012.

We have also set a record for CdTe Open Circuit Voltage (VOC), a critical parameter for PV performance, reaching 903.2 millivolts (mV) in NRELcertified testing. This new record marks the first substantial increase in CdTe VOC in over a decade of international R&D. Further, in the BOS space, we are introducing tracker solutions that enhance capacity utilisation factors, and are also working with leading inverter manufacturers to create higher voltage systems that will lower quantum of components being used, thereby lowering cost/watt installed.

domestic content requirement

We believe that restricting imports through measures such as local content requirements only serves to raise prices, limit solar adoption and hinder the growth of domestic solar industries, in

Policy initiatives required

Our efforts should be directed towards creating demand for solar energy by encouraging deployment of solar power generation. That will help drive capacity creation across the industry value chain not just in cell/module manufacturing but also in areas of localisation of BOS components, engineering, O&M and project development. The key will be to enforce existing policies like RPO and create a T&D infrastructure that matches the generation capacity creation, and allows export of solar energy from resource rich areas into demand centres as well as makes debt capital available at prices that ensure sustainable investment.

Major international projects

First Solar has engineered, constructed and operated many of the world’s largest and most advanced PV power plants. It is currently executing one of the largest contracted solar project pipelines in the world (nearly 3 gigawatts). Some of the notable projects in our portfolio and contracted project pipeline include Desert Sunlight Solar Farm, California,

With over 20 years of industry experience, Sujoy Ghosh, has worked in a diverse range of businesses with a knowledge base extending from T&D to thermal power generation and renewable energy. At First Solar, he is responsible for advancing and executing business strategies for overall expansion of the market for utility-scale solar PV power plants and value delivery to Indian solar power producers. Prior to First Solar, Sujoy played eminent roles at GE Energy and Tata Honeywell. which manufacturing plays a relatively minor role in overall economic value creation. We support India’s efforts to become a world leader in solar power generation, and we believe India’s longterm interests will be better served by creating a stable policy environment that supports the broader growth of the industry value chain, which will provide ample opportunities for both domestic and global competitors.

Open markets, low-cost financing and consistent, bankable government policies are the best path to ensure local solar investment and job creation.

USA – 550MW (AC). When completed in 2015, Desert Sunlight will power about 160,000 homes annually. Also, there is Topaz Solar Farm, California, USA – 550MW (AC), which will be the world’s largest PV power plant when completed in 2015. Besides this, Sarnia, Ontario, Canada – 80MW (AC) is the largest operating PV power plant in Canada and Greenough River Solar Farm, Geraldton, Australia – 10MW (AC) is the country’s first utility-scale PV plant connected to the grid. arindam.ghosh@network18publishing.com

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Stick Welding Techniques

CLAMS Formula For Greater Success!

The CLAMS formula can better the skills of a stick welder. Want to know how? Bringing together CLAMS, i.e., Current setting, Length of arc, Angle of electrode, Manipulation of the electrode and Speed of travel, in a single moment of welding may seem like a lot to think about. However, it becomes natural flair with practice. Even someone who is just learning the stick welding process can improve their welding techniques by bearing in mind the CLAMS formula.

PRATEEK SUR

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urrent setting

by observing others, practicing and creating a method that produces good results. It has been universally noted that on material 1/4 inch and thinner, weaving the rod characteristically makes a bead that is wider than essential.

In many cases, plain, straight-ahead travel works fine.

To make a wider bead on thicker material, the user should manipulate the electrode from side to side creating a continuous series of partially overlapping circles, or in a ‘Z’, semi-circle or stutter-step pattern. Side-to-side motion should be limited to 2-1/2 times the diameter of the electrode core. To cover a wider area, the user should make multiple passes or ‘stringer beads’.

When the user needs to weld vertical up, the focus should be on welding the sides of the joint and the middle will take care of itself. ength of arc Reader’s tip: Do not get discouraged.

Hence, the user should wait for the The right arc length varies with each This process was christened stick far side of the bead to cool and the electrode and usage. The arc length welding not because the electrode weld puddle to catch up & guarantee should not go beyond the diameter appears like a stick, but because solid ‘tie-in’ to the sidewall. If the weld of the metal portion (core) of the everyone sticks the rod to the looks like fish scales, then it should electrode. Holding the electrode very workpiece while learning how to weld. be understood that the user moved close diminishes welding voltage. This forward too rapidly and did not hold crafts an erratic arc that may extinguish long enough on the sides. itself or cause the rod to freeze, as well as produce a weld bead with a high crown. Exceptionally long arcs (very high voltage) generate spatter, low deposition rates, undercuts peed of travel and may be, porosity. Many welding beginners weld with The appropriate travel velocity makes a weld bead with a very long arc, so they generate rough beads with lots of the preferred contour (or ‘crown’), width and appearance. The spatter. With more practice, the user would get a tight and user needs to adjust travel pace so that the arc remains within controlled arc length and thereby improve bead appearance the leading one-third of the weld pool. Slow travel velocities by creating a narrower bead while ensuring minimal spatter. generate a wide, convex bead with low infiltration. Extremely high travel velocities also lessen infiltration; create a narrower and/or highly crowned bead and possible undercuts. ngle of travel In flat, horizontal and overhead positions, stick welding uses a ‘drag’ or ‘backhand’ welding technique. The user Must Remembers should hold the rod at right angles to the joint and tilt the The user should always keep in mind that a good view of top of the electrode in the direction of travel—more or less the weld puddle is a must. The best view can be ascertained 5⁰–15⁰. For welding vertical up, the user should use a ‘push’ by keeping the head off to the side and out of the smoke or ‘forehand’ technique and tilt the top of the rod 15⁰ away so that the user can easily see the puddle. Also, it should from the direction of travel. be remembered that everyone learns by making mistakes.

In fact, professional welders construct perfect welds by recognising imperfections, grinding them and rewelding. anipulation Each welder manipulates or weaves the electrode in an exclusive style. The user should develop its own style prateek.sur@network18publishing.com The right current or amperage setting chiefly depends on the diameter and type of electrode chosen. For example, a 1/8 inch 6010 rod runs well between 75 amperes and 125 amperes, while a 5/32 inch 7018 rod welds at currents up to 220 amperes. The operating range is always mentioned on the side of the electrode box. The user should select amperage depending upon the material’s thickness, welding position (about 15% less heat for overhead work compared to a flat weld) and observation of the finished weld. Most new welding machines have an everlasting label that advises amperage settings for a multiplicity of electrodes and material thicknesses.

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Electrical Equipment This section gives information about products, equipment and services available in the market. If you know what you want. . . refer to Product Index on Page 142 to find it quickly

Switching power supplies

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IN rail mounting, single and three phase switching power supplies (SMPS) are available from 5 to 960 Watts with efficiency as high as 93%. They are housed in IP20 plastic and metal casings. They offer a host of standard features like full input range selection, input fuse protection, input-over-voltage protection, internal input filters, output short circuit protection, accurate line and load regulation and high reliability because of fan-less construction.

Certain models of power supplies also carry advanced features like in-built power factor correction, output ready signal and the possibility of connecting multiple power supplies in parallel to increase the power output.

Connectwell Industries Pvt Ltd Thane - Maharashtra Tel: 0251-2870766, 3980800 Email: connect@connectwell.com Website: www.connectwell.com

Time switch

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his time switch Astro® Mini is enabled with attributes such as trigger on sunrise/set and twilight rise/set, offset, off hours and weekly off features with 6 years battery reserve for high reliability. Simple reset, easy manual override, DST feature and ease of programming with 12/24 hour formats is available. It is versatile for lighting automation applications like lighting of streets, gardens, townships, building apartments, advertising displays and glow signs.

General Industrial Controls Pvt Ltd Pune - Maharashtra Tel: 020-30680003, 30680031 Mob: 09923756505 Email: marketing@gicindia.com Website: www.gicindia.com

Switch disconnector fuse

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his switch disconnector fuse is designed for industrial applications and conforms to IEC-60947-3/ IS-13947-3. The ratings include 32A, 63A,

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100A, 125A, 160A, TP/ TPN version disconnector fuse is longer life, visible padlocking.

200A (AC 23A). It is available in version in and has fuses of DIN/BS. The switch equipped with quad break contact system for contact indication with defeat facility and

BCH Electric Ltd New Delhi Tel: 011-23316029/6539 Email: bilmkt@vsnl.com Website: www.bchindia.com

Pressure switch

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echanical pressure switch (series 8000) is designed to monitor and control pressures in hydraulic and pneumatic systems. This pressure switch qualifies for various oils, water emulsions and gases. It is used in numerous applications in mobile and stationary hydraulic systems: from hydraulic clamping in machine tooling, hydraulic steering systems off highway loaders or load monitoring on crane support struts to vertical cargo lifts and elevators.

Barksdale GmbH, Germany Germany Tel: +49–6035–949176 Email: info@barksdale.de Website: www.barksdale.de

Limit switch

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imit switch(BC-9 ‘T’) is available in three designs.

One has an adjustable top push button with a hex, bolt and lock nut, whose length can be adjusted upto 8mm. The second has solid button of 9.5mm and third has nylon roller of 17 mm diameter and 4.7mm thickness.

Jai Balaji Controlgears Pvt Ltd Chennai - Tamil Nadu Tel: 044-26251279, 26254470 Email: dchandramohan@jaibalaji.firm.in Website: www.jaibalaji.firm.in

Electrical Equipment

Step motion controller

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ow-cost IC-based step motor controller (series MC2502) is the addition to the Navigator Family 2500 series of motion processor chips.

Available in one (MC2512), two (MC2522) and four (MC2542) axis configurations, the MC2502 series consist of two components, a 132-pin processor and a 100-pin logic device. Both components are surfacemount CMOS technology and powered by 5 V. The motion processor is driven by a host microprocessor, via an 8-bit or 16-bit bus interface or through an asynchronous bi-directional serial port, giving users the ability to offload resource intensive motion control functions from the applications host.

Performance Motion Devices, Inc Massachusetts Tel: +1-781-6749860 Email: motion-control@pmdcorp.com Website: www.pmdcorp.com

Profibus controller

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he AnyBus-IC single-chip profibus controller contains a powerful micro-controller with flash and RAM memory, a profibus protocol chip and all necessary analogue functions

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Electrical Equipment

including opto-coupler, DC/DC converter and bus driver in a single housing of only 9cm 2 in size. This controller considerably simplifies the development work required to implement a profibus interface and reduces the space requirements to an absolute minimum. It is based on the same hybrid technology, which is being used in millions of consumer electronics products. The AnyBus-IC has a 32-pin dual in line case and requires a 5 V/250 mA power supply.

HMS Industrial Networks GmbH Germany Tel: +49-721-96472-0 Email: miv@hms-networks.com Website: www.anybus.de

Oven temperature controller

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he model PID-966 microcontroller-based temperature controller (version 1.1) is incorporated with features taking into consideration the application of controlling the temperature of electrically heated oven in the industry. All the required

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variable aspects are met by this controller to suit any type of end user or OEM application. The controller accepts J or K type thermocouple and displays the temperature over the full range with in 10 C accuracy. Depending upon the oven size and kilowatts of heaters, OEMs use the end controlling device as power contactor, solid-state relays or thyristor power pack.

Libratherm Instruments Pvt Ltd Mumbai - Maharashtra Tel: 022-28963823 Mob: 09821136685 Email: libratherm@libratherm.com Website: www.libratherm.com

Temperature controller

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icroprocessor-based blood refrigerator temperature controllers is available with single and double display.

The temperature controller has supply voltage of 220 V AC and comes with RTD input. Output-1 has relay contact or SSR and output-2 has alarm contact or buzzer. Temperature setting lock is as per the range adjustable in set mode.

Wavetronics Ahmedabad - Gujarat

Electrical Equipment

Tel: 079-22811329,09327003425 Mob: 09327003425 Email: info@wavetronics.co.in Website: www.wavetronics.co.in

Isolation transformer

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t offers complete line isolation along with continuous noise filtering to eliminate harmonic distortion and enhanced common mode surge suppression internal low impendence isolation transformer component. The 1-1000 KVA capacity is designed for isolating sensitive equipments from line voltage transients, spikes and DC leakage and resistance more than 100 mega ohms.

Golden Electronic Controls India Pvt Ltd Coimbatore - Tamil Nadu Tel: 422-4230990 Mob: 09842162763 Email: info@goldenservo.com Website: www.goldenservo.com

Power transformer

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he power transformer enhances the productivity and maximises the capacity level of the high power supply equipments. It is useful for the regular power without any cut off.

The ratings are up to 2000 KVA, frequency is 50 hz and ONAN cooling. Copper and aluminium winding material is used in this transformer.

Mahashakthi Energy Ltd Bathinda - Punjab Tel: 164-2280058 Email: info@mahashaktienergy.com Website: www.mahashaktienergy.com

Power and control cables

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hese power and control cables include aluminium/copper conductors, armoured/unarmoured cables, etc. The cables consist of carbon and hydrogen compounds, which essentially contain lowdensity polyethylene molecules in the form of long flexible chains. Cross-linked polyethylene (XLPE) is a thermosetting compound. It softens at the crytahne melting point of

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Electrical Equipment

polyethylene (85째C to 115째C) and assumes an elastic rubber like consistency, a property that it retains during further rise of temperature until it becomes carbonised without melting at 250째C to 300째C. All these strengthen the LT-XLPE cables against stress cracking and give them a greater resistance to fight ageing in hot air.

Empire Cable Industries Pvt Ltd Delhi Tel: 011-23867957/8832 Email: sales@empirecables.com Website: www.empirecables.com

Wires and cables

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wide range of wires and cables is offered for sensitive and critical applications. Soft and flexible wires come in 0.50, 1.0 and 1.5 sq mm conductor size offering current rating up to 15 A in industry standard OD of 3.50 mm in specially formulated flame retardant ROHS PVC. The inner conductor is made out of pure electrolytic highly annealed copper wires, which are drawn, very fine and bunched and stranded with close pitch to realise an exceptional flexibility and flex life. The

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Electrical Equipment

wires are used where flexibility is a major requirement, like in robotics, solar panels, instruments, multimeters, etc.

Allied Cables New Delhi Tel: 011-2631 1279 Email: alcai.com@gmail.com

Insucon Cables & Conductors Pvt Ltd Jaipur - Rajasthan Tel: 0141-224 0557 Email: info@insuconcables.com Website: www.insuconcables.com

Pressure transducer

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Heavy-duty cables

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hese are LT XLPE/PVC insulated power control and instrumentation cables. The XLPE insulated heavyduty power cables are offered in 1.1 KV. Cross-linked polyethylene (XLPE) is a thermosetting material obtained by forming cross linkages in polyethylene molecules. Technical advantages include higher current rating, higher short circuit rating (approximately 1.2 times than PVC), higher insulation resistance (1000 times more than PVC insulating cables), higher resistance to moisture (1000 times more than PVC), better resistance to surge currents, better resistance to most chemicals, oils and acids, low dielectric losses, better resistance to chemicals and corrosive gases, higher cable operating temperature (90°C) and short circuit temperature (250°C) and smaller bending radius longer service life.

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to 10 VDC.

Katlax Enterprises Pvt Ltd Gandhinagar - Gujarat Tel: 2764-286784 Mob: 09724506614 Email: info@katlax.com Website: www.katlax.com

he pressure transducer measures pressure differences between two points and gives proportional analogue output. This offers accuracy and reproducibility even below 10 Pa and is fully calibrated and temperature compensated. Auxiliary supply voltage is 24 Vdc ±10%, pressure range is 0 to 30 mbar, output is 0

Welding

welding machine

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elding machines minimise spatter generation and provide excellent bead appearance by hybrid pulse technology. It provides instantaneous arc start by encoder motor and new CDM control; superior performance for aluminum, stainless steel and mild steel; simple operation by simultaneous use of jog dial and direct keys. Monitoring software is available for quality control; dual input voltage is 230V / 460V complied with C-UL standard. It provides instantaneous arc start by encoder motor and new CDM control. 350HM3 has thickness of 1.0 - 12.0mm; output current is 30 - 350A; applicable wires are mild steel / stainless steel / aluminium and weight is 77 kg.

Welding Technologies India Pune - Maharashtra Tel: 020-65101340 Email: wti@weldingtechindia.com Website: www.weldingtechindia.com

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Welding

Welding machine

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hese are digital controlled CO2/ MAG machines.

350GB2 has applicable thickness of 0.8 - 12.0mm; output current 30 - 350A; applicable wire diameter 0.8 / 0.9 / 1.0 / 1.2 mm; rated duty cycle 60%; rated input 21.0kVA (16.0kW) and weight 39.6 kg. 500GB2 has applicable thickness of 1.6 - 25.0mm; output current 60 - 500A; applicable wire diameter 1.2 / 1.4 / 1.6 mm; rated duty cycle 100%; rated input 29kVA (26kW) and weight is 100 kg.

Welding Technologies India Pune - Maharashtra Tel: 020-65101340 Email: wti@weldingtechindia.com Website: www.weldingtechindia.com

Arc welding transformer

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he model SH-30 arc welding transformer is very effective for speedy production, structural work, machine building and fabrications, filling jobs, worn-out machine parts repair and in arc cutting jobs. Design features include: modern look, novel design concept, epoxy power coated body for long life

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Welding

and coil varnishing by vacuum pressurized impregnating varnishing system. Nominal current output is 300 A, primary voltage ranges from 380 to 415, frequency is 50 Hz, maximum continuous hand welding current at 60%, and duty cycle is 300 A.

Canary Electricals Ltd Morbi - Gujarat Tel: 02822-250431 Email: info@vulcanwelding.com Website: www.vulcanwelding.com

Head shield

T

he head shield is used for TIG argon welding. It is made of heat-resistant material. The head shield comes with flip-up type window, which allows users to see the ongoing operation and prevents harmful radiations and particles from reaching the eyes and face. The head shield is designed specially to protect the face, top of the head and the neck

to a vertical line back of the ears. It is provided with heat gear-type ring, which retains the shield comfortably and firmly on users head and permits the shield to be tilted back overhead.

Atul Arc New Delhi Tel: 011-25736102, 09811825256, 9810273058 Email: info@atularc.com Website: www.atularc.com / www.atularc.net

Electrode torch

C

opper plus electrode torch is exclusively for Hypertherm’s Duramax. This electrode torch is capable of cutting metals up to 12mm-thick using Hypertherm’s plasma cutting systems. The electrode is a simple drop-in replacement that requires no changes to any other consumable parts or system settings.

By simply replacing the electrode, a substantial amount of money can be saved without sacrificing the cut quality or performance of plasma cutting systems.

Hypertherm (India) Thermal Cutting Pvt Ltd Chennai - Tamil Nadu Tel: 044-28345361 Email: htIndia.info@hypertherm.com Website: www.hypertherm.com

Plasma welding torch

A

biplasWeld plasma welding torches are top economical and efficient and has a compact design which helps the torch improve accessibility even with difficult component geometries. The very stable process makes spatter-free welding and brazing possible with high-quality joint characteristics.

Complicated reworking is no longer necessary and plasma welding torch is suitable for both manual and automated applications.

Abicor Binzel Technoweld Pvt Ltd Pune - Maharashtra Tel: 020-66743904 Email: pune@abicor-india.com Website: www.binzel-abicor.com

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Send us the following: 1) Technical description (Maximum 150 words) 2) Product image (300 DPI resolution) 3) Contact details All the details should be emailed to: rishab.kothari@network18publishing.com

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Angle finder/meter

T

his angle finder/meter offers a fast, easy and inexpensive way to measure angles on any surfaces. It is widely used in various industries and DIY projects. Its features are large scale for accurate readable readings from 0-90 in any quadrant, magnetic base frees hands when used on ferrous surfaces, measurement of any angle for pitch or slope, handy rise, run, angle and pitch information on back of tool.

T.M.Mohamedally Mumbai - India Tel: 022 – 6631109/90 Fax: 022 - 22004711 Email:sales@tmmtools.com Website: www.tmmtools.com

CNC machining

3

center

axis CNC double column vertical machining center is an ideal heavy duty machine for both roughing and

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finishing of bigger components greatly increasing work envelop, permitting large workpieces to be machined, a wider range of tool lengths to be used in same set-up. With a load capacity range of 10000 kg, this series has been designed for accommodating large mould and mould base machining. With architecture of Y-axis on cross beam, moving table on X-axis and Z-axis on ram-type head greater extensions from head-stock and better reach to table area is achieved without much interference of axis elements. Wider gaps are maintained between columns to accommodate large size components. NX 2215 has X/Y/Z (2200/1500/800 mm) and 24-Tool ATC. Equipped with table (2200X1250 mm) machine has high-power spindle of 6000 rpm (32.3/21.5 kW, BT50) with an available option of choosing manual head changer/90 0 autoindexing head for different applications.

Jyoti CNC Automation Ltd Rajkot – Gujarat Tel: 2827-287412 Fax: 2827-287480 Email: info@jyoti.co.in Website: www.jyoti.co.in

Electrical screw driver

S

118

antus HD 2200 is a portable and economically priced product used in small to large scale industries. With its streamlined design and the use of plastic gives durable life. It

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is equipped with imported heavy duty motor offering advantages like reduction in noise. The screwdriver can stop running automatically when the load exceeds the present torque, thus providing protection to the work piece and device itself. This product can be operated up to hundred thousand times under normal working conditions. Speed is 1001000rpm and Torque 0.4-1.2 Nm.

T.M.Mohamedally Mumbai - India Tel: 022-6631109/90 Fax:022-22004711 Email:sales@tmmtools.com Website: www.tmmtools.com

Fluid bed dryer bag

A

variety of fluid bed dryer (FBD) bags are available. The usage of anti-static cloth in the preparation of these bags overcomes the limitations posed by the carbon loaded epitropic yarn. It is independent of the air humidity and is chemical resistant, non

General Products

brittle and wash-proof. It can withstand continuous temperature of 450 0 C in presence of and upto 550 0 C without oxygen.

N. K. Filter Fabrics Pvt Ltd Mumbai – Maharashtra Tel: 022-25786870 / 25786927/ 25794161 Fax: 022-25784400 Email: sales@nkfilter.com Website: www.nkfilter.com

Louvering tool

I

t is a standard type of press tool which makes louvering a straight forward and easy operation. The tool can accept louvers for length upto 40 mm. It comes with interchangeable punch and die. Turning the punch and die provides either left hand or right hand louvers. Ventilation for instrumentation, cabinets, made out of sheet metal is achieved by louvering the sheet metal wherever required. None of the tool component needs to be fixed in a press.

It can be used in a fly press, power press, hydraulic press or even a ball press.

Unipunch Toolings Pvt Ltd Chennai – Tamil Nadu

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Tel: 044-26253436, Mob: 09941905061 Fax: 044-26252349 Email: unipunch@gmail.com, unipunch@vsnl.com, Website:www.fabmachinesindia.com, www.sheettools.com

Moisture separator

T

his moisture separator is designed for the removal of bulk water and oil from compressed air streams. It features wide range of 19 standard models with capacities from 50 m 3/hr to 10,000 m 3/ hr with choice of higher capacity and compact design. Moisture separator is built in accordance with international design code like-ASME, IS-2825, BS, etc.

Instrumentation such as manual drain valve etc is also available. The separator is duly tested pneumatically and hydrostatically.

Delair India Pvt Ltd Gurgaon - Haryana Tel: 0124-4091111 Fax: 0124-4091100 Email: delair@pahwa.com, Website: www.delairindia.com

General Products

Multi tasking machine

F

ifth generation multi-tasking machine helps reduce total machining time by utilising the milling spindle, second spindle and lower turret. It features long strokes for large workpiece capacity, 5-axis simultaneous machining for complex workpieces, processing from raw material to finished workpiece in a single setup, high-power spindle for heavy-duty cutting. The maximum machining diameter is Ď•500mm, maximum spindle speed is 6,000rpm/6,000rpm, maximum milling spindle speed 12,000 rpm and tool storage capacity 36 tools.

Yamazaki Mazak India Pvt Ltd Pune, Maharashtra Tel: 2137-668800 Fax: 2137-668829 Website: www.mazakindia.in

Programmable logic controller

T

his micro-to-medium range of PLC has class leading memory capabilities and scan times. The PLCs follow industry standard IEC 61131 of programming and can be programmed in Ladder, FBD, IL, ST and SFC styles. The PLC

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General Products

software has dedicated function blocks for motion control rendering programming of stepper and servo motors. It supports upto 4 axes of control with linear interpolation. It also supports upto 8 high speed counters simultaneously.

The software also has options of creating customised function blocks giving OEM customers the option of creating their own IP and protecting the same. Options exist to connect these PLC to industry standard networks like Profibus, Devicenet, CANOpen, CCLink, Slink etc. A wide range of communication options also exist on the CPU which includes RS232, USB, RS485 and ethernet.

Strategi Automation Solutions Pvt Ltd Bengaluru – Karnataka Tel: 080 – 32329798, 32467879 Fax: 080 - 41163047 Email: sales@strategiautomation.com Website: www.strategiautomation.com

Portable calibrator

F

122

B series portable calibrators features lightweight temperature dry block, high-accuracy temperature dry block for industrial field use. It has built-in high-accuracy

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reference probe input supporting plugand-play smart probes. Temperature ranges from -25 °C to +660 °C with accredited calibration certificate included as standard. This machine is a part of integrated calibration solution (ICS) and comes with a 1 year warranty.

Beamex Oy Ab India Goregaon - Mumbai Tel: 09833102694 Fax: +358 10 5505404 Email: rajesh.panchal@beamex.com Website: www.beamex.com

RTA stepper drives

I

t is a powerful, reliable and compact range of 2-phase stepping motor drives. These drives are available in both AC and DC input versions. The range begins with the CSD series of drives for currents upto 4.4 A and DC input voltage upto 45V for low-to-medium speed applications. This progresses to the NDC series of drives

WEST BENGAL INVESTMENT PORTFOLIO General Products

which are ideally suited to drive NEMA 34 series of motors with currents upto 6A and 75VDC operation. AC input drives are available operating from 55V AC to 230V AC. These drives are suited for high speed applications. Drives are also available with networking capabilities and to operate with motors fitted with encoders. Special drives have been designed to operate with NEMA43 size motors and for motors designed to operate at high voltages. All the drives carry protection against shorting of the motor output terminals, under voltage and over voltage protection.

They are all CE certified.

rkable in the nergy. ctricity as not on of er this

wable ile the round ing to arts of have d Joy Energy

Strategi Automation Solutions Pvt Ltd Bengaluru – Karnataka Tel: 080-32329798, 32467879 Fax: 080-41163047 Email: sales@strategiautomation.com Website: www.strategiautomation.com

taking s in its power rough id and

Self feed drilling unit

T

his self feed drilling unit is Drillmatic’s versatile drilling machine which is ideal for auto component manufacturing and drilling SPM’s . It is an auto feed machine and it is available in wide range for varied applications like tapping, drilling and tapping, peck feed drilling for deeper holes, muti spindles for multi hole drilling etc. The machine is very high productive, maintenance free and reasonably priced.

ustrial t have There state. more

n from similar h East harma of this hub/ eutical ositive

Dolphin Special Machines Technologies [P] Ltd Chennai – Tamil Nadu Mob: 09840332583 Email: chandrasekar@dolmatic.com; info@dolmatic.com Website: www.dolphinspm.com, www.drillmatic.com

ducive of the

Vertical machining center

M

ultiple-surface / simultaneous 5-axis high-speed vertical machining center is designed for exceptional versatility.

It is equipped with high-rigidity tables supported on both sides for large, heavy workpieces. It has #40(i-500), #50(i800) taper spindles. Available optional spindle specifications meet any production requirement. The table size is ϕ500 mm×400 mm ϕ800 mm×630 mm, travel ( X/Y/Z/A/C) 350/550/510 mm /-120°~+30°/360° 730/850/560 mm /-120°~+30°/360°, maximum spindle speed 12,000 rpm 10,000 rpm and tool storage capacity is 30 tools.

cope, much mains ourist of the which borty.

er the years higher great ucture

Yamazaki Mazak India Pvt Ltd Pune - Maharashtra Tel: 2137-668800

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General Products

Fax: 2137-668829 Website: www.mazakindia.in

Workstation

To make the product of superior quality, it must . adhere to safety and contamination-free norms the in ted accep well ct produ end This makes the market reducing its rejection rates.

Agnish Roy (Manager - Business Development) Marsap Services Pvt Ltd

M

CS200 workstation is a calibration workshop solution. A workstation is ideal when most maintenance and calibration tasks are performed in the workshop. The machines modular design allows configuration based on user specific requirements. It can perform many different types of applications and has a safe, ergonomic and a versatile workstation.

Documenting feature communicates with calibration software.

Beamex Oy Ab India Goregaon - Mumbai Tel: 09833102694 Fax: +358 10 5505404 Email: rajesh.panchal@beamex.com Website: www.beamex.com

Salt aerosol filter tester

I

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t is available in size 71cm W × 69cm D × 89cm H (28“ W × 27" D × 34" H), weight 150bs (68kg), 0.075µm count median diameter, 0.26µm mass mean diameter and gravimetric standard

General Products

deviation < 1.7. Concentration 35 to 45 milligrams per cubic meter (mg/m3), efficiency upto 99.9995%, pressure 0 to 200 millimeters of water column (0 to 7.88 inches of w.c.), accuracy Âą 2.5% of full scale, flow rate 10 to 120 liters per minute (slpm or alpm).

Power requirement is 110VAC/60 Hz or 220VAC/50Hz, compressed air is of 283 SLPM at 5.6 kg/cm2 (10 SCFM @ 80 PSIG).

MeasureTest Corporation Mumbai - Maharashtra Tel: 022 - 23645282 Mob: 09869012701 Email: measuretest@yahoo.com Website: www.measuretest.com

Scissor lift table

F

oThese scissor lift table comply with the European safety of machinery standards EN 292. Machinery Directive 98/37/ EC and safety requirements for lift tables EN 1570. Type 1-E Ergo-lift single scissor lift table features even distribution of loads with smooth surface top platform and maximum speed of 20 cycles/ hour. It has single acting hydraulic cylinders with drainage facility.

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General Products

Upper and lower travel is limited by mechanical stops. It has self lubricating bearings on pivot points and hydraulic power pack inside the table provided with relief valve against overloading and compensated flow valve for controlled lowering speed.

Electrical equipment is controlled by electronic system with low voltage transformer and thermal overload protection. Wide range of accessory is available to achieve higher safety functions.

Gandhi Automations Pvt Ltd Mumbai – Maharashtra Tel: 022- 66720200/66720300 Fax : 022-66720201 Email: sales@geapl.co.in Website: www.geapl.co.in

Cold chamber

T

he temperature range is 2° C to 8 °C with +1.5 °C accuracy and +2.0 °C uniformity. It features 21 CFR PART11 Compliance, log data, event data, audit trail data, e-records and e-signatures, graphical analysis and data acquisition. Optional features like scanner, GSM technology, hooter system and extra tray are available.

Mack Pharmatech Pvt Ltd Nashik - Maharashtra Tel: 2551 230877 Fax: 2551 230877 Email: info@mackpharmatech.com Website: www.mackpharmatech.com

Barcode reader

D

ataMan 50L holds a premium barcode reading technology in a compact barcode reader. Its high read rates can read damaged, distorted, blurred, scratched, low height or low contrast. The high performance compact DataMan 50L brings in premium reading technology to single- line laser scanner arena. Its key features are high read-rate performance, fast, accurate reading of 1-D oriented barcodes (either ladder or picket fence), best-inclass reading of 1-D omni-directional barcodes, IDQuick™, for fast, accurate reading of 2-D codes (S models), high read rates than single-line or raster laser scanners and high read rates of 1- D liner barcodes. It has no moving parts and it does not require any replacement.

It also features a no read analysis wherein the user can see what the reader

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General Products

sees, either live on a monitor or through image archiving.

Cognex Sensors India Pvt Ltd Pune - Maharashtra Tel: 020- 40147840 Fax: 020-66280011 Email: sisd.support.asia@cognex.com Website: www.cognex.com

Steam steriliser

S

team Steriliser is available in two basic models - Gravity displacement system and vacuum sterilisers.

Gravity displacement systems is suitable only for sterilisation of liquids [in open containers], vacuum sterilisers can sterilise liquids and variety of other materials / components. Customised chamber size ensures flexible loads and load patterns, it features cabinet enclosure for GMP installation, contamination seal to prevent cross-flow of air between the clean and unclean area, loading / unloading carts & trolleys for easy and convenient operation, mechanical vacuum pump for prepulsing [for air removal], post sterilisation vacuum drying, sterile air filter for vacuum break. In-built test programs for vacuum leak test, pressure leak test and bowie-dick test for higher process

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General Products

assurance, automatic FO Calculator with facility for control in case of heat labile materials. It is 0.2 bacteria retentive.

Machinfabrik Navi Mumbai - Maharashtra Tel: 022-67368200 Email: abk@machinfabrik.com Website: www.machinfabrik.com

TOOL POST GRINDER FOR LATHE

T

he tool post mountingtype grinding attachments can be mounted directly on the existing square or quick change tool post of a lathe without the need of removing the tool post. The grinding attachment consists of a standard 2 HP/1440 RPM motor, L shaped holding arrangement and an add-on driven unit. The addon driven unit supports the drive shaft extension with the help of matched pair angular contact bearings and grinding wheel mounting arrangement. The entire grinding attachment measures 350 mm in length, including the grinding wheel and the motor. The overall height of the attachment is 200 mm. The grinding attachment is suitable for mounting a grinding wheel of Ă&#x2DC;250 x 25 mm width maximum and it is most ideal for heavy duty lathes and

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General Products

for intermittent OD grinding applications.

Shenoy Engg Pvt Ltd Bengaluru - Karnataka Tel: 080-28361767 Fax: 080-28361725 Mob: 00-9243437487 Email: info@shenoyengineering.com Website: www.shenoyengineering.com

Air monitor

T

he air monitor developed by UEPL is a microprocessor based non dispersive spectrophotometer tailor-made for the analysis of the five pollutants SO2, NO2, NH3, Cl2, O3 at parts per billion levels. The instrument is light weight and moderately priced.

Ambient air is sampled for the required time duration e.g. 4, 8 or 24 hrs. using the Uniphos air sampler which can sample three different gases simultaneously using three impingers filled with recommended gas absorbing solvents. The solutions from the impingers are further treated with other reagents to form coloured dyes. The measurement of absorbance on this colored dye is made on the Envirotrack. The analysis is simple and all the calculations are done by the microprocessor with results displayed on the

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General Products

instrument. The results can also be transferred to a computer or Laptop with date, time, location and other identification using GUI software which can be separately bought with the instrument.

Uniphos Envirotronic Pvt Ltd Valsad – Gujarat Tel: 260-2730156/158 Fax: 260-2730160, 2431823 Email: cel@uniphos.com Website: www.uniphos.com

Digital panel meter

F

our digit single phase and three phase digital panel meters with bright red LED display is available. This digital panel meter can display voltage, current and frequency in with auto scrolling and manual scrolling facility. It is available in current ranges of 1A & 5A and can be scaled to show primary CT current from 0A to 9999A, 500 V and 50 Hz. Available sizes are 48*96, 72*72 and 96*96mm.

These instruments are available in standard size 48*96mm, 96*96mm and 72*72mm. Height of the meter is 14.3mm.

Goliya Electricals Pvt Ltd Mumbai – Maharashtra Tel: 022 – 24120456, 24133206

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General Products

Fax: 022 â&#x20AC;&#x201C; 24168498 Email: sales@goliya.com Website: www.goliya.com

Level leaf filter

S

harplex level leaf filter is used for polishing filtration in post filtration stage to trap the fine particles from the filtrate of main filter. The filter elements have filter surface at both the sides and hence this filter becomes very compact even at higher filtration areas. The filter medium can be cloth or paper. The filters are available from 2m 2 upto 15m 2 .

Sharplex Filters (India) Pvt Ltd Navi Mumbai - Maharashtra Tel: 022-27696322, 27696339 Fax: 022-27696325 Email: sharplex@vsnl.com Website: www.sharplex.com

The information published in this section is as per the details furnished by the respective manufacturer/distributor. In any case, it does not represent the views of

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EVENT LIST

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NATIONAL

ABROAD

6-8 June, 2013

6-10 June, 2013

18-20 June, 2013

Automotive Engineering Show Focus: Automotive manufacturing sector Where: Chennai Trade & Convention Centre, Chennai, Tamil Nadu Tel: +(91)-(22)-32019137/40201000 Fax: +(91)-(22)-28324404 Email: sales@aes-show.com Website: www.aes-show.com/index.aspx

INTEC Focus: Industrial machine tools sector Where: CODISSIA Trade Fair Complex, Coimbatore, Tamil Nadu Tel: +(91)-(422)-2222396/2222397 Fax: +(91)-(422)-2222131 Email: intec@codissia.com Website: www.intec.codissia.com/index.php/site/index

Automation Technology Expo East Focus: Manufacturing and automation equipment and products Where: Pennsylvania Convention Center, Philadelphia, USA Tel: +1 310/445-4200 Fax: +1 310/445-4299 Email: tssalesadmin@ubm.com Website: www.canontradeshows.com/expo/atxe13/index.html

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2-4 July, 2013 Composites China 2013 Focus: Industrial equipment & components Where: Shanghai New International Expo Centre (SNIEC), Shanghai Tel: +86-10- 5933 9357 / +86-10-5933 9314 Website: www.chinaexhibition.co

3-5 July, 2013

3-5 July, 2013

Wind Power China 2013 Focus: Renewable energy Where: China National Convention Center, Beijing Tel: +86-10-6590 7766 ext 736 Fax: +86-10-6590 6139 Email: h.chen@koelnmesse.cn Website: www.chinaexhibition.com

Indo Renergy 2013 Focus: Renewable energy system, waste management systems Where: Balai Sidang Jakarta Convention Centre, Indonesia Tel: 62-21-8644756 Fax: 62-21-8650963 Website: www.indorenergy.com

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01-03 August, 2013 Solarcon India Focus: Solar power appliances, solar PV manufacturing Where: Bangalore KTPO Trade Centre, Bengaluru Tel: +91 80 4040 7103 Email: rgurumurti@semi.org Website: www.solarconindia.org

ABROAD

26-29 August, 2013

27-30 August, 2013

automechanika Moscow Focus: Automotive products in Russia and CIS countries Where: Expocentre Fairgrounds Krasnopresenskaya nab, Moscow Tel: +7 (4)95 7211057 Fax: +7 (4)95 7832326 Email: ksenia.komina@russia.messefrankfurt.com Website: heimtextil.messefrankfurt.com

Miconex Focus: Measuring instruments and automation Where: China International Exhibition Center Beijing, China Tel: +86 (0)10 82800755 Fax: +86 (0)10 82800879 Email: zm@cis.org.cn Website: www.miconex.com.cn

EVENT LIST

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NATIONAL

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4-6 September, 2013 Electronica India 2013 and Productronica india 2013 Focus: Electronics industry Where: Pragati Maidan, New Delhi Tel: 09833213370 Email: urmi.kothari@mmi-india.in Website:www.electronica-india.com

01-05 September, 2013

04-07 September, 2013

CIEME 2013 - The 12th China International Equipment Manufacturing Exposition Focus: Manufacturing & repair Where: Shenyang International Exhibition Center (SYIEC), Shenyang Tel: +86-532-5555 2901/2902 Fax: +86-532-5555 2903 Email: service@china-jinnuo.com

Jakarta International Expo (JIExpo) Focus: Electronics & electrical, energy & power Where: Gedung Pusat Niaga Lt, Indonesia Tel: +62-21-26645000 /131 Fax: +62-21-65700010 Email: marketingvenue@jiexpo.com

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10-12 October, 2013

24-26 October, 2013

9-12 October, 2013

Used Machinery Expo Focus: Used machineries Where: Bombay Exhibition Centre (BEC), Mumbai Tel: +(91)-(11)-40828230 / 40828282 Fax: +(91)-(11)-40828283 Email: gagan.sahni@itei.in Website: www.umexonline.com

IFAT India Focus: New technologies and alternate options for power Where: Bombay Exhibition Centre (BEC), Mumbai Tel: +(91)-(22)-42554710 / 42554714 Fax: +(91)-(22)-42554719 Website: www.ifat-india.com

Manufacturing & Industrial Trade Fair (MITF) Focus: Automotive manufacturing, fluid power Where: Putra World Trade Centre, Malaysia Tel: +603 7832 3031 Fax: +603 7832 6031 Email: info@expoworks.com.my Website: www.manufacturing-expo.com.my

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ABROAD

05-09 November, 2013

12-15 November, 2013

26-28 November, 2013

China International Industry Fair Focus: Manufacturing equipment industry Where: Shanghai New International Expo Centre (SNIEC), Shanghai, China Tel: +(86)-(21)-22068386 Fax: +(86)-(21)-62895703 Website: www.ciif-expo.com

Productronica Focus: Electronics production Where: Messe München, Munich, Germany Tel: +49 (0)89/949-20720 Fax: +49 (0)89/949-20729 Email: newsline@messe-muenchen.de Website: www.messe-muenchen.de

SPS IPC Drives - Electric Automation Systems and Components - International Exhibition and Conference Focus: Automation, Robotics Where: Messezentrum Nürnberg, Nuremberg, Germany Tel: +49 (0)711/61946-39 Fax: +49 (0)711/61946-92 Email: anja.faulhaber@mesago.com Website: www.mesago.de/

Hyderabad 31 May-3 Jun 2013 Ludhiana 20-23 Dec 2013

Ahmedabad 20-23 Sep 2013 Aurangabad 10-13 Jan 2014

Pune 18-21 Oct 2013 Indore 31 Jan-3 Feb 2014

Chennai 14-17 Nov 2013

Jaipur 29 Nov-2 Dec 2013

Kolkata 21-24 Feb 2014

Tel: +91-22-30034651 • Email: engexpo@network18publishing.com • Web: www.engg-expo.com

Rudrapur 7-10 Mar 2014

BLECH India 2013

‘Forming’ the Growth Ladder for the

Sheet Metal Working Industry

The growing demand for sheet metal in various sectors including automotive, consumer electronics and white goods has generated a plethora of opportunities for the suppliers and manufacturers of sheet metal machines, tools and systems.

Providing a platform to this never ending growth, BLECH India 2013 kickstarted on April 17, 2013, with an aim to provide an ideal opportunity to bring in the latest technologies and products for the burgeoning sheet metal working industry, under one roof. The four-day event proved to be a one-stop shop for one and all! A report...

NISHI RATH

T

aluminium construction, rolling mills more than 7,000 trade visitors. As a he increasing consumer as well as the shipbuilding industry. dedicated trade exhibition focusing on demand, particularly sheet metal working, BLECH India in the automotive 2013 covered all sectors of the sheet industry and its Adding Brand Value metal manufacturing process, viz. suppliers, construction, For many exhibitors at BLECH India metal forming and bending solutions, home electronics and white goods 2013, it proved to be a continuation stamping, pressing, automation, industries and the growing steel of existing projects and possible flexible manufacturing systems, metal production industry, offers outstanding applications whereby pre-planned supply, cutting, punching, joining/ opportunities for international meetings took place in a technical welding, tooling, laser technology, suppliers of sheet metal machines, environment. “Some of the technical CAD/CAM, finishing/coating, quality tools and systems. With a view to offer meetings will hopefully lead us into assurance and material handling. a unique platform to showcase various the next step of cooperation, whereby Majority of the exhibitors at products for the booming market, the current economic challenges in BLECH India 2013 were Indian the third edition of BLECH India, India will not immediately lead us companies, while major exhibitor the Technology Exhibition for Sheet into a signature below contracts,” countries included Germany and Italy.

Metal Working, was inaugurated said Chirstian Hollands, Customer on April 17, 2013, at Support Engineer, Spaleck the Bombay Exhibition Oberflächentechnik Gmbh BLECH India 2013 covered all sectors of the sheet metal Centre, Mumbai. The Co KG. Many exhibitors manufacturing process, viz. metal forming and bending trade show was inaugurated exhibited to create solutions, stamping, pressing, automation, flexible

by David Tellett, MD, brand value and increase manufacturing systems, metal supply, cutting, punching, Mack Brooks Exhibitions visibility among potential joining/welding, tooling, laser technology, CAD/CAM, Ltd, and KV Rajeevan, finishing/coating, quality assurance and material handling. customers. “We wanted to Exhibition Director, Intertake this opportunity to According to the industry, this event Ads Exhibitions. talk to auto manufacturers about our proved to be an opportunity for foreign initiatives to reduce carbon footprint. exhibitors to gain new contacts and We have special processes, which Getting Bigger and Better develop their business relations in the help automotive manufacturers reduce BLECH India 2013 saw about 180 buoyant Indian market. Furthermore, weight of cars, thus reducing fuel exhibitors from 14 countries presenting international partnerships have become consumption. We showcased these a variety of new products and services essential in fostering technology processes via audio visual displays for sheet metal working. It also saw an transfer, opening unique opportunities and technical seminar,” added Sachin increase of 50% in exhibition space and for Indian and foreign companies Nirgudkar, VP, Schuler India Pvt 26% more exhibitors than the previous in the sheet metal working business Ltd. The trade show that came to an edition in 2011. BLECH India 2013 alike. The trade show aimed at trade end on April 20, 2013, proved to be was the biggest to date, according to visitors from sectors like mechanical a platform to interact with customers its organisers—Inter-Ads – Brooks engineering, sheet metal products, and generate awareness about their Exhibitions (India) Pvt Ltd. automotive industry and its suppliers, product offerings.

The previous edition of BLECH iron and steel companies, the India held in April 2011 attracted household appliance industry, steel and 139 exhibitors from 18 countries and nisi.rath@network18publishing.com

140

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product index Looking For A Specific Product?

Searching and sourcing products were never so easy.

Just type SRCH (space) Product Name and send it to 51818

eg. SRCH Pump and send it to 51818

Product

Pg No

3 in 1: decoiler-straightener -feeder 141 AC electric motor 132 AC motor 55, FGF AC variable frequency drive 45 Accessories 6, 22 Acoustic enclosure 14, 79 Actuator 110, 134 Adaptor 128 Adaptor for drilling 130 Air monitor 134 Air operated diaphragm pump 134 All geared auto feed pillar drilling machine 108 Alu-cera polymer 5 Aluminium oxide ceramic composite 5 Angle finder/meter 117 Annunciator 47 Application and precision component machining 22 Arc welding transformer 115 Auto electrical test bench 18 Auto feed radial drilling machine 108 Automatic charger 18 Automatic rolling shutter 17 Automation 115 Axial flow fan 113 Ball bearing 124 Bar 111 Barcode reader 130 Battery tester 18 Bearing 41, 70, 124 Belleville washer 115 Beverages accessories 25 Blower/fan 113 Blowgun 25 Brake motor 24, 55, FGF Cable accessory system 129 Cable and hose carrier 87 Cable and lead for fixed intaction 21 Cable carrier 70 Cable conduit 19 Cable connector 70 Cable for bus system 21 Cable gland 77, 117, 119, 129 Cam follower 113 Cam indexer 85 Capacitance and tan delta tester 117 Carbide 128 Carbide tool 128 Cast/extruded 107 Centre drill 128 Centrifugal air blower 113 Centrifugal fan 149 Centrifugal pump 37 Chain 70 Chain pulley block 24, 120 Chrome bar/shaft 111 Chuck 128 Circuit breaker analyser 117 Clamp hose pipe 135 Cleaning equipment 145 CNC 150, BIC CNC machine 150, BIC CNC machine tool 22 CNC machining center 117 CNC tap chuck and tap adaptor 130 CNC tap holder and pull stud 130

142

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Product

Pg No

CNC tooling 128 CNC tools holder and pulley stud 130 CNC turning center 150, BIC CNC vertical machining center 150, BIC Coil spring 137 Cold chamber 130 Collet 128 Collet chuck 128 Compressed air division 143 Compressed air system 23, 105 Compressed air treatment 118 Compression spring 115 Compressor 23, 105, 113 Conductor 115 Connection technology 12 Connector 6, 8, 15, 39, 70 Construction electric hoist (modular) 65 Container pump 134 Control cabinet 39 Control damper 110, 134 Control panel 39 Control system 39 Conveying blower 113 Conveyor and automation system 17 Counter 12, 47 Crab 120 Crab assembly 111 Crab hoist 24 Crane 24, 65, 111, 11, 120 Crane component 112 Crane duty motor 24, 133 Crane kit 111 Crane technology 112 Cross connection acc 6 Current injector 117 Cushion dock shelter 17 Custom spring 115 Custom-made cable 21 Cutting tool 22 Damper 110, 134 Data cable 21 DC motor 55, FGF Demagnetiser 116 Didactic equipment for training 39 Digital AC servo motor 109 Digital frequency meter 122 Digital panel meter 63,135 Digital temperature controller 63 Distribution board 94, 121, 135 Dock leveller 17 Dock shelter 17 Door - pvc flap 17 Door - pvc strip 17 Door - rapid flexible 17 Door - rapid roll up 17 Door - sectional overhead 17 Door - telescopic 17 Double and triple drum magnetic separator 116 Double girder EOT crane 111 Draw wire system 12 Drawer magnet 116 Drill 108 Drill chuck 143 Drill chuck arbor 128 Drill mill 128 Drilling machine 108

Product

Pg No

Drive 16 Driver compact AC gear motor 109 Drum pump 134 Dry van pump 14, 79 Ducting insulation 95 Duel fuel burner 113 Elastomeric cable 109 Electric actuator 127 Electric hoist 99 Electric wire rope hoist 24, 65,111 Electrical actuator 110, 134 Electrical connectivity 115 Electrical product 45, 77, 117, 119 Electrical screw driver 118 Electro valve 25 Electrode torch 116 Electronic connector 63 Electronic product 77, 117, 119 Electronic timer 26-35, 47 Electronic tool 131 Electropneumatic positioner 130 Element shrink disc 113 End clap/shop 6 End mill 128 End plate 6 Energy meter 47 Engineering plastic 107 Engineering plastic plug and socket 26-35 EOT 112 EOT crane 24, 65, 99 EOT/HOT cranes 120 EPDM 121 Excellence Awards 2013 114 Exhibition - Engineering Expo 136 Extended trolley 111 Extension spring 115 Fast charger 18 Fire damper 110, 134 Fire safe ball valve 110 Fixed mounting hoist 111 Flame proof hoist 120 Flame proof motor 55, 133, FGF Flange mounting motor 55, FGF Flat cable for submersible pump 21 Flat high tension single-twin ignition 5 Flexible cable and wire 21 Floating holder 130 Flooring insulation 95 Flow meter 134 Fluid bed dryer 113 Fluid bed dryer bag 118 Flush bottom ball valve 110 Forging 6 Four way ball valve 110 Freewheel-oneway-clutch 113 Fuel burner 113 Gantry 112 Gantry crane 24, 111 Gap frame press 131 Gas purification system 105 Gate valve 110 Gear 99 Gear box 99, 120 Gear motor 24, 55, 109, FGF Globe valve 110 Goliath crane 24, 65, 99, 120

product index Product

Pg No

Goods lift 120 Grab bucket 65 Grinding media 5 Guide rod 111 Haconan free cable 21 Half jacketed ball valve 110 Hand tool 131 Handling system module 39 Hard chrome plating bar 111 Head shield 116 Heat shrink tubing 77, 117, 119 Heat transfer equipment 149 Heavy-duty cable 112 High alumina wear resistant ceramic tile 5 High efficiency standard motor 133 High pressure blower 149 High pressure jet clean equipment 132 Hipots (high voltage tester) 117 Hoist 65, 99, 112 Hoist with trolley 111 Hold back 113 Hook 99 Hopper magnet 116 Horizontal CNC machine 150, BIC Horizontal machining center 150, BIC Hose 25 Hose clamp 135 Hospital equipment 132 Host ring 129 Hot water generator 113 Hour meter 12 HRC fuse fitting 63 Human machine interface 45 Hump magnet 116

Product

Pg No

Hydraulic press 131 Hydraulic shearing machine 131 I/p transducer 130 Inclinometer 12 Indirect air heater 113 Induction seal/wad 115 Inductive proximity switch 19 Industrial automation product 45 Industrial ceramic 5 Industrial electric power distribution system 94,

121, 135 Industrial lubricant 109 Industrial oven 113 Inline helical geared motor 133 Instrument 21, 122 Instrumentation and control 10-11 Insuboard 95 Insulating oil tester 117 Insulation 95 Insulation resistance tester 117 Insureflector 95 Insushield 95 Insusound 95 Interface module 6 Interface module acc 6 Inverter duty motor 133 Isolation transformer 110 Jacketed ball valve 110 JIB 112 JIB crane 24, 111, 120 Keyless transmisson element 113 Ladder 132 Large diameter welded pipe 137 Large helical geared box 133

Product

Pg No

LED 19 LED egress route 89 LED emergency 89 LED flash light 89 LED module pilot light 63 LED signal tower light 26-35 LED solar street 89 Leep plastic spring 115 Level leaf filter 137 Lexis MCBâ&#x20AC;&#x2122;s 109 Lift and conveyor cable 21 Lifting magnet 116 Lifting solution 129 Light 89 Lighting 109 Lighting solution 89 Limit switch 104 Limit switch 26-35, 130 Limit switch box 127 Linear rod 111 Liquid pump 134 Liquid ring vacuum pump 113 Liquifit fitting and tubing 25 LM shaft 111 Load break switch 19 Louvering tool 120 Machine tool accessories 130 Magnetic pulley 116 Magnetic rack 116 Marker 6 Marker plotter 6 Material handling 99 Material handling equipment 24 Metal cutting tool FIC

J U N E 2 0 1 3 | SEARCH - THE INDUSTRIAL SOURCEBOOK

143

product index Product

Pg No

MGM brake motor 101 Micro control switch 63 Micro switch 26-35, 63 Mill lining block 5 Miniature micro switch 63 Modular conveyor 57 Moisture separator 120 Monorail trolley 120 Motor 55, FGF Motor protection circuit breaker 19 Motorised chain pulley block 120 Motorised valve 110, 134 Mounting bracket 6 Mounting pad ball valve 110 Mounting rail 6 Multi battery charger 18 Multi tasking machine 121 Multimeter and clamp tester 131 Multistage centrifugal air blower 113 Neoprene 121 Network power 109 New and used machinery auction 102 Nitrile rubber product 121 Oil 113 On/off ball valve 127 On/off butterfly valve 127 On/off control valve 127 On/off plug valve 127 Oven temperature controller 108 Packaging solution 115 Packaging test equipment 115 Panel meter 122 Paper cone machine 106 Paper tube machine 106 Parallel shaft helical geared motor 133 Partition plate 6 Permanent magnetic chuck 116 Permanent magnetic drum type separator 116 PF controller 122 Phase monitoring device 47 Pillar drilling machine 108 Pilot light 19 Piping insulation 95 Piston bar 111 Plasma welding torch 116 Platemagnet 116 Platform 132 Plug and socket 19 Pneumatic actuator 127 Pneumatic cylinder 25 Polyacetal 107 Polypropylene 107 Polyurethane 107 Portable calibrator 122 Power and control cable 110 Power line transducer 122 Power magnet 116 Power press 131 Power tool 109 Power transformer 110 Precision switch single and multiple 19 Press brake machine 131 Pressure switch 104 Pressure transducer 112 Process automation and control equipment 39 Process controller 12 Process display 12 Process gas blower 149 Product tool box 131 Profibus controller 107

144

SEARCH - THE INDUSTRIAL SOURCEBOOK | J U N E 2 0 1 3

Product

Pg No

Programmable logic controller 121 Proximity sensor 26-35 PTFE/teflcon 107 Pull stud 128 Pump 14, 37, 79, 113, 123, 134, BC Push button 19 Push button switch 63 Quick change tapping chuck 130 Radial drilling machine 108 Reamer 128 Reaming and tapping 130 Rear cylinder hydraulic press brake 131 Relay socket 63 Robtoic cable 21 Roots blower 14, 79 Rope guide 111 Rotary and linear encoder 12 Rotary dry vacuum pump 149 Rotary switch 19 Rotating electrical connector 115 RTA stepper drive 122 Safety protection device 19 Salt aerosol filter tester 128 Scable ties 77, 117, 119 Scissor lift table 129 Screwdrivers and accessories 131 Seamless pipe 137 Self feed drilling unit 124 Separator plate 6 Servo drive 45 Servo motor 45 Shaft 111 Shearing machine 131 Side channel blower 113 Side lock adaptor 128 Sider paste 115 Silence flow package 149 Silicone 121 Single girder EOT crane 111 Single limit switch 19 Slip ring crane duty motor 55, FGF SMPS 47 Socket and accessories 131 Socket and switch 6 Solderless terminal 77, 117, 119 Solid carbide drill FIC Solid carbide drills with IC FIC Solid carbide mill FIC Solid carbide reamers FIC Solid carbide reamers with IC FIC Solid carbide special drill FIC Solid carbide special mill FIC Solid carbide special reamer FIC Special applicatin motor 133 Special tool 128 Speciality fastener 129 Spirac cable 21 Spray gun 143 Stainless steel pipe 137 Steam boiler 113 Steam steriliser 131 Steel mill duty and flame proof crane 65 Step motion controller 107 Straightener 141 Straightener-feeder 141 Suspension 112 Swing check valve 110 Switch disconnector fuse 104 Switchgear 109 Switching power supplies 104

Product

Pg No

Tachometer 47 Tap adaptor 130 Technical ceramic 5 Temperature controller 47 Temperature controller 108 Temperature-resistant cable 21 Tensioner nut 113 Terminal block 6 Terminal strip 63 Textile and yarn trolley 132 Thermal imaging camera 20 Thermal insulation 95 Thermic fluid heater 113 Three way ball valve 110 Time switch 47 Time switch 104 Tool 128 Tool bag and tool case 131 Tool chest 131 Tool post grinder for lathe 132 Torque motor 133 Torsion spring 115 Track roller 113 Trade fair for metalworking technology 107 Transfer trolley 120 Transformer ratio meter 117 Transformer winding resistance tester 117 Tray dryer 113 Trim handling system 113 Trolley wheel and casterd 132 Truck blower 149 Tube 25, 137 Tubing accessory 39 Twist drill 128 Two way ball valve 110 Uâ&#x20AC;&#x2122; tube 137 Uhmw-pe 107 Universal quick change chuck 130 Vacuum booster pump 14, 79 Vacuum system 14, 79 Validation of pacs 115 Valve 39, 110, 134 Valve positioner 127, 130 Valve terminal 39 Vane damper 113 Vertical machining center 124 Very low frequency hipot 117 Vibro motor 132 Vise 143 Viton 121 Wafer check valve 110 Wall travelling crane 112 Water accessories 25 Water faucet and tap part 5 Water ring vacuum pump 113 Wave spring 137 Welded pipe 137 Welding equipment 143 Welding machine 1,13,115 Winches 65 Wire and cable 109,111 Wire connector 77, 117, 119 Wire rope hoist 120 Wood working tool 131 Workholding solution 129 Workstation 128 Zirconia polycrystal ceramic 5

ADVERTISERS’ list

To know more about the advertisers in this magazine, refer to our ‘Advertisers’ List’ or write to us at search@network18publishing.in or call us on +91-22-3003 4653 or fax us at +91-22-3003 4499 and we will send your enquiries to the advertisers directly to help you source better.

Advertisers’ Name & Contact Details

Pg No

Actuators India Pvt Ltd

T: +91-250-2480916

110

Pg No

CNP Pumps India Pvt Ltd

T: +91-22-25818400

Aditya & Associates

99

T: +91-22-25828676

Connectwell Industries Pvt Ltd T: +91-251-2870636

E: abhi30dsh@gmail.com

E: connect@connectwell.com

W: www.ankitaindus.com

W: www.connectwell.com 113

Cosmos Impex (India) Pvt Ltd

Advertisers’ Name & Contact Details

Everest Blower Systems

W: www.everestblowers.com 6

Everest Blowers

E: info@everestblowers.com W: www.everestblowers.com 22

Festo Controls Ltd

E: contact@aerothermsystems.com

E: mediasupport@cosmos.in

E: info_in@festo.com

W: www.aerothermsystems.com

W: www.cosmos.in 8

T: +91-22-28221404

Darling Pumps Pvt Ltd

T: +91-731-2720558

E: allied@vsnl.com

E: darlingin@satyam.net.in

W: www.aecconnectors.com

W: www.darlingpump.com

Ami Polymer Pvt Ltd

121

123

T: +91-22-29204209

Dimeco-Kirpekar Metal Forming Solution 141

Flex Link Systems India Pvt Ltd

E: amipolymer@vsnl.com

E: contact@dimecoindia.com

E: info.in@flexlink.com

W: www.amipolymer.com

W: www.dimecoindia.com

W: www.flexlink.com

T: +91-124-3005555

102

Eddycranes Engineers Pvt Ltd

T: +91-22-23522710

65

Flir Systems India Pvt Ltd

T: +91-11-4560 3555

E: info@apexauctions.in

E: eddycranes@vsnl.com

E: flirindia@flir.com.hk

W: www.apexauctions.in

W: www.eddycranes.com

W: www.flir.com/thg

Boge Compressed Air Systems Pvt Ltd

23

T: +91-44-43593453

Elak Pvt Ltd

18

Frost & Sullivan T: +91-44-66814080

E: fc.jayakaran@boge.com

E: info@elak.co.in

E: ravinder.kaur@frost.com

W: www.boge.in

W: www.elak.in

W: www.frost.com

16

T: +91-44-67103800

45

Engineering Expo E: engexpo@infomedia18.in

W: www.cecoelectronics.co.in

W: www.engg-expo.com

T: +91-22-24465251

107

Essen Deinki

T: +91-172-4600600

G L Brothers

T: +91-22-66047000

143

W: www.pilotindia.com 136

G W Precision Tools India Pvt Ltd T: +91-80-40431252

.FIC

E: info@gwindia.in W: www.gwindia.in 63

Gandhi Automations Pvt Ltd

T: +91-22-66720200

E: sales@classicpolymers.co.in

E: info@essendeinki.com

E: sales@geapl.co.in

W: www.classicpolymers.com

W: www.essendeinki.com

W: www.geapl.co.in

SEARCH - THE INDUSTRIAL SOURCEBOOK | J U N E 2 0 1 3

20

E: info@pilotindia.com

T: +91-09819552270

E: ceco@cecoelectronics.in Classic Polymers & Resins

47

W: www.eaplindia.com

W: www.bonfiglioli.com T: +91-33-22480192

T: +91-80-42802345

E: sales@eaplindiamail.com

E: sales.buins@bonfiglioli.com Ceco Electronics Pvt Ltd

Electronic Automation Pvt Ltd

57

114

T: +91-172-5078112

Bonfiglioli Transmissions (Pvt) Ltd

111

E: finechromespl@yahoo.co.uk

T: +91-124-4278844

Apex Group

39

W: www.festo.com Finechrome Shafts Pvt Ltd

T: +91-20-66741600

T: +91-22-28555107

14

T: +91-11-45457777

T: +91-80-22894100

Allied Electronics Corporation

79

T: +91-11-45457777

T: +91-265-3927000

T: +91-79-25890158

Pg No

E: info@everestblowers.com

W: www.nanfangpumps.com

W: www.actuatorsindia.net

Aerotherm Systems Pvt Ltd

37

E: sales@nanfangpumps.com

E: aiplvasai@gmail.com

146

Advertisers’ Name & Contact Details

Not Available

17

Our consistent advertisers

ADVERTISERS’ list Advertisers’ Name & Contact Details

Pg No

GGB Bearing Technology

41

Advertisers’ Name & Contact Details

Pg No

Advertisers’ Name & Contact Details

Jaibalaji Control Gears Pvt Ltd

26-35

Lapp India Pvt Ltd

T: +91-20-30616600

T: +91-44-26251279

T: +91-80-7826000

E: india@ggbearings.com

E: dchandramohan@jaibalaji.firm.in

E: sales@lappindia.com

W: www.jaibalaji.firm.in

W: www.lappgroup.com

Goliya Instruments Pvt Ltd

122

Jergens India Pvt Ltd

129

Pg No

21

Lee Spring Company India Pvt Ltd

115

T: +91-22-24149657

T: +91-22-41238039

T: +91-80-49376666

E: goliya@mtnl.net.in

E: joseph.killukan@jergensinc.com

E: janardhanapr@leespring.com

W: www.goliyainstruments.com

W: www.jergensinc.com

W: www.leespring.com

Grundfos Pumps India Pvt Ltd

.BC

Jyoti Ceramic Industries Pvt Ltd

5

Legris India Pvt Ltd

T: +91-44-24966800

T: +91-253-2350120/338

T: +91-124-4590600

E: salesindia@grundfos.com

E: info@jyoticeramic.com

E: legris.india@parker.com

W: www.grundfos.in

W: www.jyoticeramic.com

W: www.parkerlegris.com

Hafa Hoists Pvt Ltd

111

Jyoti CNC Automation Pvt Ltd

.BIC

Macpower CNC Machines Pvt Ltd

T: +91-22-27694837

T: +91-2827-287081

E: response@hafahoists.com

E: info@jyoti.co.in

E: sales@macpowercnc.com

W: www.hafahoists.com

W: www.jyoti.co.in

W: www.macpowercnc.com

Hensel Electric India Pvt Ltd 94; 121; 135

K.U.Sodalamuthu & Co Pvt Ltd

25

150

T: +91-2827-287930

106

Makson Machines Pvt Ltd

108

T: +91-44-24541669

T: +91-09810555577

E: henselelectric@vsnl.com

E: sales@sodaltech.net

E: makwana_eng@yahoo.com

W: www.hensel-electric.de

W: www.sodaltech.net

W: www.makwanaeng.com

Hi-Fab Valve Automation

127

Kabel Schlepp India Pvt Ltd,

T: +91-278-2446437

87

MGM-Varvel Power Transmission (P) Ltd 101

T: +91-22-40766539

T: +91-80-41158997

E: valves@hi-fab.com

E: gm@kabelschlepp.in

E: ravik@mgmvarvelindia.com

W: www.hi-fab.com

W: www.kabelschlepp.com

W: www.mgmvarvelindia.com

Hindustan Motor Mfg Co

133

Karcher Cleaning Systems Pvt Ltd

T: +91-44-64627008

145

NI Systems India Pvt Ltd

T: +91-22-42500500

T: +91-120-4661800

E: sales@hindmotors.com

E: info@karcher.in

E: ni.india@ni.com

W: www.hindmotors.com

W: www.karcher.in

W: www.ni.com

Igus India Pvt Ltd

70

Klipco Pvt Ltd

T: +91-80-39127800

T: +91-22-28684221

E: info@igus.in

E: klipco@mtnl.net.in

W: www.igus.in

W: www.klipcoclips.com

IMI Impex Pvt Ltd

130

Knowell International Pvt Ltd

T: +91-2764-233983

T: +91-33-22304627

E: imi@imitoolsindia.com

E: hktrading@vsnl.com

W: www.imitoolsindia.com

W: www.knowell.co.in

J D Controls

110

Kuebler Automation Pvt Ltd

T: +91-80-41190000

135

NIA Controls

134

T: +91-250-2480916 E: ncvasai@gmail.com W: www.niacntrols.com 124

NMTG Mechtrans Techniques Pvt Ltd 113 T: +91-79-22821527 E: nmtg@nmtgindia.com W: www.nmtgindia.com

12

Packam & Controls Pvt Ltd

T: +91-79-22205088

T: +91-20-22953819

E: info@jdvalves.com

E: info@kuebler.in

E: sales@packam.co.in

W: www.jdvalves.com

W: www.kuebler.in

W: www.packam.co.in

Our consistent advertisers

10-11

85

T: +91-22-61206600

Not Available J U N E 2 0 1 3 | SEARCH - THE INDUSTRIAL SOURCEBOOK

147

ADVERTISERS’ list Advertisers’ Name & Contact Details

Pg No

Progressive Engineers

115

Advertisers’ Name & Contact Details

Pg No

Summits Hygronics Pvt Ltd

105

Pg No

Trident Pneumatic Pvt Ltd

118

T: +91-22-32944289

T: +91-422-2689020

T: +91-422-2400492

E: info@progressiveengineers.net

E: info@airdryer.in

E: sales@tridentpneumatic.com

W: www.airdryer.in

W: www.tridentpneumatic.com

W: www.progressiveengineers.net Prolite Autoglo Limited

89

T: +91-22-66599223

Suraj Limited

137

T: +91-79-27540720

Swagelok Company

Ravi Electronics

15

130

W: www.fluconautomationinc.com Robin Precision Products Pvt Ltd

128

T: +91-2827-287631

149

T: +91-120-4696222

131

E: info@shaileshmachines.com W: www.shaileshmachines.com

T: +91-79-22872349

W: www.sypco.co.in

E: emo@vdw.de

T M Mohammedally

131

T: +91-22-22019954

Stahl Cranesystems (India) Pvt Ltd

T: +91-11-32222661

E: infoindia@stahlcranes.com W: www.stahlcranes.com Sumitron Exports Pvt Ltd

120

77; 117; 119

T: +91-11-41410631

Vivek Engineers

132

E: viveklaxmi@gmail.com

W: www.technoind.com

W: www.laxmivibro.com Wiska India Pvt Ltd

129

T: +91-22-27566438

W: www.tecknic.co.in 55; FGF

T: +91-20-66865200

Wont Industrial Equipments

132

E: info@wantindia.com

W: www.indianelectric.com The Supreme Industries Limited

W: www.wiska.in T: +91-261-2894847

E: iecmktg@indianelectric.com 95

W: www.wontindia.com

T: +91-22-40430000

E: sumitron@vsnl.com

E: insulation@supreme.co.in

W: www.sumitron.com

W: www.supreme.co.in

SEARCH - THE INDUSTRIAL SOURCEBOOK | J U N E 2 0 1 3

24

W: www.venusengineers.com T: +91-79-22871813

E: info@technoind.com

The Indian Electric Co

T: +91-44-43523955

107

E: enquiry@venusengineers.com

E: teknic@vsnl.com 112

109

W: www.emo-hannover.de Venus Engineers

T: +91-22-26592392

W: www.sonalmagnetics.com

VDW Verein Deutscher

T: +49-69-7560-8156

Teknic 19

E: info@sonalmagnetics.com

Vashi Electricals Pvt Ltd

E: syppumps@gmail.com

T: +91-79-25830742 116

W: www.vacunair.com

Werkzeugmaschinenfabriken E.V.

Techno Industries

Sonal Magnetics

E: info@vacunair.com

W: www.vashielectricals.com 134

T: +847-719-5900

W: www.smalley.com

113

E: sales@vashielectricals.com

137

E: info@smalley.com

Vacunair Engineering Co Pvt Ltd

T: +91-2522-661600

E: sales@swamatics.com

T: +91-22-28489969

T: +91-281-2461102

Smalley Steel Ring Company

Swam Pneumatics Pvt Ltd

Syp Engineering Co Pvt Ltd

W: www.bloodtools.com Shailesh Sales Corporation

W: www.swagelok.com/connections

W: www.swamatics.com

E: info@bloodtools.com

W: www.udeyraj.com T: +91-79-22910771

T: +91-79-65722609 E: sales@fluconautomationinc.com

117

E: udeyraj@udeyraj.com

W: www.surajgroup.com

W: www.prolite.in

Udeyraj Electricals Pvt Ltd T: +91-22-66916181

E: suraj@surajgroup.com

E: sales@prolite.in

148

Advertisers’ Name & Contact Details

Not Available

Our consistent advertisers

Vol 16 No 06

RNI No; 67827/98 Postal Regd. No: G2 / NMD 81 2011-13 Posted at Mumbai Patrika Channel Sorting Office - GPO - Mumbai 400 001 on 22nd & 23rd of Every Previous Month Date Of Publication: 18th of Every month

June 2013 152