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Contact: Todd MARSHALL Editor in Chief: editor@industryemea.com Send your press releases to: editor@industryemea.com

To receive Industry EMEA magazine free of charge, please subscribe online at www.industryemea.com Industry EMEA is the English-language magazine for engineers, published by IPM (Industrial Portal Media) It contains the latest product and company news for industrial markets.

Industry EMEA edits its articles with the greatest of care, however we cannot guarantee the accuracy of the information presented in them. Our teams disclaim all responsibility concerning the content of this media or how it might be used.

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NEWS

NEW MERIDIAN HYDROGEN SENSOR NOW AVAILABLE

Tyco Gas & Flame Detection is pleased to announce that the Meridian Hydrogen (H2) Sensor is now available.

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he Meridian Hydrogen sensor comes standard with two user selectable gas ranges: 4% by Volume or 1%

by Volume, and is ideal for Hydrogen detection in environments where Catalytic bead sensor use is impractical, or available power is limited.

This new sensor follows other available Meridian sensor features including: Range Invariant calibration, true Hot Swap replacement, and the ability to calibrate in the lab and put it quickly into operation in the field. The sensors employ an electrochemical sensing element that needs recalibration just once every three months for optimum performance.

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For more information visit www.TycoGFD.com

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NEWS

DELTA DEMONSTRATES A HIGHLY DIVERSIFIED PORTFOLIO OF POWER ELECTRONICS, COOLING SYSTEMS AND INTEGRATED POWER SOLUTIONS AT ELECTRONICA 2016 MUNICH

Featuring telecom power rectifiers with 98% efficiency and best-in-class 56.8W/in³ power density.

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elta, a global leader in power and thermal management solutions, and its subsidiaries Cyntec and Eltek, will present at Electronica 2016, a wide spectrum of state-of-the-art power electronics, cooling systems and integrated power solutions capable of optimizing performance and energy savings in industrial, automotive, medical, and telecom applications. Delta’s superiority will be reflected by its Telecom Power Solutions featuring best-in-class 56.8W/in³ power density and by Eltek’s Rectiverter, the world’s first bidirectional power module.

Delta’s Electronically Commuted (EC) Fans deliver lower electricity consumption by 40% to 50% versus traditional AC fans in several applications while Cyntec’s AEC-Q200qualified power chokes boast maximum thickness of only 2.1mm to support high-frequency operations of up 1MHz in automotive applications.

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“Delta’s core competence of delivering industry-leading energy efficiency is based on its long-term focus in R&Dbased innovation and commitment to a low-carbon world.

A testament of such endeavour is the official launch, here at Electronica 2016, of our new telecom power rectifiers offering impressive efficiency at up to 98%”, said Mr. Jackie Chang, President & General Manager for Delta in Europe, Middle East and Africa (EMEA).

Delta’s leading technologies at Electronica 2016 will include: 1) Telecom Power Solutions: Our showcase will include eco-friendly Telecom Power Solutions by both Delta and Eltek. Delta’s DPR3000E-48 series rectifiers now offer leading energy conversion efficiency of up to 98% and best-in-class power density of 56.8W/in³, remarkable qualities to help enable not only further opex and space savings but also lower carbon emissions for our telecom carrier customers. The OutD “M” series modular outdoor cabinet system includes energysaving cooling options such as air ventilation (AV) only and AV + air conditioning (AC). The iF Design Award and Red Dot Award winner 96%-efficient Golden Eagle small cell system for 4G applications will also be available.

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Cyntec will also exhibit its advanced 95%-efficiency nonisolated and isolated Point of Load (POL) DC-DC converters which integrate controller chips, chokes and I/O capacitors into a single power management module to deliver up to 75% space savings. These qualities are essential for engineers seeking to construct ultra-compact high-performance DCDC conversion systems.

3)Thermal Management Solutions: Delta will also exhibit its full portfolio of Electronically Commuted (EC) Fans (blowers and axial fans) featuring superior thermal management with roughly 40% to 50% energy savings and lower noise operations compared to traditional AC fans in applications such as HVAC, data centres, commercial refrigeration and renewable energy. A wide range of input voltage options available for 3-phase fans (200-480Vac) simplifies our customers’ procurement process substantially. Unlike AC fans, Delta’s EC Fans also offer communication properties for effective speed control and status monitoring via MODBUS RS485 protocol for enhanced energy efficiency and operating reliability.

Eltek’s Rectiverter, the world’s first bidirectional power module, facilitates optimum simplified AC and DC-powered system structures for higher efficiency, reliability and control and lower total cost of ownership even beyond telecom applications. Eltek will also exhibit its Remote Power System and Flatpack S modules at Electronica 2016.

2) Power Electronics: Our growing Industrial Power Supply (IPS) portfolio (currently more than 500 products) offers an extensive set of product types to support power conversion in applications as diverse as factory automation and medical.

For example, the high-performance Delta CliQ M series DIN rail power supply features >90% efficiency and Advanced Power Boost (APB) in a high power density design. The APB function detects a faulty current path within a multiple loads connection and in turn trips the circuit breaker connected to that path, ensuring other connected loads can continue operations without interruption.

For telecom applications, our cabinet thermal solutions, including heat exchangers, thermoelectric coolers, heaters and air conditioners, also leverage Delta’s world-leading position in DC brushless fans to maximize operating performance and even are capable to run continuously for up to 80,000 hours (~9 years). Our heat exchangers and thermoelectric coolers also operate with excellent lownoise properties, in some models as low as 54 db-A. Delta’s cabinet air conditioners utilize variable-speed DC inverter compressor and dual rotor design to achieve a coefficient of performance (COP) of up to 4.5, meaning significantly lower energy consumption in the cooling process.

4) Uninterruptible Power Supply (UPS) Systems: Delta’s 3-phase modular Modulon DPH series UPS system, designed for better flexibility and strong performance with 96% AC-AC efficiency is an ideal option for mediumsized data centers. While a 75kW Modulon system will be displayed at the show, its power rating goes up to 200kW. Other UPS systems for IT, industrial and retail applications are part of Delta’s proposition at Electronica 2016. www.deltaww.com

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Delta’s subsidiary, Cyntec, will unveil its next-generation passive components, power modules, RF components at Hall B6, stand 411. For the highly demanding automotive sector, Cyntec’s best-in-class miniaturized AEC-Q200qualified power chokes offer high saturation currents and low DC resistance, are capable of tolerating high-frequency conditions of up to 1MHz and boast not only a super-thin design with maximum 2.1mm thickness but also a metal dust core for excellent performance.

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NEWS

LINEARIZATION AND TEACH – AN INVINCIBLE TEAM FOR SIMPLE AND PRECISE MEASUREMENTS

AlphaProx IR18 – easy evaluation thanks to linearized calibration curve.

Thanks to linearized calibration curves and very low standard dispersion rates, the new distance-measuring inductive sensors IR08, IR12 and IR18 from the Baumer AlphaProx family offer easy and reasonably priced analysis of the measurement results without any additional cost or effort for programming. Complex reference measurements are also things of the past.

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simple and innovative 1-point teaching process makes it possible to set or adapt the sensors to a special application quickly and easily, more or less at the press of a button. The sensor is only taught at one certain position. The output signal from the teaching point is linear, with the required steepness. This means that the sensor can also be installed wherever the teaching of a second point is not possible on account of the dynamic range of the application. An example of this is the measurement of the deformation of a shaft. Installation tolerances are eliminated directly in the sensor, guaranteeing reproducible measurements and reducing installation costs.

The steepness of the calibration curve can be adapted individually to different applications using an easy-tooperate 2-point teaching function. The sensors assume an exactly defined value at the minimum and maximum distances, and between these the output signal is linear. For applications in which, beside the analog signal, a switching signal is to be generated at certain points on the calibration curve, for example to indicate a critical range, Baumer also offers AlphaProx models with an additional digital output.

This combination of two outputs in one sensor allows the sensor to be installed even in places where there is no room for two sensors, thus cutting costs as well.

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More information at: www.baumer.com/alphaprox

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You get the support that you need throughout the whole purchasing cycle thanks to an extensive local and international network of sales staff and distributors.

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NEWS

DP TECHNOLOGY CONTINUOUSLY FORGES PARTNERSHIPS WITH ACADEMIA TO ACCELERATE SMART MANUFACTURING

DP Technology along with the College of Electromechanical Engineering at Beijing Union University and the Beijing Intelligent Mechanical Innovative Design Engineering Research Center hosted the ESPRIT CAM & Smart Manufacturing seminar on September 22, 2016.

The ESPRIT CAM & Smart Manufacturing seminar hosted by DP Technology in Beijing, China on September 22, 2016 was a great success.

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P Technology joined the College of Electromechanical Engineering at Beijing Union University and the Beijing Intelligent Mechanical Innovative Design Engineering Research Center to host the ESPRIT CAM & Smart Manufacturing seminar in Beijing on September 22, 2016. The seminar brought into focus the most critical manufacturing topics in China today in order to better support the ten-year national plan, Made in China 2025.

The Made in China 2025 program promotes the transfer into smart manufacturing, improves applications in smart manufacturing and fosters the next generation in a wide array of manufacturing industries. The event was attended by more than 60 people from local manufacturing companies, universities and members of the press. The seminar was a joint speaking engagement for outstanding businessmen and technicians. It featured many topics to support attendees and ESPRIT users on their path to success, including Industry 4.0, smart manufacturing, manufacturing automation and the partnership between industry and academia.

Guang Cheng, Dean of College of Electromechanical Engineering of Beijing Union University, addressed the current status and major trends in the future of

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smart manufacturing from historical, conceptual and practical aspects. Mr. Cheng stated that the College of Electromechanical Engineering is committed to developing high quality application engineers with an international point of view. He also stated that, “We would like to facilitate cooperation with DP Technology to further the development of smart manufacturing. The current research focus of Beijing Intelligent Mechanical Innovative Design Engineering Research Center covers a wide range of smart manufacturing technologies, including prototype design and manufacturing, human-machine interaction and usability testing, and smart manufacturing and service.”

“With more than thirty years’ experience, ESPRIT CAM is the only software which is capable of supporting B-axis multitasking, 2-5 axis milling, 2-22 axis turning and 2-22 axis, Wire EDM and offers a platform which gives users customized solutions through any object-oriented programming language. With customers across the world, ESPRIT CAM has been applied in a wide range of industries, including aeronautics and astronautics, automotive, industrial machinery, education, medical machinery, energy and so on. In order to provide better service to customers, DP Technology operates sales and technical support centers in

NEWS DP Technology application engineers provided training in ESPRIT CAM programming

Mike Lauer, General Manager at DP Technology Asia Pacific, explained how ESPRIT CAM supports the Made in China 2025 plan.

Guang Cheng, Dean of the College of Electromechanical Engineering, addressed the current status and future trends of Chinese manufacturing.

multiple locations: Beijing, Tianjin and Guangzhou in order to provide high performance professional and efficient services. DP Technology also adds value to education in China as a part of their ongoing commitment to support the ‘Made in China 2025’ plan. For many years DP Technology has partnered with higher education institutions, technical middle schools, technical high schools, and technical colleges. DP Technology works hand in hand with local schools and colleges to create certification and training centers and to help build the education revolution in China.

DP Technology will be an official and major sponsor of the 7th National Vocational Students Skills Competition- CNC machining contest and will also provide technical support at the event. To sponsor the biggest machining contest in China, DP Technology is taking a proactive approach in engaging with the stakeholders in these industries, but also shows the capability and determination to support the Made in China 2025 plan “ said Mike Lauer, General Manager at DP Asia-Pacific.

David Zhang, Vice General Manager for DP China, presented ESPRIT to the Chinese audience.

has always been committed to being the world’s leading CAD/CAM technology to college educators and students, specifically when multi-tasking machining with high-speed cutting. Introducing CAD/CAM technologies also helps provide high-end technical personnel to the industry. While we have been in this game for a long time, we will never stop learning and improving upon our cooperation with academia.” said David Zhang.

Cliff Ji also shared several benefits of ESPRIT CAM in the seminar.

1. ESPRIT CAM offers customized solutions for any type of machine tool to cut parts with any shape of geometry 2. ESPRIT CAM provides edit-free post processors with accurate G-code 3. ESPRIT CAM’s full machine simulation prevents machines from collisions 4. ESPRIT CAM is a cloud-enabled CAM to simplify the selection of cutting tools and automatically obtain the recommended ones.

In the seminar, application engineers from DP Technology also demonstrated ESPRIT CAM’s multi-tasking and 5-axis capabilities with ease to allow attendees to experience the power of the innovative ESPRIT CAM software.

The manufacturing industry has evolved into a new generation with automation, numerical control and smart manufacturing. DP Technology continues to improve their technologies by watching new cutting-edge developments in the manufacturing industry, fulfilling customer requirements, and providing innovative solutions to improve product quality, productivity and reduce production costs.

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In the seminar, David Zhang, vice General Manager in DP China, and Cliff Ji, sales engineer in DP North China also shared the most up-to-date CNC technology in ESPRIT CAM. “With a continuing thirst for new technology in the modern industry, CNC manufacturing has become popular in many areas. ESPRIT CAM is able to provide a complete package for customer’s manufacturing solutions in many different industries. In addition, ESPRIT CAM is compliant with IoT and the Industry 4.0 initiative. In this way, ESPRIT CAM not only provides users a new concept of automatic machining but also reduces the programming time with easy operations for high quality parts. As a global CAD/ CAM company, DP Technology believes that through the cooperation with educational institutions, they have the power to improve manufacturing in China. DP Technology

Cliff Ji, Sales Engineer in DP North China, shared several benefits of ESPRIT CAM.

www.espritcam.com 07 | Industry EMEA | November 2016

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NEWS

DELTA TO DISPLAY SMART ELECTRIC VEHICLE (EV) CHARGING SOLUTIONS FEATURING INDUSTRY-LEADING CHARGING SPEED AND CONVENIENCE AT ECARTEC 2016 MUNICH

Delta, a global leader in power and thermal management solutions, announced today it will present its smart EV Charging Solutions, featuring world-class charging speed, convenience, connectivity and reliability, at eCarTec 2016.

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mong these, Delta’s Stromtankstelle 4.0, a 150kW DC ultra-fast EV charger, offers simultaneous charging for up to 4 EVs, and is capable of charging an EV battery with approximately 100km range within 13 minutes. The 25kW DC Wallbox Quick EV Charger, suitable for shopping malls, workplaces and similar sites, optimizes installation time and costs through its modular design and lightweight casing. Their connectivity capabilities and the use of Delta’s site management systems enable smart remote control and monitoring.

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Mr. Jackie Chang, President & General Manager of Delta in the Europe, Middle East and Africa (EMEA) region, highlighted, “Delta’s core competence in leveraging significant R&D resources for the development of innovative energy-saving solutions is palpably reflected in our growing portfolio of smart EV Charging Solutions which continue their successful deployment across major European markets such as Germany, United Kingdom, France and Nordic countries. We facilitate superior productivity and efficiency to system integrators and charging site operators by combining industry-leading charging speed, compatibility with all major connector standards, lightweight yet durable design, and intelligent site management platforms. By 07 | Industry EMEA | November 2016

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integrating all these qualities to the user-friendly features of our chargers, we aim to provide a top-notch charging experience to EV drivers”.

Delta’s EV Charging Solutions unveiled at eCarTec 2016 include: Stromtankstelle 4.0 The state-of-the-art 150kW DC ultra-fast EV charger is an ideal option for charging site operators seeking to optimize the investments necessary to fulfil requirements from the foreseeable battery capacity upgrades of longerrange EVs. Its ability to charge up to 4 EVs simultaneously through CCS (up to 100kW DC), CHAdeMO (up to 63kW DC) and Type 2 (43kW AC and 22kW AC) connectors deliver not only exceptional charging speed (an EV battery with approximately 100km range within 13 minutes) but also the highest level of convenience to EV drivers in applications such as long-distance service stations.

Enhanced efficiency in monitoring, control and back-office processes is achieved by the Stromtankstelle’s connectivity to wireless and wireline platforms (via Ethernet, 3G and GPRS), RFID card reader and also its OCPP-based Charge

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Point Operator (CPO) back office system which enables integration with Electro Mobility Service Providers (EMSP), roaming platforms, smart grid management systems and smartphone apps. Excellent reliability is supported by its grid overload protection and modular power system design features. Supported by the design, remote access and the service organisation a special attention in the overall product concept has been paid for the quality and maximum uptime of the charging service.

Its network connectivity through OCPP, energy conversion efficiency of up to 94%, RFID authentication functions, IP55 / IK08 (vandal-proof) protection casing, and the integration with Delta’s web-based SMS platform are also value-added features that can deliver an easy and cost-effective DC charging solution to charging service providers, especially

AC Mini Plus EV Charger Delta’s newly-launched AC Mini Plus evolves with a more stylish and modern design than its predecessors while also offers a highly user-friendly interface with embedded RFID card reader and LED indications. With a maximum power output of 7.36kW, compatibility to both IEC 621962 Type-1 and Type-2 (tethered plug or socket) charging standards as well as IP55 / IK08 (vandal-proof) protection casing, this innovative EV charger is suitable for residential and commercial applications such as home charging, community parking sites, private fleets, service stations and more.

AC Slim II (Cordset) The AC Slim II (cordset) is another new product designed to improve the convenience in e-mobility with its 2.3kW power output (10A, 230V) and compact design. EV drivers can enjoy peace of mind with this innovative device which allows emergency charging when running low on power in their EVs. With its IP67 protection rating, OTP (over-temperature protection) sensor in the changeable power plug and all other ease-of-use features, the AC Slim II is highly valuable for residential, fleet and parking applications.

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25kW DC Wallbox Quick EV Charger This wallbox-type DC EV charger is specifically designed to enhance installation and maintenance productivity through its modular power system design, meaning that power modules can be easily integrated on site following easy installation steps of the lightweight casing. This provides a significant advantage in cost savings and improved flexibility. It offers dual charging ports supporting CCS and CHAdeMO standards with 25kW power output and wide voltage range (200~500Vdc for CCS and 50~500Vdc for CHAdeMO) to maximize the convenience for both installers and EV drivers.

for an ample range of commercial applications (hotels, workplaces, shopping malls, fleets, etc.).

www.deltaww.com 07 | Industry EMEA | November 2016

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NEWS

ITRANS 2 FIXED GAS DETECTOR OFFERS UP TO 2 POINTS OF DETECTION FROM A SINGLE DEVICE

Tyco Gas & Flame Detection is pleased to introduce the iTrans 2 fixed gas detector featuring a unique intelligent electronics platform that provides up to two points of detection from a single device.

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his state-of-the-art gas detector is able to monitor a combination of gases using a combination of available sensor technologies to include electrochemical, catalytic bead, and infrared. The iTrans 2 boasts a wide range of safety features including automatic sensor recognition, access code security, and zero and calibration fault protection. A single or dual-channel, split screen LED display provides optimal visibility in dark places with operator interface made simple using a magnetic wand.

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Available in aluminum or stainless steel enclosure, the explosion-proof device is designed for use in a wide range of applications and harsh environments. Other options include HART communications protocol, RS-485 Modbus, programmable relays and remote sensing. Certifications include CSA, ATEX, IECEx, INMETRO, CCC and China Ex. For more information visit www.TycoGFD.com

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NEWS

THE VERTICAL DRYER IS AN ADVANTAGEOUS ALTERNATIVE TECHNOLOGY

This new solution from De Dietrich Process System adds an important benefit for drying of powders in process industries, cosmetics and food. Recently, the GueduÂŽ vertical dryers have been installed by several clients, providing decisive quality and productivity improvements.

Short cycle times, reduced handling The vertical dryer is unlike hot air dryers and tray dryers. The powder is stirred under vacuum, that allows an improvement of the drying time by a factor 2 to 10 compared to tray dryers, and a total cycle time reduction by a similar ratio (by reducing the necessary handling). In fact, the vacuum drying technology allows savings due to the total cycle time reduction (a single pan dryer can replace several tray dryers) and also savings from the improved heat transfer during drying (reducing utilities costs).

To assist in the choice amongst its various drying equipment, De Dietrich offers to perform trials in its test hall in Semur, France. www. .com/en/solutions-and-products/vacuum-dryingsolutions/pan-dryer

Pristine quality The mechanical mixing during drying improves product homogeneity. Therefore, at the end of the cycle, the product comes out perfect evenly dried, with residual moistures below 0.1% where required.

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A ready-made Solution De Dietrich Process Systems is able to supply its customer not only with the appropriate drying technology, but also to design and supply the peripheral equipment, support structure as well as the automation and control systems.

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NEWS

TOPLUS IQ CLAMPING CHUCK WINS THE “MM AWARD” FOR INNOVATION AT AMB 2016

The Toplus IQ chuck scored high ratings in all categories.

After receiving the “100 places for Industry 4.0” award last May, from the Baden-Württemberg Industry 4.0 Alliance, for two manufacturing/networking solutions, Hainbuch, has now scored a second success in 2016.

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t the AMB exhibition, the newly developed intelligent Toplus IQ clamping chuck won the MM Award for innovation. A large number of AMB exhibitors were in the competition for the innovation prize. In the clamping device category, an 8-member jury had the task of selecting a winner from three finalists, and Hainbuch's chuck emerged victorious. The jury praised the pioneering spirit and the exceptional engineering performance of the family-run company from Marbach. The chuck scored good ratings in all the decisive criteria, including degree of technical innovation, usefulness for industry, environment and society, and economic efficiency. “Innovation is when the customer says »Wow«. And it seems like we got that reaction from the jurors”, said CEO Gerhard Rall smiling joyfully after the award.

“In the past, not to put too fine a point on it, it was all about iron and steel, but now mechatronics and digitalization play a very important role in product development”, explained Rall.

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A chuck with exceptional capabilities With its sophisticated integrated sensor technology, it permanently measures the actual clamping force applied to the workpiece. Using contactless transmission of both data and energy, measurement results are sent directly to the machine´s control system for processing. The control system performs a comparison with the target values and then outputs messages or makes adjustments as required.

In-line checking of the dimensions of each workpiece when it is clamped can even be performed directly using an integrated system of measurement sensors. The temperature near to the workpiece is also monitored to allow temperature compensation for example.

Data produces big pay-offs Using the data harvested by the control system, it is possible to perform long-term monitoring, so-called »Condition Monitoring«. Condition monitoring has two objectives: safety and machine efficiency. Monitoring the status of the machine is a mandatory prerequisite for need-oriented and status-oriented preventive maintenance and servicing.

Modern condition monitoring systems however put very tough requirements on the sensor systems, data capture and automated measurement data processing, as well

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A happy and visibly proud Gerhard Rall holds the award in his hands [from left to right: Attillio Mandarello, Research & Development Manager at Hainbuch, Sebastian Ivenz, Research & Development Engineer at Hainbuch, Anke Reichenecker, Marketing Manager at Hainbuch and Gerhard Rall, Hainbuch CEO.

as system specific knowledge. However they also have the greatest cost savings potential, because the expected working life of critical machine parts can be exploited to the maximum while any required maintenance interventions can simultaneously be planned to mesh in with production schedules. This makes it possible to prevent unnecessary downtime which in turn increases machine availability and reduces production shortfalls. It is good for the bottom line because the chuck can detect reject parts. For example, if a workpiece breaks, it is discarded and the value-adding process is interrupted.

This improves quality and reduces personnel costs. As a result, employees can focus more on proactive tasks.

Permanent monitoring reduces the risk of workpiece loss and the resulting damage to man and machine. And that is a very significant advantage. www.hainbuch.com

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NEWS

AC/DC DRIVES FROM CONTROL TECHNIQUES GIVE CRANE OVERHAUL SPECIALIST A LIFT

A US-based specialist in the supply of complete electrical packages for oil rig cranes is using Control Techniques AC and DC drives as part of a landmark $500,000+ order involving the upgrade of 10 LeTourneau cranes.

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hree cranes have already been completed with no reported down-time in the first 18 months of operation, whereas prior to the upgrade, maintenance would be required on a weekly or even daily basis in some instances. The financial benefits for the oil rig operator are proving substantial.

Headquartered in League City, Texas, JC’s Marine Oilfield Services was established in 1992. The company’s Power & Distribution Division specialises in a variety of motor control solutions that are customised to match the needs of oil rig cranes, as well as drilling barges, supply vessels and land rigs.

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When a Texas/Louisiana-based customer was seeking an electrical contractor to help upgrade the drive systems on 10 LeTourneau oilfield cranes, JC’s Marine Power & Distribution was in prime position to secure the order thanks to its technical support and AC/DC capabilities. As a long-standing advocate and user of drive technologies from Control Techniques, the company proposed the use of a Unidrive SP AC variable speed drive for the boom, and two Control Techniques Mentor MP series DC regenerative drives for the swing and hoist.

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“The technical advice offered by Control Techniques is one their best selling points,” stated John Costanza, President at JC's Marine Oilfield Services. “Their technicians always address problems quickly and comprehensively, which means a lot to a business such as ours, and is certainly better than we have experienced elsewhere. We exclusively use Control Techniques drives on our projects, ranging from 75 to 750 kW, both AC and DC.” Around 1600 LeTourneau cranes are currently in service on oil and gas rigs around the world. Although they were originally fitted with large motor-generator sets, these do not offer variable speed, meaning there is total reliance on the skill of the boom operator to lower heavy loads.

“By changing to a Control Techniques variable speed drive for the boom we can ensure complete control over the speed and rate at which the boom moves, so that loads up to 50 tons are ‘feathered’ rather than ‘banged’ to the ground,” said Mr Costanza.

The boom motor drive system comprises an SP5402 Unidrive variable speed AC drive rated at 210 Amps continuous, while the hook motor drive system features a

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Mentor MP420A4R DC drive rated at 420 Amps continuous.

A Mentor MP210A4R, rated at 210 Amps continuous, is fitted to the swing motor drive system. All of the drives are purposely sized for twice the normal power required, which means the system never runs at its maximum capacity.

“I’ve been operating with the new system for 12 months and have not had one issue,” said Justin Hillard, LeTourneau crane operator on Atlantic 7 rig. “The controls are user-friendly, very smooth and have a wide variable speed in hook, swing and boom. In my opinion, the boom is the biggest operating improvement. With its variable speed you can ease into boom and keep the load stable and personnel safe on deck.”

Jason also praised the increased safety afforded as a result of the new system: “The crane is also much quieter without the motor-generator sets running; you can hear what the crane is doing and what’s going on around you. I’ve also noticed that if you’re in a position where you cannot see the hook, you can actually hear the hook motor running and know how fast the hook is travelling. I highly recommend this system, it’s safer, smoother, quieter and virtually maintenance-free.”

David Powers, fellow LeTourneau crane operator on Atlantic 7 rig, also likes the new control system, which carries a Certificate of Design Conformance from the American Bureau of Shipping (ABS): “The new system gives the crane a better parameter of operation and is more responsive. Most importantly, these changes have made a much safer work environment.”

“Braking is automated, which promotes safety and takes responsibility away from the operator,” added Mr Costanza.

“Also, there is better reliability as the load is not being »snatched«” Further benefits delivered to the end user as a result of AC and DC drive technologies from Control Techniques include conformal coating on the PCBs, which helps impart protection in marine environments, while the large working temperature range is also advantageous.

The project to complete the upgrade of the 10 LeTourneau cranes will continue through to the end of 2017. www.emersonindustrialautomation.com www.emerson.com

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NEWS

PCD PERFORMANCE

KBDM PCD inserts are available in a variety of sizes. Here, a mini-tip suitable for finishing cuts is shown.

Automotive aluminum has met its match with the new KBDM face milling platform from Kennametal.

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nyone who’s replaced a head gasket on an internal combustion engine knows a smooth, flat surface on both cylinder head and block is needed for proper operation. No one understands this better than automakers, who strive for predictable, controlled surface finishes and high production output, together with maximum tool life and the lowest tooling cost per machined component.

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Many machinists might think, “What’s the big deal?

Aluminum is one of the easiest materials around.” And while that is certainly true of the ubiquitous 6061-T6, nothing could be further from the truth when it comes to the aluminum alloys used in automotive applications. Grades 319 and 390, for example, are readily cast into the complex shapes needed for engine blocks, pistons, heads, pulleys, and similar parts, but due to their high silicon content— easily 20 to 30 times that of 6061—they’re like cutting sand.

Fortunately for those charged with machining these abrasive metals, there’s a better alternative than carbide cutting tools, one that produces mirror finishes and produces tens of thousands of parts per edge.

“Finishes of 2 to 3 μm Ra are easily obtainable, as is tool life between indexing of 40,000 engine blocks, cylinder heads, and other automotive components,” says Tim Marshall, Senior Global Product Manager for Indexable Milling at Kennametal. “This new face milling platform uses a fine-pitch aluminum body with wedge-style clamps and adjustable pockets. A variety of polycrystalline diamond (PCD) inserts are available, from mini-tips for light finishing cuts to full-face wipers, standard cartridge inserts, and 1/2 in. (12.7 mm) axial cutters for heavy roughing and shoulder cutting.”

He’s talking about the KBDM PCD face milling system from Kennametal. Designed for high-volume machining, the KBDM is stocked in standard sizes of 2.5 - 8.0 in. (63 - 200 mm), although Marshall is quick to point out the company’s custom solution capabilities. “We can offer cutters up to 21.5 in. (550 mm) in diameter. This allows customers to machine very large components in a single pass. We also have options for integral shank bodies, HSK mounting, left hand cutter rotation, as well as special edge preps and nose radii.”

There’s more to the KBDM than a robust body design, however. Since automakers often create their own

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KBDM cutters are stocked in standard sizes of 2.5 - 8.0 in. (63 - 200 mm), although specials up to 21.5 in. (550 mm) in diameter are possible.

proprietary aluminum alloys, Kennametal has developed two PCD grades to complement it: KD1400 uses small diamond grains and offers excellent chipping resistance and good wear attributes, while KD1425 uses large diamond grains, giving it excellent abrasion resistance and thermal stability but only slightly lower performance where chipping is a concern. Both are capable of very high-cutting parameters—depending on the alloy and setup rigidity, Kennametal recommends an initial cutting speed of 3280 ft/min (1000 m/min) and feedrates of .004 in. per tooth (0.01 mm), although substantially higher values are possible.

“A major machine builder conducted cutting tests for us against several competitive solutions,” Marshall says. “Using a 24-tooth, 6.0 in. (150 mm) diameter face mill at 80% radial engagement and 0.04 in. axial DOC (1 mm), we ran at a feedrate of 0.006 in. IPT (0.15 mm) and 9600 ft/min surface speed (2926 m/min). This comes out to 6112 rpm, with a table feed of 880 IPM (22,350 mm). It was really moving.

Even so, the KBDM produced a 14.7 Ra surface finish, several points better than the other cutting tools.”

to its final height position. If using a wiper insert, set it 0.0006 - 0.0008 in. (0.015 - 0.020 mm) higher than the rest.

“It’s simple to set up,” Marshall says. “You can easily get everything within a couple microns. That's one of the keys to successful face milling, not only for proper balance at high spindle speeds but also for achieving the desired surface finish—when you're finishing a deck face on a block or head, both are critical.”

Adjusting the KBDM is a straightforward process—use an optical presetting device whenever possible, and DON’T OVERTIGHTEN! www.kennametal.com

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Marshall recommends presetting the KBDM offline using an optical or video-style presetter. A small amount of lubricant should be applied to the adjustment and locking screws, and also the wedge side of the pocket. Turn the axial adjustment screw until the insert is 0.0004 - 0.0006 in. (0.010 - 0.015 mm) below the final set height, tighten the locking screws to 31 in/lb. (3.5 Nm)—don’t overtighten—then adjust each insert 07 | Industry EMEA | November 2016

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ACURO® AX73 COMPLETES HENGSTLER’S RANGE OF ATEX-RATED ABSOLUTE ROTARY ENCODERS

The new Hengstler ACURO® AX73 is ideal for ATEX-rated applications demanding precision or smooth speed regulation.

The new Hengstler ACURO® AX73 is a class-leading optical encoder offering attributes such as ease of installation, high precision and compact dimensions. In addition, the introduction of the AX73 completes the company’s comprehensive family of ATEX-rated absolute rotary encoders, both optical and magnetic.

Equipment designers now have an unprecedented choice for a host of hazardous environment components.

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n the development of equipment for use in hazardous environments, selecting the right encoder is vital. Here, explosion protection is the first consideration, which is why the Hengstler ACURO-AX73 carries ATEX and IECEx certification for gas and dust explosion proof requirements.

However, this advanced optical encoder offers many more features of specific benefit in applications such as winches, cranes, drills and other oil and gas industry equipment, as well as at paint plants, petrochemical facilities, bottling plants and grain mills, for example.

Among the principal advantages is the connection concept of the AX73, which allows the routing of cabling and the final encoder installation to be done in separate steps. This provides significant cost and time savings during installation, as cabling can be done in advance. Emergency servicing can also be completed more quickly, resulting from the ability to simply unplug the cable and connect it to the replacement encoder. Since many oil and gas platforms use heavy and cumbersome cables measuring 40m in length or more, the design of the AX73 represents an attractive proposition for customers looking to lower their total cost of ownership (TCO).

Another ease-of-maintenance innovation is the use of just two screws for the connection hood. Many comparable encoders use six or even eight screws, while insufficient corrosion protection makes such units very difficult to uninstall. Instead, special patented screws are deployed on the AX73 to protect against dust, water and corrosion.

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The introduction of the AX73 completes the family of ATEX-rated absolute rotary encoders from Hengstler.

Inherent precision is a further beneficial characteristic of the ACURO® AX73. The optical scanning system provides a highly accurate, 22-bit resolution sensor signal for wherever precision or smooth speed regulation is necessary. However, despite its accuracy, the encoder is of robust design, with impressive resistance to shock, vibration and external magnetic fields. In addition, the unit provides users with IP67 protection class rating for the stainless steel housing, and offers an Ex-related ambient temperature range of -40 to +70°C. Although the AX73 is seen as the ‘big brother’ of the AX65 introduced by Hengstler last year, with a housing diameter of 76 mm it is still smaller than comparable competitor products. This will prove extremely valuable to system designers seeking space-saving solutions. Available immediately, the AX73 can be ordered with SSI, BiSS-B, BiSS-C and Profibus interfaces.

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The introduction of the AX73 now completes Hengstler’s ACURO®-Xproof absolute shaft encoder line. The new AX73 and AX65 offer the special mounting system, while also available are the AX70 and AX71 absolute encoders, as well as the RX70 and RX71incremental variants, with integrated cable. www.hengstler.com 07 | Industry EMEA | November 2016

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EOVE VENTILATORS GIVE PATIENTS BACK THEIR MOBILITY

EOVE revolutionizes the market by significantly reducing the weight of its life-saving ventilators. ASCO is proud to have contributed to this improvement.

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OVE designs, manufactures, and markets medical and surgical devices used during home care. Launched in 2015, the EO-150 has a big advantage over its competitors. Weighing just 1.8 kg, it is the lightest ventilator on the market and allows patients greater mobility. “The EO-150 is designed mainly for patients with serious medical conditions, many of whom use a ventilator 24/7,” explains Fabien Cotteaux, founder of EOVE. “Mobility is not just a convenience, it is also a reason for living. Patients who are active and mobile live longer and have undeniably better social relations”.

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“The ASCO solenoid valve is an essential component of our ventilators,” says Mr. Cotteaux. “This is because it meets a twofold need – it contributes to controlling a complex process and is light enough to ensure that our ventilators remain portable”.

Expiration is achieved by a pneumatic valve on the patient circuit that is controlled by ASCO's PreciFlow IPC solenoid valve. The unit operates in a closed loop via various sensors.

Control is achieved by varying the current and the function was entirely programmed by EOVE. “The first thing we wanted was a solenoid that could combine high-precision control with high repeatability. We contacted our regular partner, ASCO, which immediately proposed a solution that proved to be ideal due to its progressive opening and excellent repeatability,” says Mr. Cotteaux.

ASCO's PreciFlow IPC proportional solenoid valves are especially suited to medical and industrial analysis applications, in particular medical ventilators and mass flow controllers. The core of these solenoid valves is held in the core tube between two specifically profiled flat springs to completely eliminate friction and offer excellent control performance with a hysteresis of less than 5% and a repeatability and sensitivity of less than 1%.

“In terms of the EO-150's portability, ASCO was the only company to come up with an adequate solution. Unlike

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during the tests we conducted with the competitors' valves, the PreciFlow IPC does not overheat, control and reliability are not affected, and the consumption is extremely reasonable,” says Mr. Cotteaux.

www.asco.com/en-gb

The EO-150 consists of a portable module with six hours of battery life and a docking station. The module can be safely be removed from the docking station for easier portability.

It is also networked, making it possible to obtain data remotely.

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The Series 202 PreciFlow IPC (Inlet Pressure Compensated) solenoid valve proportionally controls the flow of air. This innovation enables high pressures and flow rates with a lowenergy coil (2.5 W max.). Although compact, it offers a high variable flow rate (190 l/min at 2.6 bar) without a minimum operating pressure. The PreciFlow IPC is available in 2/2 NC function with a 3 mm orifice and can be used over a pressure range of 0 to 7 bar with a maximum inlet pressure of 10 bar.

The valves were delivered to EOVE in order to immediately meet the requested function of being fitted with an adequate connector with a specific cable length.

“Since being launched in 2015, more than a thousand EO150s are in use. There have been zero reports of failure, which is crucial considering what it the EO-150 is used for,” says Mr. Cotteaux. These devices meet stringent safety standards and bear the CE marking for medical devices.

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FOR AUTOMATED DECORATION CDDR DIRECT DRIVE AND AKD PDMM MOTION CONTROLLERS FOR ACCURATE LACQUERING OF SCREW CAPS

View of Todema COLTAL machine for printing and decorating screw caps and cages for the beverage sector.

A fully servo-driven machine that can be used for various types of printing and lacquering. The machine has the capability to increase production whilst retaining high quality: today Todema meets the goal – Thanks to CDDR direct drive motors and to the KOLLMORGEN AKD PDMM motion controller.

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odeschini Mario Srl company, known by the brand name Todema (www.todema.it), was founded in 1960 in the province of Lecco and, since then, has acquired expertize in the manufacturing of industrial machinery and in the implementation of evolved automated systems. These automated systems include machines for the production of capsules,cages for bottling wine and other liquids, bending machines, lamination and printing systems, systems for the production of electro-welded chains, packaging systems and lines for the household appliances industry, as well as control systems that can be integrated in woodworking. The client portfolio ranges from a number of different industries, from the food sector to the metal and woodworking industry, and from different countries including Italy, Germany, Spain, USA, Argentina, Australia and New Zealand.

During the past few years, the design and programming of automated and robotic lines has given a strong boost to the industrial processes covered by Todema.

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“For this project, we contacted Kollmorgen because we needed to develop a system for colouring and printing screw caps for bottling wine and spirits. Our client required highquality and production standards concerning rotogravure colouring, tampography, silk screen and hot foil printing.

Our objective was to build a fully servo-driven machine, which was going to be a first of its kind in this sector,” Ing. Giovanni Todeschini, owner and Chief Technical Officer, explains.

The biggest challenge was to replace the traditional mechanical systems of our machine with mechatronic systems in order to obtain a new type of machine, which would be highly versatile and configurable by the client depending on their production needs. It was necessary to develop an integrated mechanical and electronic control system, achieving a seamless combination of the two engineering aspects. More specifically, the Todema design team, consisting of mechanical and electronic engineers, had to work quickly and systematically with KOLLMORGEN experts from the very first drafts of the project.

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In the fully servo-driven Coltal machine, the table control takes place by means of the Cartridge DDR motors, which are controlled by AKD drives. One of the advantages is the considerable increase in the production speed. The high quality of printing and embossed lacquering is noteworthy.

Coltal machine Aluminium screw caps are largely used for bottling spirits, mineral waters, oil and most recently wines too. Todema provides COLTAL for the lacquering of cylindrical objects and capsules: lacquering and silk screen printing or embossing, from video, hot foil or tampographic with very high visual quality. COLTAL is effective on various materials, such as Tin, Aluminium, Plastic and Poly-laminated materials. An integrated servo-driven system fully controls the machine operation ensuring a check of the result even with variable or unforeseeable conditions, such as the different quality and level of deformation of the materials, the type of friction or the difference in dyeing.

AKD PDMM: motion controller, PLC and servo-drive in a single device The process is controlled by a smart AKD PDMM system with integrated PLC and motion control for the development of a virtual master for the generation of the main reference, and electronic cams for the positioning and motion sequential control. This key development, which has led to a great reduction of costs in terms of hardware and installation, as well as space needed in the electrical cabinet (up to 30%) and wiring reduction, was made possible due to the cooperation with KOLLMORGEN from the very first steps of this project.

The AKD servo amplifier combines innovative technology and outstanding performance within very small dimensions.

These servo amplifiers with multiple features provide solutions for nearly any application, from basic torque and speed control, to register control, through to fully programmable multi-axis applications with embedded Kollmorgen Automation Suite™.

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High performance in a small space: Direct Drive Cartridge DDR servomotors In order to check the exact positioning of the two spindleholding tables without further mechanical parts, 2 Direct Drive Cartridge DDR servomotors are used together with the related AKD drives. Such motors allow a direct control of the motion, thus eliminating all the mechanical transmissions that used to generate too much elasticity in the motion. In order to ensure the required precision, a direct-drive motor system was needed. Cartridge motors are the quickest and simplest solution to implement.

The quality of printing and embossed lacquering depends on the precision and accuracy of the machine movements, which are provided by the torque motors and the related Kollmorgen control systems. The disposal of the mechanical

transmission systems has considerably reduced the frequency of maintenance operations,need for spare parts and ease of maintaining the overall machine accuracy level over time.

Universal AKDs set the standards for efficiency and power density. The ADK series has been designed with the versatility, connectivity and power needed to increase the 07 | Industry EMEA | November 2016

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High performance in a small space: Direct Drive Cartridge DDR servomotors.

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Multi-programmable motion controller: Integrated IPC, AKD D, fully programmable.

machine performance as well as the speed of integration.

The motor setup mainly occurs through plug-and-play and offers a wide range of feedback. Among the various possibilities of Ethernet connection, options for both open and closed protocols are available. Online diagnostics and the data verification enable faster and error-free programming. A wider power range, enclosed in a compact design, allows you to use these robust drives with a single interface.

“Our client’s objective – Todeschini recalls – was a machine with a production of approximately 60/70 pieces per minute.

We largely exceeded that target”.

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Recap “Our clients are highly satisfied with COLTAL – Todeschini points out –, the quality standards have been fully met and the production targets have exceeded our expectations by 15%. Kollmorgen staff worked with us painstakingly and quickly to ensure that the components that we used were highly reliable and high-performing. Our initial objective has been fully achieved and in fact we have highly exceeded our expectations particularly in terms of accuracy and quality”.

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Direct Drive Cartridge DDR servomotors www.kollmorgen.com/en-gb/products/motors/directdrive/cartridge-c-and-ch/cartridge-ddr/ AKD PDMM www.kollmorgen.com/en-gb/products/drives/servo/ akd-pdmm/akd-pdmm-programmable-drive-multi-axismaster/ AKD servo amplifier www.kollmorgen.com/de-ch/products/drives/servo/ akd/akd-ser voverstärker/?utm_source=pr&utm_ campaign=press-release-ch www.kollmorgen.com

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MORE EFFICIENCY AND FLEXIBILITY IO-LINK SENSOR/ ACTUATOR HUB WITH EXPANSION PORT

IO-Link actuator/sensor hubs from Balluff feature eight ports for 16 in-/outputs.

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hey allow for example signals from up to 16 switching sensors to be collected from a distance of up to 20 m so that they can be made available to the machine controller via IO-Link and an IO-Link master using a simple 3-conductor cable. Brand new in the market are versions with an expansion port.

Here Slot 7 can be reconfigured as an expansion port by means of a simple parameter entry. A complete valve plug or an additional sensor hub can be connected to it. For the user this means a significant gain in flexibility and efficiency.

Now it is possible not only to cost-effectively process additional in- and outputs, but also expand the range to a circle of another 20 m. Thanks to plug-and-play and the use of unshielded standard cables, the system can be started up in no time at all. www.balluff.co.uk

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NEW INTERNATIONAL TRAMWAY LINK WILL JOIN FRANCE AND GERMANY

Plan of the 2.9 km route for the extension of line 15 between Orbey Briand in Strasbourg and the Kehl train station.

Historically linked to the construction of the Strasbourg tramway, Vossloh has provided a whole range of track and signalling equipment for the extension of line D towards the German city of Kehl.

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t the recent project, the 2.9-km extension of line D between the cities of Strasbourg and Kehl in Germany across the Rhine, Vossloh had to face new parameters that have led to new choices. They developed and manufactured a new transition track, linking the grooved rail to the Vignole rail on the bridge. The expansion joints are able to absorb 120 to 140 mm of deck expansion.

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Developments over the course of time In Strasbourg, and in the six neighbouring communes that form the EuromĂŠtropole, the tramway is an integral part of the community's DNA, with a very long history behind it.

The first horse-drawn line was inaugurated in 1878 and the first electrical one in 1894. In the 1930's, mass production of automobiles caused the tram to lose some of its prestige and it finally disappeared in 1960. However, like a phoenix rising from the ashes, it made its comeback in 1994, and has been expanding ever since. Today, six lines form a 45 kmlong network and an international link to Kehl in Germany is being constructed. The new extension of Strasbourg tramway line D to Kehl will improve the connections between the two cities and will help to redevelop unused industrial zones. This has necessitated however, the construction of two bridges; the Citadelle Bridge over the 07 | Industry EMEA | November 2016

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Vauban basin and the bridge over the Rhine River. They allow the new 2.9 km-long line to cross the border, inside the Strasbourg-Kehl urban agglomeration and beyond the Strasbourg-Ortenau Eurodistrict.

Dedicated to Rail infrastructure Rail infrastructure is the core of Vossloh Group’s activities supplying equipment and solutions worldwide for all types of rail transport and associated services. For the extension of line D to Kehl, Vossloh, who had already equipped the Strasbourg tramway network, supplied the points and crossings, and extended the signalling, while integrating it to the existing network. The points and crossings are assembled in the 11,600 m2 workshop building of Vossloh Cogifer S.A. in Reichshoffen (fig 1.).

Fully assembled premium turnouts As turnouts are the most sophisticated element in a track system, their design, manufacturing process and maintenance require expert knowledge. With this in mind, for tramway turnouts for example, Vossloh has since 1993 relied on a monobloc design of switch cradles and

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Signalling diagram for the new Port du Rhin tram yard.

crossings (frogs) rather than welding them from individual parts. Monobloc designs are much more robust over their entire lifecycle and offer the added value of comfort, safety and reliability. The Strasbourg Transport Company (CTS, Compagnie des Transports Strasbourgeois) has always selected this kind of premium points and crossings for its tramway lines as their wear even after near twenty million axle passes is so low that grinding is only required as part of the normal maintenance. This means less maintenance work over a significantly longer service-life than with other solutions and above all, savings of up to 50%.

The Vossloh turnout systems are delivered assembled on concrete sleepers to simplify their installation. The different elements are manufactured in the workshop by machining laminated sheet metal and profiles with high performance mechanical specifications. For example, the flexible and mobile switch blades are manufactured of steel whose breaking strength is 1100 Mpa and which has a Brinell hardness of 400 HB. These components and their manufacturing processes ensure that they function safely and remain reliable over time.

Also the switch control system, the switch blade position controller and the heating system – essential in winter, during low-temperature periods – are all installed in the workshop to ensure a »Plug & Play« installation.

well as the corresponding expansion of the track. Vossloh's »V-Net« range that was selected has a bidirectional model that has been derived directly from technology used for the TGV. As this was adapted to the Vignole rail, Vossloh designed and manufactured a transition track, linking the grooved rail to the Vignole rail on the bridge. In order to guarantee the security of the transition, anti-derailment guard rails have been set up.

Signalling and security The functional security of the tramway is directly dependent on the signalling and the equipment installed to prevent any accidents on the track. The equipment is under the driver's control, who is the master of the tramway, selecting the destination, seeing where he is driving, respecting the crossroads, modulating the speed to keep a safe distance between trams and avoiding collisions. The driver must take into account all of the occurrences on the track, and, in the mixed traffic zones, watch out for all the pedestrians, cyclists and motorists crossing the platforms. In turnout zones, he must follow the signalling and control the turnouts to follow his route, in accordance with the command and control centre (CCC) based in Cronenbourg.

Bridging the Rhine River requires expansion joints The new bridge over the Rhine River, with a length of over 290 m, joins France with Germany. It constitutes the last link of this first international tramway. Its steel deck is composed of two equal parts that meet at the central pillar. To ensure a perfect continuity of running despite temperature variations between seasons, expansion joints have been installed in different locations of the bridge. Around twenty meters from its edge, they absorb 120 to 140 mm of deck expansion, as

A private optical cable, installed along the tracks in a protected pipeline, carries all the data transferred between the CCC and the command, control, signalling and visualisation units. This centre is equipped with a server with hot redundancy. Its central units work in parallel to control the whole line. Security is ensured locally by SIL3 CENELEC bi-processors located in the machine rooms. If one of the processors is faulty or they are in conflict, the controller system automatically turns all signals red to place the related zone in security mode.

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Whether it is on a separate track or in a mixed zone in the city centre, where the tramway has to integrate with road traffic, the switches and points of Vossloh fit to all types of surfaces, such as grass turf, asphalt, cobblestones or others if necessary, to adapt to the track's environment and to ensure total physical continuity of the road traffic.

For the new line extension to Kehl, the new Port du Rhin tram yard allows partial journeys and »stocking« of trams.

The Orbey-Briand tram yard, which is both a siding and a terminus, was modified to allow two-way traffic to Kehl. In terms of security, this modification involved replacing the relays of the automation system with a computer CPU. For both these yards, appropriate rail infrastructure was created and the new signalling was integrated into the existing network.

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Expansion joints as well as points and crossings are assembled in the 11,600 m2 workshop of Vossloh Cogifer S.A. in Reichshoffen.

In the CCC, the staff in charge of regulating traffic is at the heart of the system of control and security. They have access both to the dynamic visualisation of what is happening on the line, and to all the information concerning the position of the switches, the state of the traffic lights and the section of the tracks where the trams are located. In case of a malfunction or anomaly, a radio conversation is initiated with the driver who has an exact view of the situation and can take the appropriate decision in order to allow the tram to continue its journey as quickly as possible. At the CCC, all the operating data is archived. Thus, in case of a problem, the »Replay« function allows to come back to a past event and take the time to analyse it.

A close collaboration between Vossloh and its customers Vossloh's long experience in manufacturing points and crossings, as well as setting up signalling on tramways is a solid guarantee of their reliability for its customers who are Alstom, ETF and the CTS. The extension of line D towards Kehl train station, and perhaps later to the Town Hall on the German side, is facilitated by the previous collaboration between the different teams that have worked on various projects in Strasbourg since 1994.

The extension is expected to be in operation by April 2017, and will make both cities even closer than before. www.vossloh-cogifer.com

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All along the track, it is essential to detect the presence of a tram or a vehicle, and most importantly to differentiate them. Concerning vehicles, detectors are set up under the surface, and, in turnout zones, tram detection is operated by track circuits which guarantee the necessary level of security. With regard to crossroads, and parts of the tracks open to traffic, a selective detection loop allows the trams to be distinguished from other vehicles. However, on the other parts of the track, a magnetic loop detects the tram´s presence.

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BUREAU VERITAS LAUNCHES EXCLUSIVE LUBE OIL ANALYSIS MANAGEMENT SYSTEM SOFTWARE IN THE MIDDLE EAST

Global Testing, Inspection and Certification Organisation Increases Support for Equipment and Maintenance Managers with Expanded Oil Condition Monitoring Capabilities

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ureau Veritas, global leaders for testing, inspection and certification services, have launched the exclusive Lube Oil Analysis Management System (LOAMSSM) software at their Dubai Oil Condition Monitoring (OCM) laboratory.

Bureau Veritas has been providing lubricant and oil analytical services in the Middle East for over 5 years, assisting maintenance managers in the industrial, heavy duty equipment and aviation markets to predict failures and prevent catastrophic maintenance events. The organisation is now looking to leverage this experience and increase the level of support so that clients can make timely, informed decisions that can improve machine reliability, reduce maintenance and repair costs and significantly extend equipment life.

Used oil analysis identifies trends in wear and contamination and monitors changes in the physical properties of lubricants and hydraulic oils. Laboratory data analysts can then pinpoint equipment problems in their earliest stages and make informed recommendations to customers.

“Bureau Veritas is committed to investing in our network to ensure we are the global provider of choice for oil condition monitoring services. Increasing our capabilities in the Middle East is integral to our global expansion strategy and will provide our customers in this region with industry leading expertise,” said Matt Hopkinson, Senior Vice President, Global Oil & Petrochemicals of Bureau Veritas’ Commodities Division.

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The continuing global expansion of the OCM program within the Bureau Veritas network has now provided the Dubai laboratory with access to the LOAMS software, whereby clients will have access to one application that brings equipment testing and analysis data together from locations around the world. The LOAMS software provides online tools that bring clarity and meaning to complex laboratory results, maintenance recommendations that improve production and save money, and programs and support that foster collaborative customer partnerships.

“The launch of the LOAMS platform confirms our commitment to support client needs for lubricant and oil analysis services,” said Rupert Crasto, Sales & Marketing Manager for Bureau Veritas Oil & Petrochemicals in the Middle East. “In addition to our local experience, the Bureau Veritas network has over 55 years of global experience in OCM, so our clients can benefit from the expertise in OCM testing, data interpretation and advisory services.”

www.bureauveritas.com

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AVAILABLE NOW: EPLAN SMART WIRING “THAT’S CERTAINLY EASY”

Introduced at the Hannover Messe – and now available: Eplan Smart Wiring software opens up new potential for wiring switchgear systems. This system is easy to use since the technical switchgear knowledge is anchored within the system. It also enables better weathering of personnel shortages. Solutions provider Eplan is forging new technical pathways with this software, which can also be used on mobile devices: the system is being made available free of charge for up to four months.

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plan Smart Wiring software has been available for customers since early September, opening up completely new perspectives for wiring switchgear systems. The most important highlight is the system’s simplicity: the clearly arranged, touch-optimised user interface is suitable for mobile devices and is therefore always ready for use directly at the control cabinet.

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Furthermore, the specific expertise is just as important, but now instead of being stored in people’s minds it is instead anchored within the system. Step-by-step directions for the wirer make the process practically foolproof. Significantly, no schematic is necessary for wiring – thus making superfluous any interpretation of this often complex documentation.

Eplan Smart Wiring visualises the mounting layout, devices, connections and routing tracks, based for instance on data from Eplan Pro Panel. But even without a 3D layout from Eplan Pro Panel, Eplan Smart Wiring can be used to increase productivity. Connection lists and wiring list can for instance be prepared in other ECAD systems, read into an MS-Excel format and then processed in Eplan Smart Wiring. The automatic project comparison for last-minute changes ensures that all changes find their way into production and are taken into consideration in a timely manner. Problem and error reporting, status reports and manufacturing reports can be prepared at the push of a button and can

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then be e-mailed to engineering or those responsible in production planning.

The system’s simplicity further means that even lessqualified personnel can take over the wiring process. This offers companies optimal scalability of their resources while simultaneously increasing efficiency along the entire workflow.

Free Introduction – For a Limited Time Solutions provider Eplan has released Smart Wiring in German and English, and it will be available in sixteen additional languages starting in November. Aside from forging new technical pathways, Eplan is further offering use of the software free of charge from 1 September 2016 to 31 January 2017 with a user’s licence restricted to four months.

Interested parties can therefore take the system for a test drive, put it through its paces and, after the restricted licence expires, can then decide whether they wish to purchase the system. Prospekts can find out more at www.eplan.de/ smart-wiring or contact an Eplan sales representative.

Conclusion Eplan Smart Wiring is the next logical step for integrated engineering through to manufacturing. Data relevant to manufacturing can be standardised with Eplan Pro Panel, thereby be quickly prepared and made available for manufacturing with Eplan Smart Wiring. This provides greater flexibility in the wiring process and high-quality results.

Eplan at the SPS IPC Drives Hall 6, Stand 210

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ANYBUS WIRELESS BOLT CONNECTING DEVICES WIRELESSLY

HMS Industrial Networks now introduces The Anybus Wireless Bolt — a wireless access point designed to be mounted on a machine or cabinet to give it wireless access via WLAN, Bluetooth or Bluetooth Low Energy. This access makes it possible to do configuration via a regular tablet or smartphone or connect to a cloud service, realizing Industrial IoT.

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he Anybus Wireless Bolt is mounted onto a machine or cabinet (just like a bolt) to give it a robust and IP67-classed wireless interface. It is typically used for configuration purposes. For example, the Bolt makes it possible to Bring Your Own Device (BYOD) such as a tablet or smartphone to a machine and use it as an HMI. Another typical use case is connecting a machine to a cloud service.

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The Wireless Bolt can communicate wirelessly up to 100 meters via WLAN, Bluetooth or Bluetooth Low Energy. On the wired side, the Anybus Wireless Bolt can communicate with devices on serial (RS232/485), CAN or Ethernet. Regardless of communication method, it has the same connector (2x9p Plug Connector) for both power and communication.

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Industrial quality “We have seen a steadily growing interest in wireless connectivity through our Anybus Wireless Bridge,” says Martin Falkman, Product Manager at HMS Industrial Networks. “Therefore, we wanted to offer machine builders a robust, industrial-grade wireless solution for on-machine mounting. The Anybus Wireless Bolt is yet another way that HMS enables customers to realize IIoT with solid and secure wireless solutions, getting them ready for the communication demands of the future.” www.anybus.com/products/wireless-index/anybuswireless-bolt

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SPOT ON IN ZONE 1 VERSATILE AND ROBUST LED FLOODLIGHTS The new 6125 series (for zone 1) and 6525 series (for zone 2) floodlights from R. STAHL are designed for challenging environments such as chemical, food and oil and gas extraction. Offering a service life is of 50,000 hours, they feature high corrosion resistance supported by a robust IP66/67-rated enclosure.

The extremely robust new LED floodlights from R. STAHL provide highly efficient and long-lasting lighting solutions for zone 1, 21, 2 and 22 hazardous areas.

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nergy-efficient LED technology makes R. STAHL's new generation of flexible floodlights for hazardous areas shine. High-quality TIR lenses minimise scattered light and glare effects and enable light distribution focussed on angles of 10°, 40° or 120°. The devices are therefore not only suitable for spot and wide-angle lighting, but can even be installed as pendant lights. The new 6125 series (for zone 1) and 6525 series (for zone 2) floodlights achieve excellent luminous flux: 21,000 lm in versions with 210 W power consumption and 12,000 lm in 120 W models.

With this luminaire efficiency of 100 lm/W, they are not only far more efficient than conventional HID lights, but also require significantly less maintenance. The lense panel modules are equipped with hinges for easy installation, maintenance and repair of the removable components.

For some applications such as general lighting in production and storage facilities in the food industry, they can be ordered with a scatter protection for the glass front panel.

The robust enclosures provide IP66/67 ingress protection and a very high shock and impact resistance (IK10). They are available either in powder-coated steel sheet or stainless steel versions.

For explosion protection expert R. STAHL, these new floodlights are the final complement to a now comprehensive portfolio of highly efficient LED lighting solutions.

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Even under extreme conditions, the service life of these products is specified at 50,000 hours of operation at maximum ambient temperatures. Their superior durability fully enables them to sustain challenging environments e.g. in the chemical industry or in oil and gas extraction over the long term.

Their high tolerance for ambient temperatures in a very broad range from -40 °C to + 60 °C is a stand-out feature in this product class. Featuring a corrosion-resistant body and comparably low weight, these floodlights are an especially good choice for onshore and offshore applications. Special designs with heat sinks made from sea-water-resistant aluminium are also available.

R. STAHL presents further information about this new series, LED technology in general and real-life experiences with explosion-proof luminaires in harsh conditions www.stahl-explorers.com

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FOUNDRY’S BESPOKE TURNTABLE CRANE FEATURES VERLINDE HOISTS

The two VERLINDE EUROBLOC VT3 electric wire rope hoists each offer a safe working load of 8 tonnes.

A bespoke turntable crane system installed at the Hereford, UK foundry of world leading superalloy manufacturer, Special Metals Wiggin Ltd (SMWL), features a pair of EUROBLOC VT3 series electric wire rope hoist manufactured by VERLINDE. Sitting either side of the crab unit, the hoists support loads up to a combined total of 16 tonnes. The bespoke crane system was designed and implemented by Pelloby, which has been working as a UK distributor of VERLINDE products for several decades.

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MWL, which can trace its roots back to 1835, is today the world leader in the innovation and manufacture of high nickel, high performance alloys. The company’s products, which include world-recognised brands such as Inconel®, Nimonic®, Udimet® and Monel®, are specifically engineered to offer a combination of heat resistance, corrosion resistance, strength and toughness in some of today's most technically demanding industries and applications.

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The company produces nickel alloys in all standard forms, from large ingots and billets to plate, sheet, tube, bar and extruded section. Naturally, some of the alloy goods are large and heavy, which means the application of a capable crane system in the foundry is a prerequisite.

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SMWL regularly looks to invest in new foundry machinery and equipment in order to streamline ongoing operations, and the thinking behind this latest crane was to offer a way of quickly rotating lengthy or cumbersome goods and materials when moving them between various workstation or storage positions.

Having ordered several overhead, jib and portal cranes from PELLOBY in the past, the company was well aware of the scalable nature of the UK crane manufacturer’s design and production process. Indeed, this proved to be a big part of the reasoning behind the selection of PELLOBY for this specific project.

The system solution supplied to Special Metals incorporates a special turntable crane which utilises a 360° slewing crab unit that can traverse freely along two double-girder overhead beams. Spanning a considerable 23,470mm, the crane’s girders are supported by existing gantry steelwork

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within the building. A handheld radio control is used to operate the longitudinal motion of the beam, the crab movement and the turntable’s rotation.

VERLINDE EUROBLOC VT3 electric wire rope hoists are located either side of the crab unit on the turntable crane at Special Metals.

The two VERLINDE EUROBLOC electric wire rope hoists are VT3 models, each offering a safe working load of 8 tonnes. Further features of the system include a two-speed parallel rotor hoist motor with low starting current, thermal protection to the hoist motor and a self-adjusting disc brake.

In addition, there is a compact hoist gearbox featuring heattreated gears and a precision machined rope drum with high ratio to rope diameter. SMWL can also take advantage of easily adjustable upper and lower limit switches with automatic reset, as well as synchronised lifting capability.

“Where previously we might have had to use a forklift truck to ensure these goods were facing in the right direction before deploying one of our existing cranes, being able to rotate materials as they are being moved has helped improve our workplace efficiency immeasurably,”states Marcus Upcott, Engineering Supervisor at SMWL. MORE INFORMATION

www.pelloby.com www.verlinde.com

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© Stephane Lariven

STRONGER TOGETHER: INNOVATION, CREATIVITY, AND INDUSTRIAL COOPERATION IN EUROPE

An interview with Bruno GRANDJEAN, new President of the FIM (Federation of the Mechanics Industries - France).

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oday, the main challenges in the mechanics industry are dealt with at the European level, and rely on improved European industrial cooperation. In this context, the “Industrie-du-Futur” project shall result in fruitful partnerships, based on the French industry strongest points, such as collaborative spirit, quality, creativity and innovation.

What are the key strengths of French industry?

In our country, there is a strong industrial tradition, as well as a culture of creativity and innovation. France has the largest network of high-speed trains, a first class aeronautic and aerospace industry, a highly-respected automotive industry and we are one of the few leaders in the nuclear industry.

We benefit from the wide-ranging skills and passion of our highly qualified engineers, technicians and workers as well as a strong research sector. It is no accident that France has an outstanding presence in the luxury and aeronautics industries, two sectors of excellence.

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The French industry has had to face the challenge of globalization and has lost some market share. How can it come back to the top?

At the heart of the Industrie-du-Futur's project is the idea that the digital revolution provides the opportunity to come back into the race. French industry must take advantage of this dynamic to get back among the top 5 of the world's industrial nations.

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NEWS The rebound of investment in production and factories' modernisation is going along with the Industry-du-futur's plan; more than 3000 french companies have joined this effort of modernization with the support of our technical centres.

The development of a French additive manufacturing industry, as highlighted by the Fives-Michelin joint venture, BeAM and Prodways (Gorgé group), is a good example of a rebound of investment driven by innovation. Further examples are Dassault with the Rafale jet fighter sold around the world, Alstom, whose TGV (high speed train) has been selected to connect Boston to New York, Bolloré with its “Blue Car”, an innovative concept of electric car and service, or Renault, which is launching a brand new production of the Alpine, a high-end car and a symbol of French excellence.

The network of companies involved in the mechanic industries is supplying every other industry sectors with essential technologies. It follows that the mechanic industries is at the very heart of this renewal.

Should the European Union adopt an industrial policy?

Today, Europe has become the home market for all industrial companies in the EU. It is clear that many of the challenges of globalization have to be handled at a European level, which is why policies need to be coordinated in order to optimize investments. So, France and Germany would benefit from the development of converging strategies in the energy or in the defense sectors.

It is essential that Europe shall not accept standards imposed from outside, especially in terms of safety for the digital data exchanges and for the bank transfers. We must also protect our patents, fight against dumping, and obtain a full balance for international exchanges rules. Many issues which cannot be solved apart from the European level.

How to improve European cooperation in regards to industry?

The addition of the international strengths of German and Italian industries, together with the French innovation and creativity, appears to me as a really fruitful idea.

In the mechanical industry, strong ways of cooperation already exist. Many German and Italian companies are also located in France and vice-versa. There are successful examples such as SEW Usocome, Schaëffler, or Bonfiglioli.

REDEX, the company I manage, is also located near Stuttgart and in Milan since a long period of time.

Today, very few products are from pure French, Italian or German origin; the value chains are integrated, and the final added-value is commonly created by additionnal inputs of several countries.

Bruno Grandjean is the CEO of REDEX, a middle size industrial French company whose products are exported to over 50 countries worldwide, and which is an European leader in “precision engineering”, high-tech equipment for steel and non-ferrous industries, and for the high-tech machine tool industry.

He has been appointed as new President of the F.I.M. (Federation of Mechanical Industries - France), in June, 2016. Graduated engineer, graduated from Stanford University, Bruno Grandjean is involved in the industry for over twenty five years. He holds several patents, and is heading the Redex Group since 2005.

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The FIM (French federation of Mechanics Industries), regularly exchanges with the VDMA, its counterpart German organization. At the heart of these exchanges are the Industrie 4.0 , sponsored by the German government, and the Industrie-du-Futur launched by the the french AllianceIndustrie-du-Futur These positions are shared by political leaders, as it was shown by the summit between Angela Merkel and François Hollande at the Elysee Palace in October 2015, during a common conference on digital. It is somehow the evidence that the competitiveness of European industry is an unifying topic for our countries. www.fim.net/fr 07 | Industry EMEA | November 2016

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PNEUMATIC SAFETY BRAKES WITH THE SAME POWER AS HYDRAULICS

With the new pneumatic ROBA®-guidestop, mayr® power transmission provides an innovative braking concept which fulfils the high safety requirements and achieves high performance density without the use of hydraulics.

Image: mayr® power transmission

High-performance, highly rigid ROBA®-guidestop profiled rail brakes.

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compact safety brake in a small construction space with high forces and all this without using hydraulics – mayr® power transmission has developed a new, high-performance, pneumatically-released version of the ROBA®-guidestop profiled rail brake. With this innovative braking concept, which fulfils the ever- increasing safety requirements and achieves a high performance density without the use of hydraulics, the company sets new standards.

mayr® power transmission is extending the tried-and-tested ROBA®-guidestop series with a pneumatically-released version, which provides users with new possibilities thanks to the high holding forces. For machines, in which a hydraulic system is already available, users can still use the hydraulically-released ROBA®-guidestop safety brakes.

However, in applications where a hydraulics system would have to be installed first in order to operate a brake with high holding forces or in which several brakes would be necessary to achieve the required forces, the pneumatically-released ROBA®-guidestop safety brake is now used. It clamps profiled rails equally accurately and backlash-free while achieving the same high holding forces as the hydraulic design of the brake.

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Innovative concept with pressure booster The pneumatic ROBA®-guidestop is opened with compressed air at 20 to 30 bar. In order to achieve the necessary operating pressure, a compact pressure booster is used in combination with the brake, which mechanically increases the system pressure from 4 to 6 bar as is usual in pneumatic networks, without the use of external energy.

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In order to achieve the necessary operating pressure, a compact pressure booster is used in combination with the brake, which increases the pressure existing in the system purely mechanically and without external energy. This innovative concept enables a selective pressure increase directly prior to the individual brake.

Image: mayr® power transmission

the higher pressure is required – as a result, short highpressure lines suffice. The pneumatic ROBA®-guidestop safety brake is available in five construction sizes – each size in both a standard design and in a compact, short design – covering a range of holding forces from 1 to 34 kN. The brake is designed for the different rail construction sizes of conventional linear guidance manufacturers.

Like all safety brakes by mayr® power transmission, the brakes of the ROBA®-guidestop series operate according to a fail-safe principle, i.e. they are closed in a de-energised condition. They reliably guarantee operational and functional safety in machines and systems around the globe. www.mayr.com

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Safety thanks to direct clamping Just like the hydraulic brake design, the pneumatic ROBA®guidestop safety brake acts with extremely high rigidity directly applied to the linear guidance. This means that it is mounted directly on the masses which should be held.

This provides a decisive advantage, especially concerning gravity-loaded axes, where the hazard risk for people should be reduced: Drive elements between the motor and the moving mass, such as spindles, spindle nuts, shaft couplings or gearboxes, therefore have no influence on the safety – as opposed to the concepts using motor brakes, where all drive elements transmit the braking torque to the carriage.

Systems using ROBA®-guidestop safety brakes therefore enable a significantly higher rigidity than solutions featuring rotary brakes integrated into servomotors.

technological advantages for heavy machining, for example.

The machining produces less vibrations and therefore the surface quality of the workpiece is positively influenced. In case of a stationary axis, for example during machining, the brake can absorb the load. As a result, it is possible to switch off the drive motor in this phase and remove it from the controls. This eliminates control movements and is therefore gentle on the ball screw spindle. The closed brake absorbs the axial forces. The service life and maintenance intervals of the drive components are extended.

Reliable and precise The backlash-free clamping of the ROBA®-guidestop directly onto the profile rail provides yet further advantages: The additional rigidity of the NC axis increases process accuracy, improves machining performance and can provide further 07 | Industry EMEA | November 2016

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HIGH TEMP TOUGH

WIDIA offers a variety of coolant-fed cutter bodies such as shell mills, shoulder cutters, end mills, and more, all able to accept WS40PM and other indexable milling insert grades.

WIDIA’s new indexable milling grade is the first choice for titanium and other superalloys.

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osef Fellner, WIDIA Products Group’s Manager Portfolio Management for Turning and Indexable Milling, says the company recently took its newest advanced milling grade, WS40PM, on a world-wide testing tour. The results have been quite impressive: • An aircraft manufacturer enjoyed a 90% reduction in machining time per piece and increased tool life by 50% during Ti-6Al-4V face milling operations.

• Insert flank wear decreased by more than 90% at a UK shop cutting Inconel 625, resulting in a 70% reduction in tooling costs.

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• At a turbocharger producer in China, tool life increased 80% while machining an austenitic stainless steel component using WS40PM, with improved part surface quality, reduced cutting forces and better chip flow.

• In another titanium component, the WS40PM/VSM490-15 platform doubled metal removal rates and delivered 80% longer tool life through increased depth of cut and feed per tooth in face and shoulder milling operations.

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• The testing laboratory for a well-known brand of machine tools reports metal removal rates 49% greater when shoulder milling Ti-6Al-4V. In each instance, WS40PM competed with the test subject’s legacy carbide grade. Speeds and feeds were kept the same or in some cases increased to take advantage of WS40PM’s exceptional toughness, wear-resistance, and ability to resist thermal cracking.

WS40PM was designed to meet the needs of the aerospace, defense, and medical industries, where titanium is used for everything from landing gear and seat tracks to lifesaving implants and surgical instruments. As the testing results show, however, WS40PM is suitable for far more than titanium. High-temp steel alloys, austenitic and PH stainless steels, nickel-based super alloys such as Hastelloy and Nitronic—these materials cause tool failure due to builtup edge (BUE), notching at the depth of cut line, cratering, chipping, and extreme heat generation, which in the case of wet-cutting operations leads to cracking.

“WS40PM’s advanced cobalt-rich substrate provides robust fatigue resistance and edge integrity, while the multiphase

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WS40PM’s cobalt-rich substrate provides robust fatigue resistance and edge integrity, while the multiphase AlTiN-TiN PVD coating reduces tool wear, making it the first choice for a wide range of hightemp steel alloys, austenitic and PH stainless steels, nickel-based super alloys such as Hastelloy and Nitronic, and titanium.

AlTiN-TiN PVD coating reduces wear,” says Mike Sperhake, EMEA-region Product Specialist for WIDIA. “Using an initial cutting speed of 175 ft/min (53 m/min) we’re seeing 25-35% productivity gains and consistent improvement in tool life, even when milling very tough materials like Ti-5553 and Super Duplex steels.”

Sperhake recommends a balanced approach to cutting parameter selection. “As radial engagement increases, cutting speeds should be reduced proportionately,” he says.

“That’s because the amount of heat entering the insert goes up substantially on heavy cuts. At around 90% engagement, for instance, you’ll probably want to reduce the RPM by 25% or so, depending on the material. Feedrates may also have to be lessened somewhat, depending on setup and machine rigidity. And smaller cut widths, of course, spindle speed and feedrates should be kicked up substantially.”

Finally, consider the machine tool, toolholder, and spindle interface. Rigidity across the board is needed for productive titanium machining. WIDIA offers the KM4X platform, which according to Global Product Manager Bill Redman is “the strongest connection available, period,” and is available on a wide variety of toolholders and machine tools alike.

Says Sperhake, “From Tier 1 aerospace suppliers to the job shop on the corner, everyone wants the same things from a tooling solution: higher accuracy, better surface finish, reliability and productivity. All are critical factors to their success, and that’s what we intend to deliver. WS40PM is a big part of that.” www.widia.com

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“Going too easy” is a common mistake when machining titanium and other difficult materials, Sperhake says, leading to poor productivity levels and shortened tool life. For example, problems such as BUE and edge wear can often be eliminated by pushing the tool harder. “Tool life, especially in superalloys, is a three-legged stool of feed, speed, and cutter engagement. Each has a direct impact on the others.”

body for the application is likewise important. WIDIA’s VSM490 shoulder mill offers a state of the art insert and cutter design, one that supports WS40PM and other highperformance grades.

Success with superalloys takes more than a good carbide grade, however. Sperhake also recommends increasing the cutting fluid concentration, and using a high-pressure coolant pump wherever possible. Selecting the right cutter 07 | Industry EMEA | November 2016

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HEAVY DUTY MACHINING BUT SAFE

Roughing operation with titanium: without Safe-Lock™ the tool pulled out of the standard shrink fit chuck and broke at ap = 2 x D. With HAIMER Power or Heavy Duty Chucks and Safe-Lock™ it was possible to reliably mill full slots at ap = 2 x D. Pictures: Heller / Haimer

The importance of the tool holder is still understated, especially when it comes to roughing and heavy dutymachining. Metal removal rates in these types of processes are absolutely crucial for the productivity of the machining operation. By using special shrink fit chucks with drive pins and spiral grooves in the tool shank it is now possible to performhigh-feed full slotting of up to 2 x D (50 mm) or more indifficult to machine materials. Application studies conducted by the machine tool manufacturer Heller have proven the effect of the HAIMER Safe-Lock™ system.

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specially within the aerospace, energy and mechanical engineering sector, production managers have to bridge the gap between economic efficiency and high process reliability when working with materials that are difficult to machine. Fortunately there is peace of mind in knowing that the machine technology innovations continue to develop to meet the ongoing demands of manufacturing.Heller machine tools is known as a source of inspiration for these kinds of innovations. The company, located in Nuertingen, Germany, is known for its high quality 4 and 5-axis CNC machining centres, CNC mill/ turning centres, CNC machines for crankshaft and camshaft machining as well as flexible manufacturing systems.

Customers value their availability of products and their competency in managing special processing demands. Both qualities stem from Heller’s in-house manufacturing, which

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relies on closer collaboration with customers, suppliers and researchinstitutes to remain on the forefront of innovation.

Roughing is a highly promising process Werner Kirsten, who is working in the Technology Development Department at Heller and is responsible for the area of “difficult to machine materials“, explains: “our service includes optimizing the machining processes together with our customers and suppliers. To support such services with practical trials, our Technology Center is equipped with a variety of machines”. In most cases the aim is to increase the productivity without compromising the process reliability. Technologist Kirsten adds, “We often achieve this aim with an optimized roughing operation which ultimately results in a reduced finishing process. By maintaining the same technological values, but shortening

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In order to equip tool holders with the HAIMER Safe Lock™ system, spiral grooves are ground into the tool shank. In combination with special drive keys within the chuck, the system prevents milling cutters from getting pulled out of the chuck during extreme machining.

the finishing depth of cut by 50%, the overall machining time is reduced to half. However, this requires process reliable and controllable systems during roughing.”

Tool holding - an important factorfor productivity By selecting the right tool holder you can even achieve good productivity and surface quality results using basic standard cutting tools. Werner Kirsten refers to comparative tests with basic four-edge cutting tools without an inner coolant

When a group of representatives from the aerospace industry, the Technical University of Dortmund and Technical University of Hamburg-Harburg visited Heller,an especially extensivemilling application study was conducted in Titanium Ti-6AI-4V. Gaining new insights from difficult cases The available machining center was a four axis Heller H 5000 with a gear unit and HSK-A100 spindle, which yields torques up to 2.290 Nm. In order to demonstrate the machining potential, different 25mm diameter end mills were used to mill full slots into a titanium plate. To simulate holder conditions used in the aerospace industry, the tools were clamped into reinforced shrink fit chucks. At an axial cutting depth of0.5 to 1.0x D the machining process was found to be very reliable. Since the spindle was not running at full capacity, the trial participants agreed to increase full slottingdepth to 2 x D. Werner Kirsten explains: “Under these conditions the tool pulled out of the shrink fit chuck during the machining operation, creating a slot closer to 2.5xD as it progressed through the part. Towards the end of the slot the tool finally broke as a result of increased cutting forces.”

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In this regard,all machining components in the process chain have to be considered in order to improve productivity.

The machine tool is the most evident component of the machining process, however the tool, the tool holding system, the coolant supply and other elements are also essential for a successful operation. “In the end the weakest link of the process chain limits the success,” Werner Kirsten emphasizes. In his opinion most machine shops don't pay attention to the tool holder even though it is especially significant for high performance cutting. “Many of the trials which we carried out during the last few years have proven this point”, Werner Kirsten explains. We realized that the tool holder hasan incredible influence on the machining process.

In the case of reinforced shrink fit chucks, for example, the vibration node is closer to the bearing point (due to the larger mass). The result is a smoother machining process with less vibration and a better surface finish quality while using the same tool, machine, process parameters and fixturing technology.”

supply. As an alternative to a standard shrink fit chuck he selected a HAIMER Power Shrink Chuck with Cool Flash which ensures that the coolant is transported directly to the cutting edges. “Compared to using a normal shrink fit chuck and externalcoolant, we were able to achieve significantly better results.”

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HAIMER Heavy DutyShrink Chuck (middle) and Power Shrink Chuck (on the right) next to a shrink fit chuck with a standard geometry. Both chucks on the right can be equipped with the pullout protection system Safe-Lock™. This combination provides highest runout accuracy, process reliability and eliminates the problem of tool pullout.

The milling specialists all agreed that the clamping force of the chuck was the limiting factor in this process. As soon as the axial pressure and process related vibrations are too high the tool moves out of the chuck and further into the workpiece. At the same time the cutting pressure increases such thatin the end the tool breaks and the workpiece is irreversibly damaged.

Reasons and possible countermeasures were discussed intensively. In the end, Werner Kirsten developed the idea that the tools are forced to navigate towards the spindle when the holding forces are exceeded. This is how he ultimately noticed the patented HAIMER Safe-Lock™ system which in addition to frictional clamping forces, has the same helix pattern as the tool. Theoretically, he realized that even if the tool got loose while using Safe Lock™, it would be pulled into the holder through the helical drive keys and not into the part. A movement that can be easily prevented through the use of length presetting screws.

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Prevent tool pull-out Werner Kirsten got in contact with HAIMER, the European market leader for tool holding technology, in order to test the Safe-Lock™system: “we wanted to know if our ideas could be put into practice using the HAIMER system in an even less forgiving environment.” The Heller technology developer repeated the described trial,with a few major changes.

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again with a reduced spindle taper interface (HSK 63 instead of HSK 100), with a less rigid 5-axis gear driven spindle and a less stable diagonally fixtured workpiece.

The result: Despite these additional limiting factors, the tool was able to process a full slot of 2 x D = 50mm with complete process reliability. Werner Kirsten says: “this way we were able to indirectly prove that Safe-Lock™ works and that the shrinking technology has even more potential with HSK-A100, especially on 5-axis machining centers withgear spindles.” Afterwards this samplemachining on Ti-6AI-4V was carried out various times, including during the Airshow in Farnborough, whereby it was proven that the previous limit of 1 x D = 25 mm full slotting in titanium could be doubled with the use of Safe-Lock™.

Kirsten summarizes the results as follows: “For roughing operations this is a reliable process. Therefore I consider the HAIMER Safe-Lock™ system a practical, easy to handle and process reliable addition to the shrinking technology which we already utilize, especially in connection with standardized tools of other manufactures.”

A number of tool manufacturers are offering Safe-Lock™ products From the onset of its creation, HAIMER recognized the incredible potential of the Safe-Lock™ system, which is why the company created a licensing program to give innovative tool manufacturers the ability to integrate the patented

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The vibration resistant shrink fit chuck HAIMER Power Shrink Chuck is also available with Cool Flash. Tools without inner coolant supply benefit from the fact that the coolant is in direct contact with the cutting edge. This results in a smoother cutting process and longer tool life.

Werner Kirsten, Technology Developer at Heller: “Therefore I considerthe HAIMER Safe-Lock™ systsem a practical, easy to handle and process reliable addition to the shrinking technology which we already utilize, especially in connection with standardized tools of other manufactures.”

pull-out protection system into their tools. The result of their vision to create a more open system has been a tremendous success, with leading cutting tool manufacturers having now signed licensing agreements, including Walter, Widia, SandvikCoromant, Seco Tools, Sumitomo, Kennametal, Helical, Emuge Franken, Data Flute, Niagara, OSG, SGS Tools and recently Mapal.

www.haimer.biz

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Through the steady increase of Safe-Lock™ tooling in the market via Haimer and its licensed partners, the system has become the new standard for heavy machining and roughing. In fact, the popularity and simplicity of Safe-Lock™ is such that it is also replacing the old Weldon clamping system, particularly when new milling strate-gies such as trochoidal (dynamic) milling are involved. President of HAIMER Group Andreas Haimer explains: “With our SafeLock™ system we found a solution that combines a high runout accuracy with 100% pullout protection. The system has es-tablished itself successfully as a standard in the aerospace industry and generally speaking for roughing and heavy duty machining. And now more and more companies that make use of the trochoidal (dynamic) milling strategy are also making the switch to Safe-Lock™, and for a good reason.”

forces that result from the higher cutting performance create a situation where tool-pullout can occur very easily.

Prior to Safe-Lock, this problem was prevented with Weldon shanks and chucks.However customer had to sacrifice speed and accuracy due to the nature of this clamping system. A shrink fit chuck with Safe-Lock™ offers the same safety as the Weldon system, but provides the additional advantage of accuracy and balance. The ideal balancing and runout characteristics of the shrinking technology in combi-nation with the clamping safety of the Safe-Lock™ system permit greater productivity achieve through faster permissible speeds and increased tool life all with complete tool security assurance.

During trochoidal milling operations, where the cutting speed and axial depth of cut can be increased through software support, productivity is significantly improved.

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NORD SEVERE DUTY PERSEVERES

Corrosion-proof drives in washing and packaging line for agricultural products.

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he nsd tupH corrosion protection treatment introduced by NORD DRIVESYSTEMS is an economic method to significantly extend the lifespan of drive systems with an aluminum casing in applications with aggressive atmospheres, high humidity, or spray water.

Ambit Projects, a manufacturer of food industry machines, uses nsd tupH protected drives in washers.

In the English town of King's Lynn, Ambit Projects Ltd. designs and manufactures custom equipment for cleaning, processing, and packaging of various food and agricultural products. One of Europe’s leading fresh produce growers and suppliers is a regular Ambit Projects customer. They required a major upgrade and line expansion. The machine in question removes the root and flag of celery stalks and then washes, inspects, and packages them. Given the constantly wet environment and regular washdown with water and foaming agents, the old drives had suffered.

Even a high-specification anti-corrosion coating was not enough to provide lasting protection. The paint had split and was threatening to peel. In order to keep debris away from the celery produce, the drives had been outfitted with trays and covers. The drives installed on the belt conveyor in immediate proximity to the washing process were in particularly bad condition. High-pressure jets are used here to remove soil and stones from the produce. The equipment manufacturer was therefore on the lookout for alternative drive solutions that required no extra enclosures.

Protection that goes under the skin NORD Gear Ltd., the English member of the NORD DRIVESYSTEMS Group, told Ambit Projects about a materials

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The nsd tupH surface treatment gives aluminum drives a smooth, permanently corrosion-resistant surface ideally suited to process industry applications (image: Ambit Projects Ltd.)

Freshly harvested celery is automatically cut, cleaned, and packaged in a continuous operation. (image: Ambit Projects Ltd.)

high-pressure steam jets is therefore not a problem. Due to their excellent thermal properties, the aluminum systems can be washed down without cooling down first from the regular operating temperature.

Made for hygienically demanding applications Ambit Projects replaced all conveyor drives and the drives in the retrofitted machine sections with new nsd tupH units. These are fitted with stainless steel DIN and standard parts and stainless steel output shafts. Food-grade oil is used as gear lubricant. Paul Oakley, Sales Director at Ambit Projects, is delighted with his new drives: “NORD nsd tupH drives have provided a real value for money solution in terms of extended protection and trouble-free reliability. This application demonstrates our commitment to working closely with our customers and suppliers with upgrades and capacity expansion initiatives that reflect the latest technology improvements – and we will certainly be using nsd tupH protection in other machines we develop.”

The new drives in the celery processing line are based on smooth-surface motors and SMI worm gearboxes. NORD has optimized these components as well as other gearbox types for hygienically demanding applications. Smooth surfaces all around without any dead spaces ensure that dirt cannot easily accumulate and that rinsing liquids run off easily.

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engineering innovation: NORD has developed a technology called nsd tupH that profoundly fortifies aluminum surfaces by permanently altering the material through an electrochemical process. Instead of applying a protective layer, as is commonly done with anti-corrosion coatings, the aluminum material itself is thoroughly hardened. A great number of NORD drives treated in this way already have a proven track record going back several years. Before the technology was deployed, systems using nsd tupH were tested for resilience against blistering per ASTM D714, corrosion per ASTM D610-08, scribe per ASTM D1654-08 according to DIN EN ISO 2409, salt spray per ASTM B11709 according to DIN EN ISO 9227, and chipping per ASTM D3170 (Gravelometer test). In many industrial environments, scratches or blows to the drives are to be expected. Under such conditions, even high-quality anti-corrosion coatings cannot reliably provide effective protection. Once the surface layer has been damaged, corrosion easily spreads to adjoining areas. Even rework will not undo the damage for good. nsd tupH is immune to this potential problem.

Gravelometer testing showed absolutely no loss of adhesion or chipping. High process safety is therefore ensured. The treatment is approved for food applications according to FDA Title 21 CFR 175.300. It also makes the drives resistant to cleaning agents in the pH2 to pH12 range. Notably, nsd tupH is perfectly suitable for use in marine environments: the salt spray test produced no corrosion even after 2,000 hours.

NORD supplies a range of geared motors and mechatronic drives with IP66/IP69K ingress protection. Cleaning with

Smart full-scale solutions The use of aluminum drive systems featuring nsd tupH protection against corrosion and mechanical damage 07 | Industry EMEA | November 2016

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NEWS

Smart solution to drive applications in aggressive atmospheres: nsd tupH can be applied to all components with an aluminum die-cast housing. (image: NORD DRIVESYSTEMS)

reduces maintenance costs and significantly extends the product life. These drives are perfectly suitable for hygienically sensitive applications in the food industry and many other demanding process applications. nsd tupH is available for all aluminum-enclosed drive components from NORD – four gearbox families, smooth-surface motors, and distributed drive electronics. Drawing on an exceptionally comprehensive modular pinion range, NORD is able to custom-configure each gearbox to precisely match application requirements. Users can choose hollow or solid shafts as well as foot or flange mounting. NORD also offers motor starters and frequency inverters with high protection ratings and with nsd tupH. These allow for distributed installations with minimal wiring effort and provide an economic way to ensure protection and efficiency.

Typical applications include conveyors, pumps, mixers, and agitators in harsh environments. The units feature all required communication and sensor interfaces and are capable of internally storing routines. NORD provides plugand-play solutions for all kinds of industrial application.

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www.nord.com

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NEWS

INSPECTORATE LAUNCH NEW OIL & GAS TESTING FACILITY IN INDONESIA

Global Testing & Inspection Organization Expands its South East Asian Service Network with New Office and Laboratory in Karimun Island in Indonesia.

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nspectorate, global leaders in testing and inspection for the oil and gas industry, announced today the opening of a new testing facility in Karimun, Indonesia, specializing primarily in the in the testing of Jet A1, Gasoline (MOGAS), Diesel (Gas Oil) and Fuel Oil.

“The ability to rely on the industries’ benchmark systems and resources from our established, state-of-the-art laboratories greatly helps to deliver high-quality services in a new location from day one,” said Ravi Parameswaran, Regional Technical Manager - Asia, Inspectorate.

Strategically located in between the international maritime shipping traffic - 7.5 nautical miles from Straits of Malacca and 25 nautical miles from Singapore - the 24/7 laboratory and inspection office will provide support services for major shipping companies, traders and energy suppliers needing real time data for oil and gas quality in the Asia Pacific.

A dedicated team of highly trained marine surveyors will be available to provide for any local needs for all inspection operations such as sampling, quantity inspection, tank transfers, blending and lightering.

This facility has testing capabilities for Jet A1 recertification, full specification for Gas Oil as per ASTM D975, Gasoline as per Platt’s specification, and Fuel Oil as per ISO 8217.

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Senior staffs from Inspectorate’s Regional Technical Centre in Singapore will be fully responsible for continuous support and assistance to the Indonesian facility, ensuring fast sample turn-around times, accuracy and value adding technical advice for customers.

“The Indonesian laboratory further consolidates Inspectorate’s already extensive network of testing and inspection facilities and reinforces our commitment to supporting customers in this important region,” said Amit Ghosh, Vice President – Asia, Inspectorate. www.bureauveritas.com

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NEWS

SCOTT SAFETY LAUNCHES NEW DURAFLOW POWERED AIR RESPIRATOR WITH REAL-TIME AIRFLOW CONTROL

Respiratory expert Scott Safety introduces Duraflow, a lightweight and ergonomically designed Powered Air Respirator with sophisticated real-time air flow control technology. The new solution gives complete wearer assurance of respiratory protection to focus on the job rather than the protective equipment itself, in a multitude of hazardous situations and industries.

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ark Andrews, Global Product Line Manager Powered Air, Halfmask & Airline at Scott Safety said: “Our design intent for Duraflow was to bring to the market a reliable, durable powered air product at an affordable price for those currently using respirators with filters fitted directly to the mask (negative pressure mode).”

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Duraflow’s automatic monitoring features ensure the airflow rate is maintained at precisely the correct level to afford protection for the user. Visual and audible diagnostics alert the user of any drop in airflow below the required level or when the battery needs re-charging. 2 high energy density battery options are available –standard and extended duration which can be selected depending on shift coverage required- less downtime more working time.

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Duraflow will help employers meet the needs of workers across all demographics- with its low respiratory burden.

As highlighted in Scott Safety’s latest whitepaper, changes in lung function in older employees working in manual positions can reduce their ability to undertake certain active tasks. By providing workers with a cooling stream of purified air, Duraflow can for some workers make the difference between whether a job can be completed or not.

Highly versatile, Duraflow is compatible with a plethora of Scott Safety headtops, filters and accessories, protecting workers from a variety of environmental hazards.

For further information, please visit www.scottsafety.com/emea

NEWS

NSK BEARINGS PROVE RELIABLE IN BUCKET-WHEEL EXCAVATOR

NSK spherical rolling bearings have been operating for six years in Excavator 290 without relubrication.

The selection of NSK spherical rolling bearings in one of the world’s largest bucket-wheel excavators has proven to be an astute decision. Despite six years of heavy duty operation at RWE Power’s opencast mine in Hambach, Germany, the bearings are still going strong – without any relubrication.

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very day, ‘Excavator 290‘ at the Hambach mine moves up to 240,000 tonnes of coal or, using its 130-tonne bucket-wheel, excavates large volumes of overburden which is then transported to a spreader on conveyor belts in its upper structure. The four central conveyor belts located here have to work hard, not only due to the volume of material transported, but because they operate 24/7 in an adverse environment heavy with dust and moisture. This is where two NSK spherical rolling bearings are helping the mine operator maximise the operational uptime of Excavator 290.

Among the reasons for this high level of performance is the efficiency of the seals, the high quality grease used

by NSK, plus the Super-TF (STF) raw material used for the bearing. STF is a carbonitrate steel that is subjected to a specific heat treatment that helps retain optimum levels of austenite content. STF bearings have twice the service life in comparison with conventional roller bearing steels with clean lubricant, and where there are contaminants in the grease, bearing life can be increased as much as ten-fold.

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The idea of using NSK bearings was driven by the need to reduce maintenance costs on the mine’s largest machines.

Excavator 290, which is 240m long, 40m wide, 100m high and 14,000 tonnes in weight, has been in service since the end of the 1970s. With this in mind, the RWE Power product managers responsible for the conveyor belt drums set up a pilot project that involved installing a sealed, dual row NSK spherical roller bearing with tapered bore inside the drive drum of belt 2 on Excavator 290.

The bearing, which has an external diameter of 500mm and a shaft diameter of 300mm, was then replaced at the scheduled time. Inspection of the removed bearing revealed that it was in excellent condition despite having been subject to continuous, intensive use. This provided RWE Power with the confidence to adopt NSK’s spherical rolling bearing technology, a move that has been rewarded with excellent service – with zero maintenance – for the past six years.

www.nskeurope.com

Sealed, dual row NSK spherical roller bearing with tapered bores are fitted to RWE Power’s excavator conveyors 07 | Industry EMEA | November 2016

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