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INDUSTRY INDUSTRIAL MARKET MAGAZINE
USA
SOFTING DIAGNOSTIC TOOL SET 8: COMPLETE SOLUTION FOR VEHICLE DIAGNOSTICS WITH LOTS OF NEW FUNCTIONS AND EXTENSIONS
10 KNICK SENSOR MANAGEMENT FOR MEMOSENS SENSORS: MEMOSUITE ADVANCED CALIBRATES UP TO TEN SENSORS AT THE SAME TIME
20 KEYENCE CV-X200 : stabilité, CLAMP-ON FLOW MONITORING précision et vitesse NOW POSSIBLE! uniques
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KOLLMORGEN DISTRIBUTED SERVO TECHNOLOGY BENDS PANELS INTO BETTER SHAPE
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INDUSTRIAL MARKET MAGAZINE
KENNAMETAL
SOFTING
MAYR
5
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8 EMERSON INDUSTRIAL AUTOMATION
SOFTING
10
14
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12 ARC INFORMATIQUE
BALLUFF
BONFIGLIOLI
HAIMER
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15 DE DIETRICH PROCESS SYSTEMS
KNICK
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HMS
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21
EPLAN
BAUMER
KEYENCE
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26
29
EPLAN
KOLLMORGEN
30
34 ADVERTISERS: MEPAX 4 - BAUMER 6 - EPLAN 33
www.magazine-industry-usa.com
BUREAU VERITAS
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EPLAN
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KENNAMETAL RECOGNIZED WITH BOSCH GLOBAL SUPPLIER AWARD
Kennametal Inc. (NYSE: KMT) announced today that it has been awarded the Bosch Global Supplier Award 2015 from Robert Bosch GmbH (“Bosch”), a leading global supplier of technology and services.
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he biannual award recognizes outstanding performance in the manufacture and supply of products or services – notably in the areas of quality, costs, logistics and innovations. “It is an honor to be recognized by Bosch as the only tooling manufacturer to receive their Global Supplier Award,” said Don Nolan, Kennametal president and CEO. “This award acknowledges Kennametal’s global team who is working relentlessly to deliver innovative products, superior quality and outstanding performance to the customer every day.”
Kennametal was among 58 suppliers out of 35,000 that Bosch presented with this esteemed award. To be eligible, suppliers must deliver best-in-class services, quality and total cost of ownership as well as guarantee global footprint and significant sales in the purchasing category. “The Bosch Global Supplier Award honors our top suppliers, who play such a key role in Bosch’s success,” said Dr. Volkmar Denner, chairman of the Bosch board of management. “Our suppliers are important partners in helping us shape the connected world. We want to work with them to develop beneficial solutions for our customers.” www.kennametal.com
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Bourdon® – The Original by Baumer.
The unique success story of Bourdon and the manometer began more than 160 years ago with the pioneering invention named after Eugène Bourdon. Today the company is the competence center of the Baumer Group for mechanical measuring instruments. In the endeavor for continuous optimization and further development, Baumer still manufactures the famous Bourdon Tube, adding on modern production and quality methods. All steps are monitored and documented by the Baumer Traceability System, called BTrace ®. Don’t settle for less! Put your trust in original Bourdon ® quality available only from Baumer. For more information please visit www.baumer.com/bourdon
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SOFTING AUTOMOTIVE - EXTENDED OPERATIVE PRESENCE IN THE US WITH MUZAFAR MOSHREF
Softing Automotive is strategically extending its global sales team with Muzafar Moshref as Director Business Development for the North American market. Muzafar Moshref joined Softing Automotive as the Director of Business Development for the North American market.
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uzafar graduated from Purdue University in 1998 and has been working in automotive industry throughout his professional career. Muzafar comes to Softing after a long and successful career in modelbased development tools, where he was managing multiple large accounts in both automotive and commercial vehicle markets.
www.softing.com
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“With the new regional representation we will give North American manufacturers and suppliers of automobiles, trucks and buses as well as mobile working machinery direct access to products and solutions from Softing Automotive.” says Dr. Peter Biermann, Managing Director of Softing Automotive.”“Therefore we see our extend sales services as an important step in the further development of the US market with an experienced automotive business expert already wellestablished on the market”
Softing has been active in the US since 2001 with its own offices (Softing North America Inc) in Newburyport (MA) and Knoxville (TN, headquarter US). In extension to the industrial networks team the sales representation for the US Automotive sector is now being both consolidated and extended.
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A PERMANENT OVERVIEW OF THE BRAKE OPERATING CONDITIONS - INNOVATIVE MONITORING SOLUTIONS FOR SAFETY BRAKES
The module ROBA®-brake-checker not only energises brakes, but also monitors them without the use of sensors. This opens up new possibilities for the monitoring of safety brakes.
The monitoring of electromagnetic safety brakes is an increasingly important topic. mayr® power transmission is therefore setting new standards with the new, intelligent brake control module ROBA®brake-checker. This module is not only able to energise brakes, but can also monitor them without the use of sensors. It is flexible and easy to integrate into existing systems.
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s the amount of networking between people, processes and machines increases, the requirements on the individual components of a drive line also rise. mayr® power transmission has therefore risen to the current challenges set by the Industry 4.0. and has already incorporated into its range intelligent products which can communicate with the superordinate controls.
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The latest developments include an intelligent brake control module, the ROBA®-brake-checker, which is not only able to energise safety brakes, but also to monitor them without the use of sensors. It recognizes the switching condition of the actuator and the wear on the brake linings, and thus detects safety-critical conditions prior to their occurrence. Any changes in the braking torque can thus be instantly detected and countermeasures initiated – for maximum functional and operational safety.
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Higher performance, less inconvenience The new module ROBA®-brake-checker serves to operate safety brakes at reduced power while simultaneously monitoring their switching condition. It is designed for an input voltage of 24V or 48V DC, and can control brakes with a coil nominal current of 10A or 5A. In comparison to the previous fast acting rectifiers, the new module is characterised by its higher performance and also by a larger input voltage range of 18-30 VDC or 42-54 VDC and a controlled output voltage at reduction. In addition, a higher cycle frequency is possible. The module ROBA®-brake-checker reliably detects when the brake condition changes; i.e. whether the armature disk has been attracted or released. The module emits the respective switching condition of the brake via a signal output. With the ROBA®-brake-checker, the switching condition of safety brakes can therefore be recorded in machines and systems even without the usual microswitches or proximity sensors. The module functions highly reliably without mechanical contacts and is wear-free, independent of the cycle
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The targeted braking torque control is carried out using the new module ROBA®-torqcontrol. The device can be operated with 24V or 48V DC voltage, and is able to control brakes with the coil nominal voltage of 10A or 5A.
Using the new, intelligent module ROBA®-torqcontrol, mayr® power transmission provides an economically attractive possibility to generate a variable braking torque on ROBA®-stop safety brakes.
frequency and count. The additional wiring and possible sealing of switches and sensors is therefore no longer required. In addition, it is possible with the sensorless condition monitoring to adapt the overexcitation time automatically if required. Here an integrated automatic system regulates the voltage to the set lowering voltage after a brake-specific overexcitation time. Using a DIP switch, the automatic system can be switched off, after which it is possible to set certain, specified values manually.
ROBA®-torqcontrol. It features the properties of the ROBA®brake-checker, and is additionally able to change the level of braking torque during operation through the targeted influencing of current and voltage. In this way, devices and machines can be evenly and gently decelerated. The module ROBA®-torqcontrol allows control circuits to be constructed and movements to be braked intelligently – ideal prerequisites for use in smart, networked machines. http://www.mayr.com
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Detect errors before they occur Through the comparison of tightening current and holding current, the module ROBA®-brake-checker is able to detect a possible wear reserve or line breakage, or, if applicable, to detect unpermitted heat-up. In this way it can reveal safetycritical conditions and errors prior to their occurrence, and thus guarantee maximum operational safety for machines and systems. The new monitoring module can be used for a wide range of ROBA-stop® brakes, and can be easily, quickly and inexpensively integrated, also into existing systems. With its compact dimensions of 30 mm in height, 69 mm in width and 73.6 mm in length, it can easily be integrated into control cabinets. Braking movements with intelligent systems For applications which require braking torque control in addition to condition monitoring, mayr® power transmission provides the braking torque control module 07 | Industry USA | September 2015
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DIAGNOSTIC TOOL SET 8: COMPLETE SOLUTION FOR VEHICLE DIAGNOSTICS WITH LOTS OF NEW FUNCTIONS AND EXTENSIONS
In the new Release 10 of Softing's Diagnostic Tool Set, alongside an increase in performance and the extended simulation engine, among other things, the focus is very much on heavy-duty diesel vehicles, the coding of ECU variants as well as Diagnostics over IP. Evaluation packages are available for DoIP and J1939.
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n the new release, the performance of the central ISO MVCI server has been further improved. This considerably reduces the CPU load when running diagnostic services and loading times for projects are shorter. Now it is possible to start several instances of the kernel in parallel.
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The integrated simulation engine, which enables the testing of diagnostic data even without an ECU and vehicle interface, has been completely revised and considerably extended: Simulations can now be recorded directly from diagnostic sessions and also support dynamic changes to measured values. Several simulations can be created and managed for each project.
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In terms of trucks, buses and mobile working machinery, universal OBD authoring has been extended with support for 29-bit identifiers on the CAN bus. The delivery scope also contains a ready-to-use SAE J1939 project which enables vehicle diagnostics without first having to create ODX data for that specific purpose. Users of the ODX authoring system DTS Venice can filter according to Audiences when exporting ODX 2.2.0. This makes it possible, for example, to only transfer the diagnostic data that is really required when fulfilling statutory requirements. To adapt ECUs to the relevant vehicle configuration or release additional comfort functions, the all-in-one engineering tester DTS Monaco was given an additional function for coding ECU variants. Furthermore, existing layouts can be reused in other workspaces or projects, and the fast, affordable Diagnostics over IP in accordance with ISO 13400 is supported.
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Special demonstration and evaluation packages are available on request both for DoIP and for J1939, including ODX authoring and hardware-based ECU simulation. Registered users with a maintenance and service package will receive the upgrade to release 10 free of charge. Softing's Diagnostic Tool Set enables developers, engineers and technicians to create, process and run consistent diagnostic data and sequences based on the latest international automotive standards. It ensures that diagnostic communication and vehicle diagnostics work reliably at all times in Engineering, Manufacturing and AfterSales Service. For more information, go to: www.automotive.softing.com/en/dts8
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MARINE TYPE APPROVAL FOR UNIDRIVE M
Emerson’s Control Techniques Unidrive M range has received the DNV type approval certificate.
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n March 5, Rob de Ruiter of DNV-GL at Barendrecht, NL, presented the certificate to Teun van der Heiden of Emerson Industrial Automation at Sliedrecht, NL. In the maritime market, DNV-GL is known as a demanding classification society which sets high standards for products for maritime applications.
The fact that Unidrive M already had many approvals and had been tested by independent bodies meant that the type approval certificate could be granted more quickly. However, given DNV-GL's specific requirements, various additional tests were undertaken to ensure effective operation under maritime conditions.
The assessment was not limited to Unidrive M's product properties, but also the quality of the production process. During an extensive audit of the Control Techniques production site in Newtown, UK, it was confirmed that the Unidrive M production process met DNV-GL's requirements concerning control at the component level, assembly process, intermediate tests, final tests and maintaining a worldwide production standard and traceability at Emerson Industrial Automation production sites throughout the world.
The issue of the DNV-GL maritime type approval certificate means a major step forward for the application of Emerson Industrial Automation's Unidrive M product range in the worldwide maritime and offshore markets.
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www.emerson.com
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RPS ENDURANCE INVERTERS WITH NEW PARALLEL OPERATION FEATURE – AVAILABLE IN 20 FT “ICON ND” STATIONS UP TO 2.25 MWAC RPS Station ICON ND – The perfect home for RPS Endurance inverters.
RPS Endurance is a robust, compact powerhouse with a rated power of up to 563 kWac for each inverter unit.
Electrical Schematic of RPS Station ICON ND with 2 x 2 units of RPS Endurance.
Bonfiglioli’s RPS Endurance inverters are now ready to tango: With the introduction of the new tandem feature, two units operate seamlessly in parallel on a single medium-voltage transformer winding. This makes the performance and ease of handling of RPS Endurance inverters now fully available for megawattscale PV stations.
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hanks to the further extended power range of single RPS Endurance units of up to 563 kWac at 50°C ambient temperature, the new features allows the effortless realization of 1MW+ tandem configurations with a common ac connection, paired with the best-in-class 15 % permanent overload capacity (up to 648 kWac) at reduced ambient temperatures. Constructed with a record footprint and designed for maximum productivity even in the toughest conditions, these ratings make the RPS Endurance a truly compact powerhouse.
The new RPS Station ICON ND series integrate 2 x 2 units of RPS Endurance inverters into a compact 20 ft container design, achieving an excellent power rating of up to 2.25 MWac per station. This great compactness is paired with a proven and easy-to-maintain forced-air cooling system. ICON ND stations are delivered ready to connect to an external three-winding medium-voltage transformer, helping customers to significantly reduce project execution times. MORE INFORMATION
A unique feature for indoor-rated PV inverters, the innovative two-zone ambient protection system distinguishes the RPS Endurance from other solutions and makes it a preferred choice wherever harsh conditions for plant installation and operation are present, such as in the “sun-belt” regions of the world. The intelligent encapsulation design maximizes uptime through a full IP54 ambient protection degree of active components. Thanks to advanced air cooling technology, the inverter design ensures outstanding reliability and serviceability. With numerous self-protection
functions and grid management options, the RPS Endurance is built to satisfy your power control requirements in the fast developing global PV market.
www.bonfiglioli.com
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ABSOLUTE FEEDBACK SYSTEMS FOR EFFICIENT DRIVES
The BML series from Balluff offers rugged, precise and quick absolute position and angle measurement systems, which are ideal for installation or direct integration into drive and positioning systems.
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he new, magnetically encoded absolute position and angle measurement systems with Permagnetﾂｮ nonius technology close a gap in the segment of compact, integrative, absolute measurement systems with IP 67 housing for external installation. As an open kit for full integration, they now have the option of being used in rotary applications as well. Using these systems, the formats, strokes and end positions of axes can be adjusted automatically, quickly and reliably.
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The new absolute encoder disk can be integrated easily into motors and actuators as a highly precise, absolute feedback solution. Because of this, it is an efficient alternative to conventional magnetic or optical solutions for accurate control of motors and drives. The low space requirement for the solution for rotary applications provides another eyecatching quality; it is just 12 - 20 mm in length and 30 mm in diameter depending on the design.
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A fully integrated, single窶田hip solution is the core of the magnetic scanning and signal generation process. The position data is generated in real time and made available in absolute form using interfaces typical in drive engineering, SSI or bidirectional BiSS C. Incremental SIN/COS analog signals and ABZ signals are also on hand for use. The evaluation kit from Balluff is also brand new to the portfolio. It includes a perpendicularly magnetized Permagnetﾂｮ absolute angle measurement system with high system accuracy. Just like the encoder kit, it offers a variety of serial (absolute) and incremental interfaces for connection to many different closed-loop systems. It is easy to use. Once adapted to the drive, the user can run required system tests to derive a customized, optimized solution using the BiSSUSB adapter and provided evaluation software. http://www.balluff.com
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ARC INFORMATIQUE AND UBIQUICOM JOIN FORCES TO BRING LOCATION AWARENESS AND SAFETY TO YOUR SCADA APPLICATION
ARC Informatique is an independent provider in HMI/SCADA software. With its core product, PcVueÂŽ, the company has been contributing to the evolution of the automation industry for 30 years. The PcVue Solutions range provides a flexible solution for supervising industrial processes, utilities and infrastructure.
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ased in Milan, Italy, Ubiquicom is an award-winning technology company specialized in the design and development of products and solutions for the positioning and tracking of people and assets in unconventional contexts and using unconventional technologies.
Easy to configure and performed via Web services, these new features allow the detection and tracking of people and assets directly displayed as PcVue markers (which can be symbols) in a geographical map. This detection and tracking is efficient whether indoors and outdoors regardless of the network’s type and available communications (GSM, WiFi, Bluetooth, BLE). MORE INFORMATION
The two companies at the forefront of technological innovations, chose to collaborate and combine their skills to offer a unique mobility solution. This partnership manifests a joint effort to instill mobility at the heart of supervisory systems. A deliberate move from ARC Informatique in order to step into the field of Internet of Things (IoT) by interfacing with established networks such as LoRa, Sigfox, etc.
New features for Indoor & Outdoor Positioning Services Based on the real-time monitoring of biometric and environmental parameters, Ubiquicom adds an upper layer application to the PcVue Geo Map Control with its Locator Suite.
Through this collaboration, ARC Informatique reaffirms its ambition to provide an innovative mobile offering for SCADA. www.pcvuesolutions.com
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QUALITY DOWN TO THE FINEST DETAIL IN THE AREA OF BLISK AND TURBINE BLADE MACHINING
Haimer shrinking technology enriches Starrag machining centers with precision.
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n order to machine engine components such as turbine blades and blisks, the aerospace industry has been relying on the quality provided by Starrag Machining Centers for a very long time. Almost no other machine supplier understands the requirements in such detail as Starrag does and can offer turnkey solutions including the right software, clamping fixtures, tool holders and peripheral accessories from one single source. At the same time, it is very important for the Swiss that external suppliers also provide the best quality possible. This is why they trust and believe in the shrink fit chucks and shrink fit machines made by Haimer
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The product brand Starrag is located at the Starrag Group headquarters in Rorschacherberg, Switzerland (more company information can be found in the textbox). The company is mainly focused on the Aerospace & Energy Industry and offers five-axis machining centers capable of high metal removal rates in order to produce highly precise turbine blades, impellers, blisks and other structurally complex parts.
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Since the beginning of the 20th century the aerospace industry has been the core market for Starrag machine tools. Even at that time they were able to distinguish themselves from other products and brands through their rigid and robust design and their high technological standard. Therefore it is no surprise that in the 1960’s Starrag was regarded as one of the pioneers in the area of 5-axis simultaneous machining. A know-how-advantage that is clearly visible in their current high quality product portfolio which includes machine types such as the STC and BTP series for titanium machining. Furthermore, machining centers that are specialized in blisk cutting and the LX series are part of the portfolio and were especially designed for the highly precise, efficient and simultaneous 5-axis machining of turbine blades. Patrick Rutishauser (Head of Application Engineering) explains: “technologically speaking, our machines are of premium quality. They are known for their high performance capacity and precision. Furthermore, we offer our customers additional value regarding the application.” Starrag considers itself to be a technology partner of its end users and is capable of designing and realizing complete processes. “When a customer approaches us with a component he needs
NEWS As a long-time partner of the aircraft industry the Starrag Group has the necessary competence to come up with precise turnkey solutions for the production of turbine elements. One standard element of such complete systems is the Haimer shrinking technology.
Because of the reinforced wall thickness in the clamping area and other constructive features the Haimer Heavy Duty Shrink Chucks are able to reach very high clamping forces and can be used for roughing processes with big tools.
Starrag uses Haimer Power Shrink Chucks for demanding roughing and finishing processes.
10,000 pieces of, we design the complete system for him and supply the machine including software, clamping fixtures, tool holders as well as peripheral components and machines.” Such an additional offer is only possible after many decades of experience regarding the development of machine tools, CAM systems and special tools – and because of the application know-how which Starrag is able to acquire during the production of prototype and small series turbine blades. One area Patrik Rutishauser is responsible for: “My tasks include technology and software development for so called Single Blade Applications. In my team, application engineers work hand in hand with CAM-Software developers. This way we can provide our end-users with exactly what they need without taking any detours or wasting time.”
An important detail: tool holding Starrag has known for a long time that “tool holding” is a very important issue when it comes to high precision machining. After all, they were using a high speed spindle (30,000 RPM’s) at their headquarters in Rorschacherberg even 20 years ago. At that time the cutting tools were usually clamped with Weldon or Whistle-Notch holders and collet chucks which, however, led to many problems because of the insufficient run-out accuracy they provide. At high rotational speeds even small deviations can lead to poor milling results, an inferior surface quality, as well as tool and spindle wear. Also the geometry of these tool holders has many interfering contours which make it impossible to reach deep cavities with minimally clamped tools.
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Experiences from the production plant His co-workers are able to gain important experiences at the CPE (Center of Production Excellence), the Starrag application center in Rorschacherberg, where they test and optimize demanding, and new machining processes. The hall which has a surface of about 2000 m2 is equipped with the new four and five axis Starrag machining centers. There the application team is able to perform various applications ranging from heavy duty cutting of highly solid titanium alloy up to high speed cutting of light metal. Patrik Rutishauser emphasizes: “We work on rotating parts, complex cubic work pieces, as well as free-formed flow surfaces – we do all of this under production conditions. We also produce prototype
and small series for our customers. This entails developing a drawing and quality production at reasonable costs in the market.” This is certainly an advantage, as the application specialist suggests, because that way you acquire valuable knowledge about the machine requirements and you can find out more about the integral machining process right down to the smallest detail. “It is different from customer demonstrations where you usually overlook minor details“, Rutishauser explains.
Based on their testing of different tool holding systems, Starrag concluded it was necessary to use shrink fit chucks, which due to their rotationally symmetric clamping body have less interfering contours and a high run-out accuracy. 07 | Industry USA | September 2015
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NEWS In order to shrink tools Starrag has a Haimer Power Clamp NG (left) at its CPE and a Power Clamp Premium. Both machines are equipped with a patented double coil which adapts itself to the length and diameter of the shrink fit chuck.
High-End solutions for professional shrinking and cooling: the Haimer Power Clamp Premium offers a spacious working area, easy handling and linear guided cooling bodies with temperature monitoring. Starrag has the optional length presetting integrated into its machine.
During the initial tests with the new clamping technology, Starrag had to overcome some weaknesses: at that time the chucks were heated up with hot air which was very time consuming and placed great strain on the material.
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About 15 years ago, in search of a solution, the Starrag specialists came across Haimer GmbH in Igenhausen who today is the European market leader in the area of tool holding technology. Patrik Rutishauser emphasizes that “Haimer professionalized the shrinking technology. Even back then the company offered a large selection of tool holders and a shrinking machine with an inductive coil and cooling bodies which were very easy to handle for anybody. Until today Haimer has kept on further developing its shrinking technology – tool holders and machines – and at the same time was always able to stay true to its high quality requirements. We constantly evaluate different systems and suppliers, but regarding precision and quality the products of Haimer are simply unbeatable. When it comes to shrinking technology we appreciate the possibility of clamping tools with short projection lengths and of course the slim contours in comparison to other clamping systems“.
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Also with Shrink Fit Chucks every single detail is important It is not without reason why the company philosophy of Haimer is “Quality wins”. Behind this concept there is the idea to only produce in the home town of Igenhausen near Augsburg in Bavaria, where the precision can be kept under control 100% of the time. There, all shrink fit chucks, even the standard ones, are made out of heat resistant steal and are fine balanced (at G2.5 at 25,000 rpm < 1 gmm unbalance). The functional surfaces are machined and ground extremely accurately and the taper tolerance is much more precise compared to the relative norm. For special machining requirements Haimer is offering special shrink fit chucks. For example, the Power Shrink Chucks are suitable for special high speed or high precision milling applications. The patented design combines a low tendency towards vibrations with a high rigidity and a slim design on top. This special construction makes it possible for the operator to increase the cutting depth and the feed and thus reach a higher cutting volume while still maintaining a good surface quality. The Heavy Duty Shrink Chucks are especially designed for heavy machining with large cutting tools and they feature a reinforced wall thickness at the clamping area, a very rigid outer contour and patented expansion grooves in the clamping bore. This way, high clamping forces which can be compared to those of Milling chucks can be reached. The portfolio of shrink fit chucks is completed with the small Mini Shrink Chucks. These are one-
NEWS Close to the shrinking station you can find the Haimer balancing machine Tool Dynamic Preset, a combination solution to balance and measure tool holders and tools. For tools produced by Starrag itself, especially multi-stage tools, this machine is being used all the time.
This is due to the fact that the turbine blades need a very precise structure in order to be very energy efficient. Nowadays you can get the desired structure through milling and without any additional regrinding. At the moment Starrag is capable of achieving a surface quality of Ra=0,8 µm – 0,4 µm.
Patrik Rutishauser, Head of Application Engineering, is convinced of the Haimer shrink fit chucks and machines: “Haimer professionalized the shrinking process.”
piece shrink fit chucks with an extremely slim design and a 3 degree outer contour – designed for mold making. Difficult material, high surface requirements For Patrik Rutishauser this variety of shrink fit holder designs works as an advantage. He explains: “during the blade production made of extrusion profiles there are generally two procedures. First, it starts with a rough cutting process. During this process it is important that the chuck operates with a damping component in order to achieve a high cutting depth and feeds and to remove as much material as possible in one production stage. During the finishing process, however, there aren’t any strong cutting forces. At this point, a high runout accuracy and the balancing quality are of importance. The Haimer Power Shrink Chucks are ideally suited for both processes and if the cutting gets even tougher we simply switch to Heavy Duty Chucks.”
“Haimer shrink fit chucks are part of our standard equipment, because they offer the best conditions for process reliable cutting which people expect from us”, Patrik Rutishauser explains. “We don’t just use these products at our CPE, but we also sell them together with our own systems. Therefore it is important that the quality of the products always remains high. With Haimer we feel secure. I can’t remember a single incident where a tool holder was the reason for a customer complaint.” The right machine tool for each application The Starrag Group (about 1617 employees and around 390 Mio. CHF turnover in 2014) is one of the leading machine tool manufaturers and combines the brands Marken, Berthiez, Bumotec, Dörries, Droop+Rein, Heckert, Scharmann, SIP, Starrag, TTL and WMW. On different locations a broad range of machines for milling, drilling and grinding metal work pieces, composite material and ceramics is being developed. Each brand has its own specialties. The complete offering ranges from small high speed machining centers from Bumotec (suited for cutting components in the watch, medical, and computer industry) up to the Gantry machines from Droop-Rein which are many meters long and can fill an entire hall (suited for working on big, heavy work pieces). Their customers include internationally active companies that belong to the three target markets Aerospace & Energy, Transportation & Industrial Components and Precision Engineering. The portfolio of machine tools is completed by their technology support and general service and allows the customers to make substantial progress. http://www.haimer-usa.com
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In terms of the shrink fit chuck quality the best is required for Starrag. This is due to the fact that during the roughing and finishing machining of titanium and other hard-tocut materials, the cutting forces can be very aggressive on the interface between the machine spindle and the tool holder. “In the end, the key element is the part quality. It has to be perfect starting from the very beginning, because even the titanium blanks cost a small fortune. We are convinced that the tool holder quality is absolutely essential for the part quality”, Patrick Rutishauser explains. This is especially true regarding the surface quality, which constitutes an important factor.
High-end-shrinking machines ensure fast and easy tool clamping In order to shrink tools Starrag has a Power Clamp Profi Plus NG in its CPE (Centre of Production Excellence) with which you can shrink all HSS and solid carbide tools with shank tolerance h6 and diameter 3mm up to 50mm within a matter of seconds. It is equipped with a patented double coil technology which means that the coil adapts itself to the length and diameter of the shrink fit chuck. During the shrinking process only the shrinking area is heated which reduces the heating and cooling time (via contact cooling) significantly. In addition there is a High-End solution for professional shrinking and cooling: a Power Clamp Premium machine that offers a spacious work surface, easy handling and linear guided cooling bodies with temperature monitoring. The machine at Starrag has an integrated length presetting – holding lengths exactly within 0.02mm – since tools always have to be shrunk to a precisely defined overhang length.
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SENSOR MANAGEMENT FOR MEMOSENS SENSORS: MEMOSUITE ADVANCED CALIBRATES UP TO TEN SENSORS AT THE SAME TIME
Up to ten sensors can be calibrated at the same time with the PC-based sensor management software MemoSuite Advanced from Knick.
Measuring technology specialist Knick now offers an enhanced version of their sensor management software for Memosens technology: MemoSuite Advanced allows for the calibration of up to ten sensors at once.
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he intuitive-to-operate PC software enables users to easily pre-calibrate sensors for pH, ORP, oxygen, conductivity and temperature measurement under optimal conditions in the lab, i.e. completely dispenses with complicated on-site calibrations in adverse environmental conditions. Sensors can be connected to a PC via USB using the interface converter MemoLink included in supply. In addition to the calibration function, MemoSuite Advanced completely records all calibration data and logs operational times (across all or under extreme process conditions) allowing for documentation according to legal requirements such as FDA 21 CFR Part 11.
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The software also displays current measuring values, sensor data and the latest adjustments and supports a multitude of established calibration methods. For pH sensors, a comprehensive buffer catalog with various buffer sets for individual compilation is available as well.
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If needed, customers can implement their own buffer sets. Calibration reports â&#x20AC;&#x201C; the software includes several templates â&#x20AC;&#x201C; or MS Excel data records can be generated. The MemoSuite database enables users to implement a predictive maintenance strategy. Lifetime sensor data records also facilitate long-term planning of replacement cycles and optimized maintenance strategies. Sensor data tables can be freely configured and database entries can be sorted, filtered or grouped and compared. In addition, the software supports visualizations of statistical findings and sensor histories, and provides an export function for detailed reports. http://www.knick-international.com
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DE DIETRICH ANNOUNCES RECORD ORDERS AT THE ACHEMA TRADE SHOW!
De Dietrich, which recently scored new successes that provide it with opportunities for sustainable growth, is continuing its international expansion and has secured, in China, the biggest deal in its history.
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nder the deal, De Dietrich will deliver a waste acid treatment system for a new toluene diisocyanate plant to be built in northwest China. Toluene diisocyanate (TDI) is used in the manufacture of polyurethane. The Chinese government, which has significantly tightened the country's environmental standards, was impressed by De Dietrich's highly efficient effluent treatment and purification processes. The project, which is scheduled for completion in 2017, will be the largest ever undertaken by De Dietrich and will further strengthen China as the group's largest source of sales.
In related pharmaceutical news, De Dietrich is going to build a complete antihistamine production plant in Spain. This turnkey project will include the production building itself, all the necessary reaction and separation equipment, and all the associated equipment. Production of the first batches will begin in one year's time.
De Dietrich has also been selected to deliver a complete pilot unit for the first company in Bangladesh to ever begin manufacturing active pharmaceutical ingredients (API). The project comprises six reactor units, a solvent treatment system, a heating and cooling unit, and automated systems. It will allow De Dietrich to further increase its already strong presence in Southern Asia.
www.dedietrich.com
Back in its home country of France, De Dietrich has just signed a green-chemistry partnership agreement to equip a research platform for the production of chemical molecules from renewable oilseed crops.
MORE INFORMATION 07 | Industry USA | September 2015
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M-BUS SENSORS CONNECTED IN 10 MINUTES!
The Anybus M-bus - Modbus-TCP gateways.
Processcomponent in Sweden has found a way to quickly connect M-Bus sensors to the OptoEMU Energy Monitoring System. By using the Anybus M-Bus to Modbus-TCP gateway they can provide building owners with real-time data from their buildings so they can do monitoring, logging and invoicing.
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modern building is not only built of concrete, wood or steel, it is also an intricate digital network linking together systems for cooling, heat, water, electricity etc. A common problem for building owners and system integrators is that not all systems and machinery can communicate with each other.
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One example is sensors for heat, water, temperature, energy etc. Sensors and meters often use the M-Bus protocol which cannot be understood by central system controllers on networks such as Modbus-TCP.
This exact problem is what faced Swedish system integrator Processcomponent AB as they were installing a monitoring system in an apartment building in Gothenburg. The system gathers data from 72 apartments, a grocery store, and the central HVAC system. All around the building, there are sensors for temperature, energy and water. The problem was that the sensors communicate via M-Bus and the energy monitoring system — the OptoEMU from Opto22— uses Modbus-TCP. To solve this communication issue, Processcomponent found the Anybus M-Bus to Modbus gateway from HMS Industrial Networks. The gateway decodes M-Bus telegrams and maps them directly to Modbus registers. This way, the sensors can be understood by the OptoEMU and their values show up directly. Quick and easy access to M-Bus data “What I really like about the Anybus M-Bus gateway is that it is very easy to use and quick to install,” says Jonas Karlsson, Sales Manager at Processcomponent. “All M-Bus sensors are automatically detected by the gateway without you having to
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The mapping of Modbus registers is highly automated. Configuration in made in a webbased interface.
Jonas Karlsson, Sales Manager, Processcomponent.
example. Users can also get alarms whenever certain levels are reached.
The OptoEMU connected to the M-Bus gateway.
do any configuration. This saves a lot of time since you don’t have to configure each meter individually — they all show up automatically, complete with serial number, name, and all current values. Indeed, you don’t even have to be on site as long as you have someone connecting the wiring from the sensor to the gateway. Before, it could take several hours to configure a single meter running M-Bus. With the Anybus gateway we can set things up in 10 minutes!” How it works “The actual process is quite easy,” continues Jonas Karlsson. “You do a search for available M-Bus sensors connected to the gateway, and you get back Modbus registers from the sensors. These can be interpreted by the OptoEMU and provide the customer with real-time data from the sensors.”
The results The building in Gothenburg is now equipped with Anybus gateways connected to two OptoEMU-DR2 one for the 72 apartments and one for the grocery store. The measured values can be logged to an Excel file which can be downloaded via FTP. The readings can also be sent directly to an SQL database or to HMI/SCADA systems via an OPC server. Since the building owners now have access to real-time values from the different apartments in the building, they can be on top of consumption and get alarms when certain thresholds are reached. Access to meter values also enable rapid and automated invoicing to apartment owners. “The Anybus gateways have certainly made life easier for us and our customers” finishes Jonas Karlsson at Processcomponent. “By getting M-Bus values into the OptoEMU quickly and easily, we can get our monitoring system up and running faster which is beneficial for both us and our customers.” www.hms-networks.com
The configuration is handled in a web-based configuration tool which allows users to set up the gateway in a web interface. No programming is necessary – the values from the meters automatically show up in the OptoEMU as Modbus registers which it can understand and process. MORE INFORMATION
OptoEMU — a solution for energy monitoring Processcomponent has been very successful in installing the OptoEMU – an Energy Monitoring System (EMU) which collects energy data from buildings, electrical subpanels, and individual equipment like chillers and compressors. The OptoEMU delivers the data so users can view it online and use it in a business application and do invoicing for 07 | Industry USA | September 2015
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FOCUS ON DEVICE DATA
EPLAN Data Portal, now with a new web service, allows users to find everything they need for design engineering and is considered a strong marketing tool by manufacturers.
EPLAN Data Portal has been expanded with new updating, enhancing and filtering functions for device data. Users can start designing without having to go through the tedious process of setting up master data. For manufacturers, the new Report Center delivers statistics about downloads and therefore important key figures for marketing and sales.
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PLAN has announced a new, fee-based web service: the EPLAN Data Portal Professional. Users get comprehensive functionalities to update or enrich device data, as well as significantly expanded filtering possibilities.
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When device data has been updated in the portal, the system alerts users as to which data is more current than that found in their local database. The advantage: users can update their data at the push of a button, without manually searching and replacing. The portal´s new data enhancement functionality begins at the start of a project, when device data is not yet available in the device management system.
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Users can send lists of devices or model numbers to the Data Portal, and then they receive a shopping cart to download with all the found device data. Besides supplementing commercial data, these updates also include important engineering data such as macros, documentation and production data. Users can begin designing without having to go through the tedious process of setting up master data beforehand. Another practical benefit: once device data has been enhanced, the change is accounted for during the routine update for the device data. Comprehensive filtering options, such as the ability to save prefilters, can be assigned to individual persons via the integrated rights administration. Components can be located more quickly, considerably increasing the speed of the design process.
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Direct exchange, precise data With the revised feedback functionality, users can use the e-mail function to contact manufacturers directly from the portal if components are not correct or not in the database. Device manufacturers receive direct answers to the following crucial questions: How many times has a component been downloaded? What countries are the products being used in? Which products are the most interesting to users? Comprehensive evaluations offer precise controlling data to manufacturers´ product management and sales departments. Fields of action can be derived using this information and product successes more precisely planned. EPLAN helps manufacturers integrate their own electronic product catalogs into EPLAN Data Portal. The services range from the migration of existing catalogs and product configurators to the development of new configurators. The result is a tailor-made electronic product catalog that offers users custom engineering support.
Advantages for users • Device data easy to locate quickly • Minimal effort to administer master data • Significant time savings for design engineering • Increased documentation quality • Supports interdisciplinary processes Advantages for manufacturers • Development of additional sales channel • Direct access to around 75,000 EPLAN users • Transparency about company´s product usage • Comprehensive evaluations with controlling data • Direct user/manufacturer e-mail contact https://www.youtube.com/watch?v=BLc712lYLHM
MORE INFORMATION 07 | Industry USA | September 2015
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PROCESS OPTIMIZATION WHILE CUTTING DOWN ON COSTS
Fig. 1: The universal CleverLevel limit switch in action: Here, installed at a buffer tank.
End-to-end sensor solutions in food and beverage technology.
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he production of mayonnaise and salad dressings confronts metrology with some really demanding challenges. Frequently changing recipes, many ingredients of different textures and specific filling levels bring conventional instruments to their limits. The Baumer sensor solutions with CleverLevel, CombiPress and CombiLyz optimize the production processes at Homann’s to ensure the high quality of their gourmet products. Since 1978, the Homann location in the German city of Bottrop has been producing premium convenience food. Gourmet salads of the Homann and Nadler brand are popular and well-known far beyond the region.
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Both traditional brands belong to the Theo Müller Group. Two years ago, in close collaboration with Baumer they elaborated on new concepts for process optimization in the manufacture of mayonnaise, salad creams and dressings.
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Limit level detection in storage, mixing and buffer tanks Precise and reproducible switching operations are a must, even in apparently simple tasks of limit level detection. In storage tanks, the conventional capacitive level switches, commonly known as “micro wave switches” provide only limitedly reliable performance. They require mediumspecific configuration. Outside the thresholds, the low dielectric constant of some media like edible oil (DK εr <10) may cause measuring errors if a film of lye has remained on the sensing tip after cleaning. To Homann, this was one criterion to decide for CleverLevel, the configurable universal level controller. Operating on frequency sweep technology, it will reliably detect the filling level of any media (fig.1) as one-sensor solution for both oil and water. Depending on recipes and dielectric properties of ingredients in mixing tanks, Homan used to deploy product combinations of capacitive limit switches and vibrating forks. Accord ing to the media, response times ranged from very slow to highly sensitive which resulted in impaired process efficiency. Homann replaced their conventional solution with CleverLevel which has an extremely fast response time. Baumer helped to find out the optimum configuration
NEWS Fig 2 : The FlexProgram software allows for configuration of stepless trigger thresholds or windows, for example to suppress or detect foam and adhesion.
Fig. 3 Even severe adhesion by viscous media like mayonnaise will not impair the CleverLevel precision in the measured results.
which is conveniently changed and visualized via FDT/DTMbased FlexProgram software (fig.2). Once the mayonnaise, salad cream or dressing is fully emulsified and dispersed, it is pumped into buffer tanks until being added to the salad in a later production step. Here, medium-specific viscosity and adhesion play an important role (fig.3). Conventional solutions using vibrating forks and capacitive limit switches were prone to measuring errors caused by adhering media. CleverLevel is maintenancefree and not affected by media adhesion. Unpredicted downtime for system ventilation and pump revision now belong to the past. Frank Piatkowski, responsible application and process engineer at Homann’s: “CleverLevel is the one-sensor solution for different media and applications. Since deploying CleverLevel, we have been experiencing a significant reduction in technical malfunctions”.
Capable of detecting medium-specific density and filling levels, Homann has CombiPress also installed in glucose containers and horizontal tanks of edible oil. Especially here, CombiPress excels with its integrated linearization function. Baumer also offers the matching adaptors for optimum process connection. Frank Piatkowski is content: “Whether indoor or outdoor”, he says, “the Baumer sensors contribute towards hassle-free automation and once installed, they are neither susceptible nor perceptible”. Conductivity measurement in CIP processes Every cycle in dressing or mayonnaise production entails CIP cleaning (Cleaning in Place). The reproducible process precisely defines detergent dosing under consideration of pressure and temperature. At the Homann CIP installations in Bottrop, dosing needed to be improved - and new conductivity sensor CombiLyz came into play. Thanks to fast response time it ensures precise measured results at a maximum deviation of < 1%. The measuring connection of the inductive sensing element provides a 6.6 mm wide channel which even will tolerate fabric or solid-containing
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Measuring hydrostatic pressure in tanks of vinegar, edible oil and glucose Homann’s Bottrop location has a large outdoor vinegar tank. For consistent level monitoring they were looking for a precise and reliable but yet easy, convenient and outdoorcapable solution. Homann decided for pressure transmitter CombiPress. Thanks to 0.1% (MEW) accuracy and active temperature compensation, it solidly performs in providing unambiguous
measured results, independent of media and ambient temperature. Easy configuration via the large touchscreen eliminates the need for an additional operating unit. The robust housing with high IP67 rating reliably endures harsh outdoor conditions and wet areas (fig.5).
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Fig. 4 CombiLyz at CIP installations ensures hasslefree CIP processes.
Fig. 5 The CombiPress display providing visual information on the measured hydrostatic tank pressure instead of a number value eases on-site readout.
media. Homann successfully optimized detergent dosing and cut down on raw material costs. “The innovative Baumer products will again be part of our considerations when investing into new and state-of-the-art CIP installations”, explains Frank Piatkowski. “Baumer tackles our requirements in terms of optimization or specialized products as incentives for new developments and ensures expert implementation.” At Baumer, hygienic designs and stringent mandatory product certifications are a matter of course. All Baumer process sensors deployed at Homann’s comply with the high EHEDG standards and are certified by the European Hygienic Equipment Design Group. Furthermore, compliance to EN 1935/2004 and EN 10/2011 for food-safe products will reduce the total Hazard Analysis and Critical Control Points (HACCP).
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Author: Stefan Imort, Product Market Manager Process Instrumentation, Baumer Learn more: www.baumer.com www.homann.de www.muellergroup.com
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CLAMP-ON FLOW MONITORING NOW POSSIBLE!
Keyence Corp. of America has found a way to accurately detect (and monitor) flow of liquid by mounting a device to the outside of a pipe. The new FD-Q series of flow sensors are arguably the simplest devices available to monitor liquid flow.
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ounting/Integration: No pipe modification is needed with the FD-Q series. The unit actually clamps-on to the outside of a pipe and can accurately sense the flow of liquid through metal or resin pipes ranging from ¼” to 2”. The Keyence FD-Q series can literally be mounted to a machine, while running, with a Phillips screwdriver.
The FD-Q series is yet another innovation by Keyence Corp. of America that is not only cutting-edge but versatile enough to integrate on a large scale. www.keyence.com MORE INFORMATION
Cost & Time Reduction Unlike traditional flow sensors, you do not have to shut down the machine, cut the pipe, thread the pipe, add external parts, or have the special knowledge to do all the above. By mounting to the outside of a pipe, both cost and time are kept at a minimum. The ease of installation, and associated cost savings with mounting externally, open up countless machines to flow monitoring that were once considered unrealistic.
Types of Fluid The FD-Q series can detect virtually any type of liquid. This includes the flow of water (including deionized), oils, chemicals, consumer products, etc. Limitations of traditional liquid flow sensors do not apply to the FD-Q because the unit does not directly contact the liquid. Concerns of contacting corrosive liquids or contaminating a product are a thing of the past.
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CHANGING CAES LED TO MAJOR WORKFLOW IMPROVEMENTS
How EPLAN streamlined order fulfillment Manufacturers upgrading to an advanced, database-centric electrical CAE like EPLAN can reap important strategic benefits over and above making their engineers more productive.
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ne such success features Curt G. Joa, Inc., of Sheboygan Falls, Wisconsin. Founded in 1932, Curt G. Joa, Inc. is a global OEM of manufacturing systems for personal hygiene products like disposable diapers and adult incontinence products. Each machine Joa builds is a complete manufacturing system, like a miniassembly line, incorporating many process steps. One of Joa’s newest platforms makes light incontinence products with a maximum output of 1,000 units per minute. Building such a machine is a large undertaking, as each is based on a standard design modified by the customer’s selection of options, and takes months to complete.
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For Joa, EPLAN’s enhanced benefits include a more rational staging of engineering work that helps streamline preproduction and allows the company to raise output without adding engineering staff. For other companies, these higher level benefits can streamline the entire order fulfillment process and improve their competitiveness.
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Such benefits include: • Shortened delivery lead times • More reliable production scheduling • More efficient workflows and procurement decisions • Opportunities for standardizing and re-using design content • Improved collaboration among stakeholders Previous approach favored early code writing Before Joa adopted EPLAN Electric P8 in 2006, its electrical engineers used an ultra-conservative approach to fulfilling an order. “The electrical engineers didn’t feel comfortable unless they began programming immediately,” said Kevin Zeinemann, Engineering Manager. Software engineers also began writing code as early as possible, but as details of the project changed out of necessity, customers required revisions, and documentation and code needed to be reworked. Joa estimated at least a 30% savings in design time by switching from their current CAD system to EPLAN Electric P8.
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Schematics produced in just a few hours.
Schematics data now leveraged for software generation Joa discovered the possibilities of a different approach when it added the optional EPLAN Schematics Generator (now part of EPLAN Engineering Configuration One, also known as EEC One) four years later. The ability to automate schematics creation while using the same spreadsheet data to automate software creation has been an enormous time saver. Now, work can be performed in a logical, sequential fashion. “In the past, it took us hundreds of hours to write the PLC code, but now we can wait until our machines have power for six weeks before we start writing code,” Zeinemann said. “Now we can wait a lot longer into the design process and give the customer more opportunities to make changes, which also gives our mechanical engineers more time to work. Now, our trigger is the lead time necessary for our hardware vendors to supply the start of production.”
These basics can be modified for the number of junction boxes, operator stations, sensors and valves – everything needed to generate the machine wiring diagrams. For the drive panels, an electrical engineer with input from the mechanical engineers creates a spreadsheet listing all servo-
“We take that spreadsheet and import everything into EEC One,” said Engineering Coordinator, Bruce Davey. “This information is tied to another set of EEC One macros with all the variables embedded, which in turn will create schematics for one, two, three, four or five drive panels.” “Each drive panel contains an average of 50 servo motors control-wise, so we might have 100, 150, 200, 250 motors on a machine,” Davey said. “It used to be a rule of thumb that if 200 pages of schematics were needed, it would take an hour per page to create, so 200 hours. Now, using EEC One, we’re able to do that in four to eight hours, and have great confidence that the results are correct.” After creation of the schematics, the same I/O configuration data is transferred to the company’s Rockwell Automation RSLogix 5000 to generate the PLC software. Overall, Joa estimates that with both the ability to automate schematics creation with EEC One and the integration to Rockwell Automation RSLogix saved at least an extra 50% on design time.
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Joa also archives templates in EEC One for each basic model. These are configurable for variables like power supplies, Ethernet switches, breakers, supporting terminals and much more.
motor requirements with part numbers, locations and safety groupings.
In that sense, EPLAN also complements the company’s emphasis on modular design and manufacturing Although Joa was familiar with EPLAN because some of their customers had requested documents in EPLAN format, it 07 | Industry USA | September 2015
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NEWS Exporting .dwg files to expedite enclosure manufacturing.
wasn’t until the launch of EPLAN’s Electric P8 in 2006 that Joa’s management was convinced to switch. Electric P8 met the company’s desire for a stand-alone CAE technology with a strong database architecture that wasn’t an AutoCad addon and would integrate well with a Microsoft environment. “If you understand databases and how a graphical database works, you immediately see the power in EPLAN,” Zeinemann said. “That’s what we’ve continued to do here over the past four to five years, leverage that database and understand how that works.” Though all machines are custom orders, as much as 80 percent of their content can be based on stored, standardized modules in EPLAN. In addition, upgrading to Electric P8 2.3 provided an effective means to begin sending 2D EPLAN layouts as .dwg files to enclosure manufacturers to expedite production of the cabinets for each order.
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The company makes EPLAN documentation available in smart PDF format for mobile devices or desktop computers. Many customers appreciate this flexibility because a complete set – up 1,000 pages – can be carried around by engineers or maintenance staff on a tablet.
“I measure our print packages in inches instead of numbers of pages,” Zeinemann said. “It would take a suitcase to carry a whole set in printed form.” Eventually, Joa will likely archive all parts data, allowing it to be called up on touch screens throughout the plant. Leveraged EPLAN for huge time savings, workflow efficiencies Curt G. Joa, Inc. designs and builds large manufacturing platforms used to produce disposable products such as baby diapers, sanitary napkins and incontinence pads. Using EPLAN and its Schematics Generator (now part of EPLAN Engineering Configuration One) to automatically create schematics and help drive its RSLogix 5000 software generator saves Joa hundreds of hours in design time and labor cost for each machine it builds. By automating most of the electrical design and software creation, the company can design workflows more efficiently. Less effort is wasted due to shortening design timelines made possible by EPLAN, giving the company confidence it can wait until customer approval of engineering packages is received before the PLC software is written. Find out more about Curt G. Joa, Inc. at www.joa.com
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Can your CAD do this? Automate the most time-consuming tasks of electrical engineering like wire-numbering, device-tagging, cross-referencing, and errorchecking, even prevent you from making errors?
EPLAN can!
Let you create and store unlimited simple, complex, even scalable macros with ease? And update them automatically?
EPLAN can!
Search a quarter-million components from over 56 leading manufacturers to find the one you need in seconds, then create the data set for it? Or translate your project into 17 other languages?
EPLAN can!
With EPLAN Electric P8, the leader in electrical design automation, you can accomplish in a day what takes a week or more using CAD tools. Request your 30-day free trial at eplanusa.com
MORE INFORMATION 07 | Industry USA | September 2015
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DISTRIBUTED SERVO TECHNOLOGY BENDS PANELS INTO BETTER SHAPE
Salvagnini simplifies the design of its machines using drive solutions from Kollmorgen.
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aking a departure from traditional drive architectures in its new P2lean generation of machines, Salvagnini the world's leading manufacturer of panel bending machines is using distributed servo amplifiers for positioning, instead of keeping drives installed centrally in the control cabinet. And with this solution, the new Kollmorgen AKD-D series generates cost savings throughout the whole value chain. Another first by the Italian machinery manufacturer: Replacing the central hydraulic pump by a synchronized network of electrically-driven servo actuators.
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Each bending machine process cycle starts by the operator laying a metal sheet on the horizontal work surface. The workpiece is aligned to the bending unit fully automatically, by positioning axes under a blankholder. This clamps the panel in place while the bending unit, with its moveable blades, quickly performs any number of upward or downward bends. The precision of the reference position is essential for subsequent manufacturing quality because it is only done once for each workpiece during the processing cycle. 07 | Industry USA | September 2015
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Drives simply placed next to the motors To drive the built-in positioning units, Salvagnini uses distributed AKD-N series servos from Kollmorgen. With the new product generation, from the drive technology and motion control specialist, it is very easy to install the drives directly where they are required, in close proximity to the motors. One advantage of this distributed architecture comes from the dramatically reduced cost of the cabling for the seven distributed servo axes in the P2lean. Using a central structure with control cabinet converters, the shielded cable between the motor and the drive and the cable for the feedback system previously could have needed laying up to 10 meters of cable. For the seven positioning axes that would have made a total of 140 meters of wiring (14 wires of 10 meters each). With this solution, using a central AKD-C power supply module in the control cabinet and seven distributed servo drives in two groups with three and four axes, this has now been reduced to only 40 meters. The total length is calculated as follows: two hybrid cables with power supply and feedback between the power supply module and the two nearest drive cables for a total of 20 meters, plus three meters for connecting the three axes in the first group and four and a half meters for a further
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three axes in the second group, knowing that the average distance between the IP67 devices in the system is not more than one and a half meters. The power supply to the motors then has to be considered. They are also installed not more than one and a half meters from the distributed AKD-N servo drives. Because the Kollmorgen solution is equipped with its innovative single cable connection technology, only 7.5 meters more cable is needed. Considering only the use of the distributed AKD-N servo drives combined with the single cable connection system, this saves 100 meters of cable - by reducing from 140 to 40 meters or roughly 71%. More efficiency by using less This careful management of equipment resources produces other improvements that are a direct result of having much shorter cables. They take up less space in the machine and not only that, they are quicker to install. The fewer number of connectors also saves time when connecting - which results in cost savings of 30 percent. The other benefits of distributed servo technology are not inside the machine itself, - but in the control cabinet. Now that the driveâ&#x20AC;&#x2122;s heat loss no longer has to dissipate behind closed doors, the cost of cooling the cabinet is reduced. This produces two knock-on effects: firstly a smaller-scale and consequently cheaper cooling system and secondly, improved energy efficiency as a result of the control cabinetâ&#x20AC;&#x2122;s lower energy consumption. Savings of 30 percent have been estimated by Kollmorgen in real applications. Space-saving, increased energy efficiency and lower installation and assembly costs are three benefits of distributed servo technology embodied by the AKD-N servo amplifiers from Kollmorgen, which also bring tangible cost savings with them. It is interesting to note that this strict management of resources, in this case also incurs lower cost for the hardware. When considering the drive equipment part of the installation, a distributed architecture costs at least 3.5% less than the central control cabinet solution for the smallest Salvagnini machine. For systems with more performance and a greater number of axes, gains of up to 10 percent can be achieved.
from this, energy efficiency is increased, because the system drives only the active bending processes and does not have to keep the entire system with all its bells and whistles ready for operation. Thanks to the standard precision of the Kollmorgen drive axes, the required bending forces can be applied faster and with higher repeat precision, resulting in manufacturing quality improvement. All in all, Savignini has succeeded with the P2lean in developing both an economic, ecological and consequently highly competitive machine for panel bending companies. The distributed servo technology from Kollmorgen adds a valuable contribution to resource efficiency especially in terms of cabling, control cabinet space and cooling. Author: Fabio Massari, Sales Manager, Kollmorgen, Italy www.kollmorgen.com
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Increased energy efficiency Savagnini are also using Kollmorgen's drive technology in another of their innovative advances. To replace the central hydraulic system, with a main pump and its correspondingly powerful asynchronous motor, they are using three highly efficient servo actuators, driven by Kollmorgen AKM servo motors and by S700 Series servo amplifiers, delivering power only at the moment the process requires it. Resulting 07 | Industry USA | September 2015
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BUREAU VERITAS AND GREEN BUSINESS CERTIFICATION INC. (GBCI) SIGN GLOBAL AGREEMENT FOR LEED CERTIFICATION
In a recent signing ceremony, Bureau Veritas and Green Business Certification Inc. (GBCI), the certification body for the U.S. Green Building Council’s LEED green building program, finalized the terms of their exclusive global agreement to facilitate LEED certification internationally.
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EED is the world’s foremost program for the certification of design, construction, maintenance and operations of green buildings, with more than 1.8 million square feet of commercial building space certified daily. There are currently more than 69,000 LEED building projects located in over 150 countries and territories, with approximately 44% of all square footage outside the U.S.
As part of the agreement, Bureau Veritas teams around the world will review LEED projects for conformity with GBCI’s strict standards for certification. Immediate plans for local LEED review teams have been drawn up for China, Brazil and India, where Bureau Veritas employs a total of approximately 21,000 staff. Local review teams will allow enhanced customer engagement and local support for LEED while advancing the goal for future site verification as part of the LEED certification process.
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“Our objective is a seamless customer experience for LEED users and project teams,” said Gerard Biessy, Vice-President of Building & Infrastructures at Bureau Veritas. “We are investing considerable resources into our local capacity building and the integration of GBCI processes.” “GBCI and Bureau Veritas will be able to offer local touch points, local reviews, possible on site verifications and other resources for green building teams on the ground,” said Mahesh Ramanujam, chief operating officer, USGBC, and president, GBCI. “Through this collaboration, we will be able to connect 07 | Industry USA | September 2015
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with our customers and deepen our engagement with them, which will help accelerate the adoption of green building practices and deliver its benefits to these key economies. Bureau Veritas is the world’s leading conformity assessment service provider in the Building & Infrastructure industry. The partnership shall enhance Bureau Veritas’ service offerings and at the front of a growing and important global market. The first buildings to be certified by Bureau Veritas within this partnership are due to be delivered in late 2015. The growth of LEED reflects its global adaptability as the world’s most widely used and recognized system guiding the design, construction, operations and maintenance of green buildings. LEED is a critical tool in creating structures that mitigate greenhouse gas emissions; create healthier indoor environments for workers, students and community members; and lower utility bills for building owners through reduced energy and water use. For further information: www.bureauveritas.com MORE INFORMATION 07 | Industry USA | September 2015
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DESIGNS IN HALF THE TIME
Pro GreyLogix designs and builds control cabinets for large automation projects – even for controlling entire factories and power plants.
Assembly design is handled by practice-oriented specialists.
How can a manufacturer of complex control cabinets achieve competitive advantages? By automating his processes! Bilfinger GreyLogix, based in Flensburg, Germany, is now working with the EEC One from Eplan – cutting the time needed for schematic creation in half.
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ith 650 employees, GreyLogix is among the largest experts in designing automation technology solutions. In business for the past fifteen years, the company specialises in large automation technology projects that require engineering expertise as well as industry-specific know-how. This is why their design teams are organised into various business units that each focus on specific market segments such as oil and gas, food and beverage and the chemical/pharmaceutical industries.
“We don’t have any standard projects, so there is no learning curve either,” says Thomas Besser, Team Leader for the CAE Centre of Excellence. “It makes expertise and experience all the more important.” This applies to programming, which constitutes the majority of the work, but also to electrical design and switchgear cabinet engineering. GreyLogix has always relied on a high degree of automation: “We recognised early on that we have to be strong in project and process management. We want to offer our customers additional value: be smarter and work more intelligently. We’re continually working on this.”
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Eplan Engineering Configuration One (EEC One) is a recent addition to the tools that GreyLogix uses for electrical engineering. The software allows schematics to be generated automatically, based on an Excel interface. This requires a specific approach: the engineer enters basic parameters into a table, such as the voltage for instance. Next, he selects components from an individually configured list, such as “75 kW motor,” hits the “configuration” button, and receives the wiring diagrams. 07 | Industry USA | September 2015
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Thomas Besser (left); Team Leader for the CAE Centre of Excellence of Bilfinger GreyLogix, explains, “You can generate 50 to 60 per cent of the project with the help of this automated design process.”
GreyLogix works with the Eplan Electric P8 and EEC One – they see big advantages in automated electrical engineering.
Preliminary work pays off The diagram still requires individual adjustments, but it offers a good foundation and saves a lot of time. Thomas Besser explains, “You can generate 50 to 60 per cent of the project with the help of this automated design process. Engineers can now use the extra time to tackle creative tasks.”
A large planning board at the front of the hall displays the current cycles in which the individual products are structured and work stations are staffed. Automation is well advanced here, too: sheet metal processing is performed directly from the CAE system – Eplan Pro Panel – on a Perforex machining centre from Kiesling.
Components and structures must be defined in advance, but the effort pays off, which is why GreyLogix is gradually phasing in EEC One in all of its business units. Engineers have the freedom to use the system as they see fit. “You don’t have to handle everything in EEC One,” Besser says. “For instance, engineers can just as well set up all the device tags in Eplan Electric P8 – it’s their choice.”
Assembly design of control cabinets using Eplan Pro Panel is carried out by experts who are solely responsible for this task. “The three colleagues originally worked in production,” Besser says. “They know how assembly is done best. The engineers turn over the designs and are also responsible for initiating orders and printing out the wiring diagrams.”
The advantages GreyLogix sees in automated electrical engineering are so big that the company is currently considering introducing a similar concept for software programming: as Besser notes, “We would be able to shave off an additional 10 to 15 per cent of the hours necessary for this very time-consuming task.”
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For control cabinet manufacturing, GreyLogix does this without a warehouse. The available components are assembled according to the Kanban system. As the components run through the production process, each control cabinet panel is placed on a specially built assembly cart, which enhances flexibility.
Both the customers and the sales department appreciate the 3D layouts generated in Eplan Pro Panel. GreyLogix follows the wishes of its customers in selecting the engineering tool: “We use nine different ECAD programs. But when we decide for ourselves which program we use, we choose Eplan. Assembly design however is always done in Eplan.”
07 | Industry USA | September 2015
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