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INDUSTRY INDUSTRIAL MARKET MAGAZINE
USA
EWON AUTOMATION FAIR 2015 – CHICAGO
8 NEC CLASS 2 APPROVAL FOR MURRELEKTRONIK’S MICO
20 WIDIA CV-X200 : stabilité, ONE HIGH-PERFORMANCE TOOL précision et vitesse SERIES FOR MANY APPLICATIONS uniques
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ISO 9001 AND 14001 2015 REVISION: BUREAU VERITAS LAUNCHES INNOVATIVE OFFER TO HELP COMPANIES WORLDWIDE GAIN CERTIFICATION
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INDUSTRIAL MARKET MAGAZINE
RADIALL
KEYENCE
EWON
5
6
8
DELPHIN
EPLAN
SOURIAU
11
12
14
EMERSON INDUSTRIAL AUTOMATION
BALLUFF
15
KENNAMETAL
18
16 MURR ELEKTRONIK
PEPPERL +FUCHS
ICON POLYMER GROUP
20
21
22
WIDIA
BAUMER
24
26
BUREAU VERITAS
28
HMS
KEYENCE
HAIMER
30
32
34
ADVERTISERS: MEPAX 4 - BAUMER 10
www.magazine-industry-usa.com
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BONFIGLIOLI
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RADIALL AND FCI ANNOUNCE JOINT PARTNERSHIP FOR OCTIS™
Radiall and FCI announce their joint partnership to develop and promote the innovative OCTIS™ (Outdoor Connector Transceiver Inside System).
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pecifically designed to address the challenges associated with the deployment of 4G+, LTE+ and future 5G in the Telecom market, OCTIS™ provides a robust I/O interconnect solution that can operate in challenging outdoor and harsh environments. The Radiall and FCI partnership leverages the expertise of both companies. Radiall’s long term legacy of developing robust outdoor I/O interconnect solutions combined with FCI’s expertise in the design of High Speed signal and Power IO interconnect products provide customers a broad portfolio of outdoor performing IO solutions.
OCTIS™ is a trademark of Radiall. www.radiall.com www.fci.com MORE INFORMATION
“This synergistic partnership creates a significant opportunity for FCI to offer differentiating I/O solutions in a ruggedized package that reliably perform in diverse harsh environments” noted Danny Morlion, Chief Technology Officer at FCI.
Luc Kaës, VP of product management at Radiall further comments, “We are excited by this partnership between the two technology and customer support driven organizations. It is rare to see such a high level of collaboration between two teams to develop an innovative I/O system.” OCTIS™ can accommodate multi-standard and varying interconnect configurations such as SFP or SFP+ transceiver integration (with dual LC cabling), RJ45 (to transmit cat5e or cat6 Ethernet signal), high data rate signal, POE+, direct power supply (AC/DC) or a hybrid of power and signal.
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KEYENCE’S LUMITRAX MAKES EASY IMAGING OF CHALLENGING PART FEATURES
LumiTrax technology provides a clear advantage for this industrial inspection and assembly equipment manufacturer.
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ince 2003, Vantage Corporation in Livonia, Michigan has been a leading provider of automatic inspection and assembly systems. The company designs and builds a wide variety of specialty products, including connecting rod gaging equipment, sorting devices for springs and other components, fuel injector nozzle assembly stations, cylinder bore inspection machines that measure roundness and surface profile, and many more.
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Its proprietary RTGC32 gage and cell control software is used in conjunction with both vision and probe-based metrology systems for real-time monitoring and automation of various manufacturing processes, and is designed for easy integration to customer assembly and machining lines. This makes Vantage a one-stop shop for many of its customers, especially those where high throughput and repeatability are prerequisites for success.
One of these is a Tier-I automotive supplier with manufacturing plants in Ramos and Saltillo, Mexico. Among other products, the company produces cylinder heads, which are marked immediately after the casting process with a dot-peened 2D matrix-style barcode for traceability. Vantage was contracted in late 2014 to design and build a dimensional test station for placement at the end of the cylinder head machining line, one that would use a camera to read the barcode on the side of each casting, then collate the serial number found there together with the different part measurements for upload to a central database. There was only one problem: due to the casting’s rough surface, scanning the barcode was proving difficult. “It’s tough to read anything on a casting,” says Nathan Ritter, controls engineering manager for Vantage. “Laser marking, dot-peen, or mechanical stamp, it doesn’t really matter—the irregular surface tends to scatter light in all directions, so you can’t see much when you view it with a camera.” Ritter and the Vantage team knew from past experience that proper lighting is a necessary component of any vision system, and is key to consistent results. Until now, the best
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solution in these situations was to flood the area with spotlights, something that complicates the setup while driving up integration costs. The use of supplementary lighting can also compromise speed—in this case, the cycle time for the entire measuring process was less than 16 seconds, so Ritter needed a way to read the barcode quickly and without interruptions. Rather than accept the status quo, he turned to Keyence for a solution. As one of Keyence’s longtime customers, Ritter already had firsthand knowledge of the company’s extensive product line and robust measuring technology. “We’ve used their vision systems many times on our equipment, and have integrated their laser micrometers and three-dimensional profile cameras as well. We push the use of Keyence products with most of our systems, because we know there won’t be any phone calls later on from unhappy customers.”
Ritter worked with Keyence to implement the LumiTrax system on the cylinder head line. He says this was a straightforward task, as the CVX controller and interface used on the new system is identical to other Keyence products. Ritter wasn’t disappointed with the results. The LumiTrax made short work of the peened barcode, easily distinguishing the 2D matrix from the cast surface of the part, and doing so in perhaps one-tenth of a second. “The LumiTrax system cuts through all the surface noise to give you exactly what you’re looking for,” he says. “I’m confident in the readings, and there was no need for any trickery with the lighting. Going forward, we’re going to use it for all our casting applications, and on any other parts where 2D imaging is a problem. The LumiTrax makes it easy.” www.keyence.com/vantage MORE INFORMATION
At that time, Keyence had recently introduced its LumiTrax technology, which combines ultra high-speed CMOS sensors, partial illumination LED lighting, and advanced inspection algorithms to deliver an imaging solution that easily detects features, shapes, and text on even the most challenging of part surfaces. Unlike traditional imaging systems, which can be adversely affected by variations in ambient lighting and workpiece orientation, LumiTrax uses a high-intensity, multidirectional lighting source to capture up to 16 separate color or monochrome images, and then analyzes the relative brightness level at each pixel to separate
irregularities from background surface patterns. The result is a system that quickly and repeatedly “sees” objects that in most cases are otherwise impossible to detect.
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EWON AUTOMATION FAIR 2015 – CHICAGO
As a New Americas Rockwell Automation Encompass partner, eWON is attending for the first time the AUTOMATION FAIR® with the new generation Remote Access product Cosy131.
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his year at Automation Fair®, eWON will feature the latest generation of Remote Access product: COSY131. The eWON Cosy (COmmunication made eaSY) is an industrial VPN router designed to offer Quick and Secure remote access across the Internet to machines and installations on customer sites or in the field. Within minutes, OEMs and system integrators can troubleshoot machines remotely without going on-site significantly reducing support costs and resources. The New Generation Cosy131 is now available with 3 new models providing additional benefits:
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1) Greater Connectivity options (LAN, Wifi, Cellular) 2) New straight forward SD Card deployment 3) Connect to USB enabled devices 4) A price point to be involved on each panel.
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New COSY131 with multiple connectivity options for Remote Access success Dominique Blanc, eWON N.A. General Manager, “LAN connectivity over the factory network is working great for most installations and now customers can benefit from wireless flexibility to setup Quick and Secure Remote Access using Wifi or the integrated cellular GSM modem” Blanc, “Cosy131 includes free Talk2M service from eWON. The Talk2M VPN service enables Quick setup and the end user’s IT department doesn’t need to change its corporate network. With servers distributed all over the world, Talk2M offers a highly reliable, efficient and secure solution for connecting to machines remotely”. 2nd factor authentication to meet highest security standard The 2-factor authentication is a major enhancement from eWON to prevent hackers from using stolen passwords. The new version of eCatcher, the eWON VPN software, includes 2FA in order to protect the connection identity. It requires both “something you know” and “something you have”: the combination of login credentials and a security code texted to the user’s phone. Using eWON 2FA, customers benefit from this additional security layer to guaranty a secure and
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reliable access to remote PLCs and machines and broad IT acceptance.
For more information about eWON, please go to www.ewon.biz
Mobile access to your PanelView HMI from any smartphone or tablet M2Web is a new solution allowing customers to view the status of their machine or industrial equipment remotely via the web browser of their PC, Smartphone or tablet. Serge Bassem, CEO of eWON, “Mobility is essential nowadays for customers to reach more productivity and using M2Web, users can quickly view and monitor the status of machine parameters remotely from their smartphone.” No additional software or apps are required. With eWON’s M2Web, you can securely monitor and pilot your remote PanelView HMI and SCADA using a regular web browser on your computer, tablet or smartphone.
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eWON’s Gateway services and the New DataMailBox for your quick Industrial IoT project The new DataMailBox is providing a new open framework for data collection of your remote equipment over a secure VPN tunnel. Bassem says “With Datamailbox, eWON is providing their industrial software partners a solution to speed up their IoT projects by allowing eWON gateways 2005/4005CD and Flexy gateways to collect data from machine’s PLC and send it over a secure VPN connection to the application server of their choice.
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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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EXPERT VIBRO
A New Dimension in Vibration Measurement.
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xpert Vibro is a new measurement device, from Delphin Technology AG (based in Germany´s Bergisch Gladbach), for the acquisition of transient signals and vibrations. Vibration measurement is made easy with Expert Vibro. Intuitive configuration means fast implementation and short commissioning times. The compact Expert Vibro is equipped with 16 synchronous analog inputs with sampling rates of up to 50 kHz per channel. A 24-bit A/D converter delivers high-precision measurement. Users are able to switch the analog inputs between voltage, IEPE and shaft vibration measurement. Integrated comparators and digital inputs enable flexible triggering. Measurement data is monitored “on the fly” with the switching in milliseconds of up to 8 digital outputs.
Characteristic values can be determined from time signals and spectra. Spectra are computed online (FFT) and recorded along with time signals and characteristic values. Expert Vibro has a built-in data storage capability to enable independent operation. Versatile software channels enable Expert Vibro to be used for complex analysis and monitoring tasks. The Expert Vibro's touchdisplay shows important configuration or measurement data. www.delphin.com
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Expert Vibro can be connected to PCs via LAN or USB. Optional WLAN, UMTS or LTE modules are available for standalone operation. Antennae can be connected via SMA sockets. Two PROFIBUS interfaces are available as well as Modbus TCP for fieldbus connections. Multiple Expert Vibro devices can be synchronized to process vibration data from many channels. 08 | Industry USA | November 2015
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EPLAN DATA PORTAL: MORE THAN 100 MANUFACTURERS
Device data – like those of Janitza or Noark depicted here – can be inserted into the EPLAN project with ease.
A new parts data wizard has made the integration of product data into the EPLAN Data Portal much easier. This benefits both the manufacturer and the user. For the first time, more than 100 manufacturers will be represented on the portal when SPS IPC Drives show starts in November.
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ith comprehensive device data, the more than 90,000 portal users worldwide will be able to simplify and accelerate their engineering processes. The necessary macros, component data and 3D data for the construction of a virtual control cabinet can be easily and directly integrated into the CAE design.
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With the start of the SPS IPC Drives show, the EPLAN Data Portal will break a remarkable record. Over 100 manufacturers – many of them from the European, Asian and North American markets – will have integrated their manufacturer data into the portal. In mid October, there were already 99 manufacturers with over half a million qualified device and product data entries listed in the portal. At the end of the fair in November there will be approximately 110 manufacturers.
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The number of new members is also interesting: In 2015 alone, EPLAN was able to gain 30 new manufacturers. One factor contributing to this extraordinary success is the new parts data wizard for manufacturers, among other things. Based on Excel technology, manufacturer data can now be made available more easily on the portal and with the push of a button. Manufacturers don't need any special knowhow. The technology can also distinguish between the commercial and graphics data within the listed allocations and collate it all together intuitively. Over ten manufacturers of clamps, cables, connectors and sensors have already experienced the simplicity of this new integration. A Further 1.2m Device Data Entries per Configurator But it doesn't end with the more than half a million integrated manufacturer data files. Those who use measuring instruments benefit from additional 1.2M variations in device data which can be configured in any specification. In addition to this, the measuring instrument manufacturer Endress+Hauser has already integrated existing web configurators into the EPLAN Data Portal interface via web front-end. Based on the EPLAN Engineering Configuration (EEC), which is online in the background, and in combination
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1.2m device data entries can be configured with the Endress+Hauser configurator integrated into the Eplan Data Portal.
with the EPLAN Data Portal, a plethora of potential variations can be configured online.
HBM, Klemsan, Lumberg, Promet and Sensopart complete the portal with their data.
Global Expansion New manufacturers within the field of measurement technology include Janitza with its digital panel meters, Ziehl with its measurement and monitoring systems and Flowserve, a North American manufacturer of measuring instruments. Other new members from the USA are Mencom, Priority Wire & Cable and Comtran Cable – all successful cable manufacturers, Molex from the cable and connector field and Hubbell, also an American manufacturer of connectors. The EPLAN Data Portal is therefore becoming the international hub of product data.
Conclusion Users benefit from high-quality product and device data whose wide range offers international manufacturers an ideal, flexible platform for true “global engineering”. The data can be incorporated into the project 1:1 and guarantees users quick, efficient design while taking into account the current manufacturer data. The huge diversity of devices allows maximum freedom within engineering.
The most significant new member from China is Chint, one of Asia's largest manufacturers of automation technology. Noark, a subsidiary of Chint, has also made contactors and circuit breakers available in the portal. Liaoning Create Cable from China produces cables and Ningbo GOOSVN Electronic is a manufacturer of connectors and addresses the Asia-Pacific market. It goes without saying that European manufacturers have also joined. For example, ILME, an Italian manufacturer of electrical connectors, KEBA, an Austrian manufacturer of automation technology and Roxtec, a Swedish manufacturer of housing accessories and cable penetration. Kabelschlepp has employed energy chains and conveying systems, Hirschmann is involved with its ethernet switches and other manufacturers such as Citel,
www.eplanusa.com
SPS IPC Drives Halle 6, Stand 210
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ESTERLINE CONNECTION TECHNOLOGIES – SOURIAU RECEIVES LABINAL POWER SYSTEMS' AWARD FOR BEST OVERALL PERFORMANCE
Just months after winning Airbus' Top Supplier Award, Esterline Connection Technologies – Souriau was chosen by Labinal Power Systems from among 450 suppliers as the recipient of its 2014 Best Overall Performance Award.
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“This third major award in six months, of which we are particularly proud, honours the efforts made by all of Souriau's teams in France and around the world – the USA, Morocco, Mexico and India – in terms of overall quality, operational excellence, innovation and the technological support provided to Labinal Power Systems”, says Patrice Cavelier-Bros, President of Esterline Connection Technologies, the parent company of the Souriau and Sunbank brands.
Labinal Power Systems chooses the recipient of its award based on two criteria – the percentage of on-time deliveries and the level of quality over an entire year. In both cases, Esterline Connection Technologies – Souriau came out on top with an on-time delivery rate of more than 97 % and an exceptional level of quality with a score of less than 50 PPM (parts per million).
www.souriau.com
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sterline Connection Technologies – Souriau provides Labinal Power Systems with connectors that are installed on commercial aircraft made by the world's most prestigious names in civil aviation. Several million connectors of all types are supplied each year. From standard power distribution connections to power and broadband transmission solutions, Esterline Connection Technologies – Souriau equips all electrical functions of aircraft.
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TRANSDUCER BTL WITH REAL-TIME ETHERNET INTERFACES
The new transducers in rod and profile housings with an Ethernet interface from Balluff offer multiple advantages for machine manufacturers and operators with respect to startup and machine output.
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he standardized communication protocols and automatic address assignment simplify integration of the transducer into the controller and the plant network. Because of this, a complex programming process is no longer necessary. This leads to a shortened machine startup time, low implementation costs and reduces fault sources simultaneously.
Selectable real-time Ethernet interfaces include Profinet IRT, EtherCAT and Varan. The product portfolio includes a total of four designs: the classic rod housing for installation in the cylinder and three profile versions for flexible mounting on a machine. The profiles are divided into a square 36x36 mm design, an extremely flat profile with an overall height of 21 mm and a round profile 30 mm in diameter.
The 4 diagnostic LEDs on the sensor head can check both the sensor status and the status of the Ethernet connection. This supports easy maintenance and quick service.
The transducers with real-time Ethernet interfaces can be used in any setting in which high control dynamics and accuracy are required. This includes areas of material processing, the plastics industry, reshaping technology and the food industry. www.balluff.com MORE INFORMATION
The transducer is ideally suited for use in advanced applications (those involving controlled axes, for example) due to synchronous, extremely fast and secure real-time data transmission and the precise, highly dynamic position measurement with 1 Âľm resolution. This advantage contributes to a higher machine output and improved production quality. The transducers of the BTL7 series can detect and process up to 16 position encoders. Two values can be output for each position encoder: the position and the speed. Because of this, a single measurement can yield up to 32 measured values.
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NATIONAL LIBRARY OF FRANCE CHOOSES EMERSON TO OPTIMISE AIR CONDITIONING SYSTEM
France's biggest library – and one of the most important in the world – has chosen drive and motor solutions from Emerson to maximise the reliability of its air conditioning units.
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he National Library of France (BnF) looked to source the drive systems from a single supplier capable of offering expertise and value-added service. The BnF's collections are unique throughout the world, comprising fourteen million books and periodicals, but also manuscripts, prints, photographs, maps and charts, musical scores, coins, medals, sound archives, videos, multimedia, stage sets, costumes and much more. And they're growing constantly. The library is home to a vast documentary heritage encompassing all disciplines, whether intellectual, artistic or scientific. Its physical spaces are frequented each year by more than one million visitors, and its digital library, Gallica, provides free access to more than three million documents.
To protect these treasures and welcome its many visitors, the BnF was acutely aware of the need to maintain an extremely reliable air conditioning system. With this in mind, an initial project was defined: to replace an asynchronous variable speed drive assembly with a new drive system that would be used to power an air conditioning pump, itself responsible for half of the library's reading rooms. “The results of an energy optimisation study revealed in particular that the application’s operating efficiency fell to just 50 % in the winter. The ROI calculation showed that it would make far more sense to swap the asynchronous drive system for the Dyneo® high-performance synchronous technology from Leroy-Somer”, explains Jérôme Hardy from GED ADREM, a partner company of the Leroy-Somer service network.
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To handle the variable torque load (also referred to as the quadratic torque) of the pump and ventilation applications, Emerson implemented a solution comprising a Leroy-Somer Dyneo LSRPM 250 (85 kW) motor and a Control Techniques Unidrive M600 variable speed drive unit. The permanent magnet synchronous motor is perfectly suited to applications of this kind, offering enhanced 08 | Industry USA | November 2015
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efficiency of up to 96 % over the whole operating speed range. Another advantage, in terms of cost, comes from the sensorless control. This function, integrated into the Unidrive M drive unit, simulates an encoder input with a high degree of precision. “With this solution, not only do we eliminate the cost of the encoder, but we also reduce the number of components and thus the probability of a breakdown”, added Jérôme Hardy. The BnF gave top priority to the service life and availability of the equipment. It commissioned Leroy-Somer as the sole supplier on the strength of its ability to guarantee operational reliability, including a performance warranty and the full interoperational compatibility of the components. A global approach was adopted with the consistent aim of maximising reliability:
This makes it easier to detect drift, premature wear and overconsumption. The original motors, also from Leroy-Somer, were overhauled and kept as backup. The assembly is connected to the BMS (building management system), an automated, centralised supervision system that gives the speed setpoint. The next phase will involve conducting an energy efficiency study on the central air treatment systems and replacing the drive solution. Further system modernisation measures are also envisaged over the coming years. For more information, visit www.Emerson.com
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“We applied Leroy-Somer's premium service centre procedure. This extremely rigorous method uses multiple control points during installation and start-up. Operations such as alignment control, dielectric measurements and phase balancing offer real benefits in terms of both reliability and power consumption”, adds Jérôme Hardy. Since then, the equipment has been monitored, particularly by means of vibratory analysis, and the resulting data compared with the data collected during commissioning. 08 | Industry USA | November 2015
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One platform that does it all. Cut-off, grooving, deep grooving, face grooving, side turning, and profiling applications.
Game-changing design brings true ease of use, notably fewer components, and high performance in multiple applications.
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Easy to choose, easy to use became the foundation of Beyond Evolution’s development. The goal to offer a system that was less complicated to navigate and select, complimented by an equally simple approach to using it.
“What would it take to launch the world’s best grooving and cutoff system?” asks Kennametal senior product manager Mark Filosemi. “We began with the expected – longer tool life and higher cutting speed. But our customers added something different. They wanted simple. That was it. They wanted to stop leafing through hundreds of pages of catalogs and thousands of items because it was difficult, time-consuming, and expensive.”
“But we didn’t stop there,” Filosemi adds. “In developing Beyond Evolution, the team questioned every detail to enhance our customer’s experience. With deep design and innovative engineering experience, Kennametal pioneered the most versatile high-performance platform to enter the market.”
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n a manufacturing world of growing complexity, a straightforward solution that works excellently and saves money can be a breath of fresh air. In grooving and cutoff, Beyond Evolution™ from Kennametal is that solution.
Proprietary Triple V Beyond Evolution is a single-sided grooving and cutoff system for deeper grooving capability than double-ended systems. A proprietary “Triple V” design with top, bottom, and backside V-shaped seating in the holder pocket creates a pull-in effect for exceptionally high stability for deep grooving, face grooving, side turning, and profiling, among other applications. The results Beyond Evolution will groove deeper than doubleended systems, turn with 90 % of the stability and allow interchangeability regardless of geometry or application.
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The proprietary Triple V design provides high side load stability comparable to longer double ended inserts.
Coolant is directed precisely to the cutting edges underneath the chip, dissipating heat and extending tool life.
It offers tighter indexing tolerances, longer cutting depths, and new plunge and turn geometries The most visible result of Beyond Evolution’s “one system for all applications” design is the most requested – fewer items, up to 35 % compared to competitors. This makes Beyond Evolution easy to choose in addition to easy to use, reducing inventory and expenses. And where conventional product launches focus on a single line item, Beyond Evolution will be launched in multiple grades for dozens of applications – a full line offering that promises higher performance and reduced costs immediately.
For more information, visit www.kennametal.com
For downloading the digital version or requesting a print copy, visit www.kennametal.com
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Innovations 2016 and NOVO Whether you’re digitally native or prefer print, much more information, including grade descriptions, feed and speed recommendations, and full ordering information is available in the new Innovations 2016 catalog from Kennametal – an invaluable resource for the latest advances across the entire range of Kennametal applications. For downloading the digital version or requesting a print copy, visit www.kennametal.com.
Beyond Evolution that can do the job. This provides far more useful process knowledge than any online catalog alone, all obtained in a fraction of the time.
Moreover, Beyond Evolution is available through NOVO™, Kennametal’s digital process knowledge application. With powerful process knowledge available on iPad™ and other digital devices, NOVO helps users define machining features, such as profiling or grooving in specific work materials, and then immediately reduces the product set to those like 08 | Industry USA | November 2015
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NEC CLASS 2 APPROVAL FOR MURRELEKTRONIK’S MICO
Murrelektronik's MICO protective modules for UL508A control cabinets are a proven solution for intelligent power distribution and efficient branch circuit’s protection. 8 different MICO modules are now NEC Class 2 approved, so you can efficiently design your power distribution scheme.
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lass 2 Circuits are circuits with limited energy and a maximum power of 100 VA. According to the NEC & UL definition, class 2 circuits limit the risk of electrical fires and electric shocks due to their limited energy. Therefore, according to UL508A standard (for control cabinets), any component used and attached devices on the branch circuit in a Class 2 circuit don’t require investigation.
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So far, an individual NEC Class 2 approved power supply was used to create a class 2 circuit and it required a lot of space. This method wasn't cost effective and caused a lot of wiring and planning effort. With Murrelektronik's MICO NEC Class 2 approved module, it is now possible to design NEC Class 2 circuits even faster, in a more compact and cost effective way. All you need is a standard power supply unit (that doesn't necessarily has to be NEC Class 2 approved) combined with MICO to design two, four or eight separate load circuits with limited energy in a simple way.
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By connecting several MICO modules with the integrated bridging system, the number of channels can be increased up to a total current of 40 A. Components attached to the MICO’s marked NEC Class 2 outputs devices no longer need UL-approval. MICO's proven functions like channel-specific switch-off in case of overload, visual warning notice, storing errors and the cascading start of the current paths provide additional benefits and enable using a smaller power supply and limit the operators need to enter the control cabinet. www.murrinc.com
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PEPPERL+FUCHS ACQUIRES ONE OF THE WORLD’S LEADING PROVIDERS OF HART PROTOCOL DEVICES
Pepperl+Fuchs, a world leader in process automation and applications, has acquired MACTek Corporation, a leading provider of HART protocol devices. The move is part of Pepperl+Fuch’s strategy to further extend its integrated solutions offerings and strengthen its position in the WirelessHART market.
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We are pleased to add the MACTek WirelessHART product line to our existing portfolio,” said Jim Bolin, Pepperl+Fuchs’ executive vice president of the Americas. “This acquisition complements our current product lines well, and allows us to provide an even greater breadth of services to our customers.”
Founded in 1993, MACTek specializes in HART modems, including VIATOR HART Interface modems. One of the company’s most recent innovations, the BULLET WirelessHART adapter, can be mounted on any device rated for hazardous areas. The HART modem family includes wireless access to HART field devices designed for hazardous areas and Bluetooth-enabled technologies. www.pepperl-fuchs.us MORE INFORMATION 08 | Industry USA | November 2015
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ACCOLADE FROM LOCKHEED MARTIN CONFIRMS ICON’S QUALITY AND INTERNATIONAL SUPPLY CHAIN EXCELLENCE
Icon Polymer Group, a technology company in engineered polymer products, has received a major accolade from a leading global player in defence aircraft for the quality of its manufacturing and supply chain management.
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S-based Lockheed Martin Aeronautics has recognised Icon Polymer for its achievement of 100 per cent on-time delivery and zero quality defects over a full calendar year. This further confirms Icon Polymer’s status as a true global partner to the aerospace sector, able to deliver highspecification, high-performance products to challenging deadlines, wherever in the world they are needed.
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Qualified to supply to Lockheed Martin Aeronautics through its accreditation with BAe Systems, Icon Polymer has for the last three years been the premier supplier of lightweight silicone ducting used in the environmental cooling system on the Lockheed F-35 Lightning II, developed as a part of the international Joint Strike Fighter (JSF) programme.
The ducting is manufactured at Icon Polymer’s facility at Retford in the UK, with consignments shipped to Lockheed facility at Fort Worth, Texas, each year to meet exacting delivery deadlines. Icon Polymer also supplies a number of other customers that support this platform. The recognition is a further validation of Icon’s unique, agile Face2Face approach, based on gaining a thorough understanding of the customer and individual application needs, then designing and delivering products to meet those requirements. Icon Polymer is believed to be the only company from outside the US to have achieved the standard during this period. Tom Simmons, Vice-President – Supply Chain Management at Lockheed Martin Aeronautics at the time of recognition, explained: “Our customers’ expectation of zero defects demands laser focus from our suppliers to enable Lockheed Martin Aeronautics to be the world’s leading designer and manufacturer of high-performance combat, air mobility, and reconnaissance and surveillance aircraft. “We wish to thank Icon Polymer and its employees for showing excellent workmanship and superior standard of performance
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Photo: L – R Lloyd Cooper – Aerospace Production Leader Peter Baker – Aerospace Shift Leader Leon Hewitt – Aerospace Shift Leader Marie Hrnekova – Trimming & Finishing Operator Jordan Tissington – Press Operator Geoff Booth – Airframe Moulder Lee Everett – Airframe Moulder
to bring the best quality and value to our customer and Lockheed Martin Aeronautics.” Tom Ludwell, Head of Business Development at Icon Polymer, added: “This accolade is testament to Icon Polymer’s unique working ethos and global capabilities, as an approved supplier to all of the major manufacturers and Tier 1 suppliers. Many of Lockheed Martin’s suppliers are US-based but this shows that Icon Polymer can deliver to meet the needs of manufacturers and Tier 1 suppliers wherever in the world they are based, making us an effective partner for any project.” For further information, visit www.iconpolymer.com
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TOP CUT 4 INDEXABLE HOLEMAKING PLATFORM FROM WIDIA: ONE HIGH-PERFORMANCE TOOL SERIES FOR MANY APPLICATIONS
The new Top Cut 4 indexable drilling platform from WIDIA is targeted to end users that machine a broad assortment of products and need one drill for a variety of drilling applications and workpiece materials.
Affordable high-quality holemaking and improved tool life equate to big advantages for operators.
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xpanded capabilities and improved performance combine for outstanding results in the new Top Cut 4™ indexable holemaking platform from WIDIA™.
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A true multi-problem-solver in one platform, Top Cut 4 is targeted to end users that need one drill that can be applied in a variety of drilling applications and different workpiece materials. Top Cut 4’s breadth of application capabilities include through – and cross-holes, inclined entry and exit opportunity, 45º corner, half-cylindrical, concave, and chain drilling. And four true cutting edges combined with WIDIAgrade technology results in notably higher speeds and feeds, higher metal-removal rates, and extended tool life, all of which means lower cost per edge.
“Process stability is a significant challenge and the driver behind Top Cut 4 and its development,” says WIDIA Product Manager Vivian Pavlov. “What process stability simply means is the ability to quickly select and successfully apply a tool even in an unfamiliar or unstable condition. Users need one drill that can be applied in a variety of drilling operations and workpiece materials. Top Cut 4 addresses this challenge with cutting performance at higher speeds, which makes it the proven choice in lowest cost per edge.” Top Cut 4 periphery and center inserts each feature proprietary cutting profiles for excellent centering capability and workpiece penetration. The inner and outer (center and periphery) inserts are clearly differentiated for no mixups, and are available in grades for high-speed applications, high toughness demands, and high metal-removal rates in general. Specific geometries are available with such features as reinforced cutting edges and a steep chipbreaker for steel, cast iron, and short-chipping materials, or an optimized chip groove for stainless steel, long-chipping steels, and where low power consumption is required. In addition, Top Cut 4 is featuring high-stability shanks in lengths of 2XD, 3XD, 4XD, and 5XD, in both metric and inch
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NEWS Large coolant holes mean efficient coolant delivery and extended insert life.
Top Cut 4 users need only one drill platform for a wide range of jobs.
Robust cutter bodies are marked by deep helix angled flutes for efficient chip evacuation even at 5XD length.
configurations. Diameter ranges from 12 to 68 mm (0.473 to 2.5 inches). Eight insert sizes cover the complete diameter range. The cutting edge profile of the central and periphery inserts works together, leading to high stabilization of the drill, preventing tool drifting even on irregular surfaces. Robust cutter bodies are marked by deep helix angled flutes for efficient chip evacuation even at 5XD length. Large coolant holes mean efficient coolant delivery and extended insert life. Moreover, Top Cut 4 is available through NOVO™, WIDIA’s digital process knowledge application. With powerful process knowledge available on iPad™ and other digital devices, NOVO provides far more useful process knowledge than any online catalog alone, all obtained in a fraction of the time. For more information, visit www.widia.com MORE INFORMATION 08 | Industry USA | November 2015
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CLEVERLEVEL: RELIABLE LIMIT DETECTION FOR BULK GOODS
The different media characteristics of bulk goods frequently pose technical challenges for commonly-used sensor systems when measuring limits in storage silos and process tanks.
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nder physical influences such as temperature variations or changes in pressure, these sensors quickly reach the limits of their operating capabilities. Baumer's CleverLevel series, based on frequency sweep technology, provides a highly flexible and secure solution for performing measurement tasks in these types of application.
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In the food industry, bulk goods in the form of powdery flour, fibrous spices, fine sugar, coarse coffee and cocoa beans, or whole nuts, are stored temporarily in various large silos or processed in mixing tanks. To ensure that all production steps function smoothly and meet the industry's high quality standards, the solids must not be allowed to go above or below a specified filling level.
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In many applications it is impossible to gauge the level of the media in the tank from outside through a sight glass. When pressure and temperature rise, coffee, cocoa beans and other granular material emit oil and humidity. When they become damp, powdery solids form lumps. In situations like these, it's impossible to detect the level in the silo just by looking through a glass. Common types of electromechanical sensors, such as the rotating paddle or vibrator types, may give faulty indications, showing the level to be within the limit when it has already been crossed. This can result in unplanned machine stoppages and loss of production, leading to high costs for repair and cleaning. In contrast, CleverLevel, which is maintenance-free, optimises processes and reduces operating costs. CleverLevel limit switches are available in different versions to allow them to be used in almost any application and positioned where they can work best in the process. In the standard version, the tip of the sensor protrudes only 12 mm into the interior and this allows it to be optimally positioned even with tricky tank geometries or with built in mixers. The 100 mm or 250 mm long variant with a sliding connection can be positioned deeper in the tank. This prevents sticky
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A bright blue halo allows the limit signal to be easily seen, even from a long distance.
deposits forming on the tip of the sensor. If space is restricted, the suspended variant can be used and installed from above, through the top of the silo. This is can be used for example when hexagonal silos are grouped together on a small surface. In this configuration, installation of the limit sensors on the silo walls is only possible in some cases.
even when using explosive hygienic environments that occur in the food processing industry when handing powders and bulk goods that generate dust. For more information: www.baumer.com/cleverlevel
Innovative technology The CleverLevel series operates with frequency sweep technology. Its electrode emits a high-frequency signal from the tip of the sensor into the tank. The medium works like a virtual capacitor that creates a resonant circuit with a spool in the sensor head. The size of the capacitor depends on the dielectric constant (DK-value) of the medium which thus alters the resonance frequency. Between air and the medium there is a significant difference in the DK value. The frequency shift of the resonance circuit associated with this is processed by the integrated microcontroller with a high margin of safety.
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The CleverLevel can detect almost all media with a DK value greater than 1.5. It can not only accurately detect solids with different granularities but also viscous media and liquids. Using the size of the DK value, the limit switch can also detect separate media layers, for example oil on water. If needed, this capability can be used to accurately distinguish between foam and the liquid limit level. The CleverLevel is ATEX, EHEDG and 3-A certified. This ensures safe functioning 08 | Industry USA | November 2015
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ISO 9001 AND 14001 2015 REVISION: BUREAU VERITAS LAUNCHES INNOVATIVE OFFER TO HELP COMPANIES WORLDWIDE GAIN CERTIFICATION
The second half of 2015 sees revisions to ISO 9001 and ISO 14001, the globally recognized standards in quality and environmental management systems. Following the new revision, and with the deadline for transition set for 2018, Bureau Veritas is launching a suite of tools to help companies achieve the new standards and retain certification, or target certification for the first time.
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ureau Veritas has created LEAD: a unique offer and approach to support companies all over the world in the three-year transition process. LEAD was developed in collaboration with clients, following a worldwide survey to fully understand their needs. It includes an all-in-one service pack, a cost-effective way to help clients move through the process with confidence. New, innovative tools enable clients to train themselves and assess the gap between their current situation and the future standard they want to reach, via e-learning courses and an online gap analysis tool.
Companies can choose between different levels of support: the essentials pack helps them prepare the first steps of their transition, while the complete pack enables them to manage all their transition and certification needs with Bureau Veritas. Companies will gain support in analyzing their requirements worldwide, and have access to advice, training sessions and audits on a country-by-country basis, thanks to Bureau Veritas’ network of experts around the world.
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As part of the LEAD project, the Group has also created a dedicated website, www.revision2015.com, providing clear information on the new standards, and the steps that companies currently certified to ISO 9001 or ISO 14001 should take to retain certification. More than 80,000 Bureau Veritas clients have already visited the website, which will be continually updated with news and information on the revision.
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Bruno Ferreyra, Executive Vice President for Industry and Facilities at Bureau Veritas, said: “The new revision is the clear proof of the continuous improvement in the standards. With the LEAD offer, Bureau Veritas aims at helping clients to make the most of the changes and set the stage for a long-term growth” Commenting on the revision, Sébastien Fox, Head of Bureau Veritas Certification, said: “The 2015 revision offers some significant benefits, including the ability to integrate quality and environmental management systems, more flexibility in use of documentation, and less directive requirements. Its emphasis on risk-based thinking also helps identify opportunities and targets long-term customer satisfaction and improved environmental performance.
www.revision2015.com www.revision2015.com/wp-content/themes/bureau_ veritas_site_iso/pdf/LEAD_brochure_web.pdf www.revision2015.com/category/watch-our-videos-andread-the-interviews-with-our-certification-experts/
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As a trusted partner, Bureau Veritas is working alongside its clients to enable them to move through the transition process with confidence. Our LEAD offer, with its innovative set of solutions, enables companies to meet the demands of the revised ISO 9001:2015 and ISO 14001:2015 standards in the way that best suits their organization: via a turnkey solution, or customized support.” The service packs are already available. Services such as training, gap analyses and audits are also available separately.
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NEW WAYS TO INTERCONNECT THE PROFI-WORLD
Markus Bladh, Product Manager, Gateways.
Automation engineers frequently need to bridge the gap between different protocols and networks used in a plant, but they also need to enable communication between equipment within the same network family.
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or example, in the PROFINET and PROFIBUS-world, there are many devices and sub-systems that cannot necessarily communicate with each other. It may be necessary to connect different physical formats such as copper and fiber optics or couple/de-couple I/O data between two controlling networks. With their recently upgraded Anybus X-gateways, HMS Industrial Networks can offer ways to get heterogeneous PROFI-equipment connected.
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“According to our latest market research, PROFINET and PROFIBUS are two of the most dominant networks on the global market today,” says Markus Bladh, Product Manager for gateways at HMS Industrial Networks. “So naturally, we get a lot of requests for connectivity to the PROFI-world, but we also get requests for connectivity within these networks. Although our Anybus gateways are mostly known for interconnecting all types of networks, it is really interesting to see the attention Anybus X-gateways get as a cost-efficient way to connect different physical formats and standards within the PROFIworld. This enables system integrators and factory owners to connect otherwise incompatible devices and systems.”
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Here are a few examples of how Anybus gateways can solve connectivity issues within PROFINET and PROFIBUS. 1. Coupling a PROFINET IRT machine with a controlling PLC Many factories need to couple or de-couple I/O data between two controlling PROFINET IRT networks – for example between two segments in a factory. The Anybus X-gateway can act as a PROFINET/PROFINET coupler enabling fast transfer of I/O data. The PROFINET interface works as an I/O-Device on the PROFINET I/O or IRT network. 2. Coupling PROFIBUS networks Coupling or de-coupling of I/O data between two controlling PROFIBUS networks are other common tasks for the Anybus X-gateway. This functionality is often called DP/DP coupling. The two PROFIBUS networks become galvanically and logically isolated from each other. 3. Coupling PROFINET I/O networks It is also possible to couple or de-couple I/O data between two controlling PROFINET I/O networks. A well-known name for this functionality is PN/PN coupling.
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Anybus X-gateway.
4. Connecting a fiber optic network to a copper network PROFINET FO is especially popular in the German automotive industry. However, many machines and systems do not come with fiber optic connectivity. Anybus X-gateway can act as a coupler between the two network versions, enabling them to communicate. 5. Migration from PROFIBUS to PROFINET Many factories have well-functioning PROFIBUS networks, either as their main factory network or as subsystems within the factory. However, there is often a need to install devices or systems which run PROFINET. With an Anybus X-gateway, this switch is easily done. The X-gateway acts as translator between the two networks and can be installed within minutes – a very fast way to migrate from fieldbus to industrial Ethernet. End users will be able to reuse and connect well-working existing equipment to new highperforming automation systems.
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“We see both fieldbuses and industrial Ethernet networks increasing at the moment,” says Markus Bladh. “Trends such as the Industrial Internet of Things and Industry 4.0 require more and more industrial machines to become networked and this also requires more connectivity within the different network worlds. With the Anybus X-gateway product range, HMS offers an easy and cost-effective way to get connectivity between different devices and networks within the PROFI-world.” www.hms-networks.com 08 | Industry USA | November 2015
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TATA STEEL USES KEYENCE SENSORS FOR HIGH-ACCURACY DIMENSIONAL INSPECTIONS OF ITS RAILS
Tata Steel Europe (whose former name was Corus) is the second largest steel producer in Europe. The parent company, Tata Steel is one of the top ten steel producers in the world. The total capacity of crude steel Group, which employs about 80,000 people on four continents, is over 28 million tons.
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ata Steel Rail Division France has 508 people for a production of 456,000 tons of rails and sleepers in 2009. This division has over 150 years of experience in the rail. The products are designed for high-speed lines, conventional networks, heavily loaded routes, metro and urban tramways.
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Tata Steel Rail France takes great care in inspecting the straightness of the ends of its rails so that its customers receive the straightest possible rails. As a result, it has recently retrofitted its end straightness inspection systems with Keyence's latest generation of CCD laser displacement sensors, the LK-G3000. During rail inspection, a carriage moves along the end of a rail at a rate of 3 meters per second and over a distance of 3.2 m. The carriage is equipped with two LK-G displacement sensors that profiles the rails surface at a rate of 10,000 samples per second. If the rail is not straight, it is transferred to a press to be straightened to the desired tolerance. Measurements are extremely fast and the accuracy achieved is in the order of a few hundredths of a millimeter.
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"We've been working with Keyence for many years. We looked around for an alternative supplier, but none of the systems we saw suited us," says Michel AndrĂŠ, automated systems manager at Tata Steel Rail France in Hayange, France. "Rail surfaces are amongst the most complex to measure and are known to interfere with measurements," says IT Officer Eric Perruzza. "They are shiny and can be mottled with rust, which is dull. As a result, a sensor will tend to feed back too many incorrect measurements, making it impossible to inspect straightness." "We have designed a computerized measurement archival and reprocessing system that allows us to accurately estimate repeatability. With Keyence, we achieve a satisfactory rate of correct measurements that is well over what the competition offers." Keyence's integration support was also a deciding factor: "This type of system is always hard to implement in conditions such as ours. Keyence was the only company
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able to quickly provide us with technical solutions to our problems." Indeed, Tata Steel needed a laser sensor that could meet a number of high requirements: be able to adjust itself to shiny and dull rail surfaces, take measurements very quickly to keep up with fast production rates and withstand harsh operating conditions. To ensure repeatability of the measurements, Keyence developed a number of algorithms to guarantee measurement stability. The ABLE function detects the condition of the surface being scanned and by intelligently controlling laser emission time, laser power and gain, accurately measures even with highly varied surface conditions, such as steel. In addition, the MRC algorithm eliminates multiple reflections from metal surfaces. When two or more peaks are generated by multiple reflections, the algorithm compares the waveforms to the most recentreceived light waveform and determines the one that most closely resembles the "correct waveform".
accuracy measurements very quickly. The Li-CCD outputs the light reflected by each pixel, enabling higher accuracy and reducing errors in pixel edges. The processor, which is integrated in the sensor head, digitizes all signals sent to the controller, dramatically reducing disturbance noise. A highly rigid die-cast body is used to reduce deviations caused by temperature changes while the Li-CCD, with 10 times better sensitivity than conventional models, is used to reduce signal noise. The sensor's novel design has allowed it to achieve an accuracy that is 20 times better than conventional models. Lastly, the LK sensor is protected inside an IP67 rated enclosure that withstands impacts and high temperatures that are common in steel mills. www.keyence.com/tata
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This sensor series offers the best in non-contact laser measurements: sampling speeds of up to 50 kHz, Âą 0.02% accuracy and 0.01 Âľm resolution. The Li-CCD (Linearized CCD developed by Keyence) features high-speed sampling that is 25 times faster than conventional models. A special waveform processor (digital signal processor) digitally processes the CCD signal at high speed and delivers high08 | Industry USA | November 2015
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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
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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. Pictures: Starrag
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. Picture: Haimer.
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. 08 | Industry USA | November 2015
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NEWS 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.
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.
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“. 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 08 | Industry USA | November 2015
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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 onepiece 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
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.
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.
Patrik Rutishauser, Head of Application Engineering, is convinced of the Haimer shrink fit chucks and machines: “Haimer professionalized the shrinking process.”
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.”
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. 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. 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.
“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.”
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BONFIGLIOLI PARTICIPATES IN THE IMPLEMENTATION OF AN INNOVATIVE POWERTRAIN FOR HYBRID FIAT DUCATO
Bonfiglioli Riduttori, represented by Massimo Palomba, Product Manager for Mobile Solutions – Electromobility sector, submitted its own electric powertrain implemented for Fiat Ducato within an event organised by the Automotive Innovation Pole in Milan on 16th July 2015.
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he conference, entitled “Vehicles for Smart, Green and Integrated Transport: efficiency and eco-sustainability path for the food industry and other sectors”, was organised by the Automotive Innovation Pole (www. poloautomotive.eu), a consortium that includes about 70 companies working in the automotive field including, besides Bonfiglioli Riduttori, Fiat Chrysler Automobiles, Centro Ricerche Fiat, Honda, Tecnomatic and Denso. The aim of the event was to present the innovative solutions identified in the “eco-smart vehicles” sector that enable drastic reduction of CO2 emissions in urban centres, these solutions were then implemented thanks to the collaboration established between different companies of the Pole. MORE INFORMATION
Massimo Palomba presented a powertrain for LCV (light commercial vehicle), applied for this project on the New Ducato, and developed thanks to the synergy between Bonfiglioli Riduttori, Tecnomatic and the other partners of the Automotive Innovation Pole. In particular, an advanced powertrain system has been developed which will permit a “bimodal” hybrid use of the vehicle thanks to an architecture 08 | Industry USA | November 2015
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integrating the normal endothermic propulsion with an electromechanical one. When the vehicle is located in urban centres, you can switch off the combustion engine and activate the limiter with the permanent magnet brushless electric motor. The system is engineered to enable the vehicle to reach 70 km/h in pure electric and provides a battery-pack that guarantees from 40 to 120 km in ECE101R cycle. The geared motor, for the same power delivered compared to those on the market, is made such as to have reduced dimensions and weights (additional weight including batteries less than 200 kg for the base configuration) so as to be easily applied in the standard vehicle. According to the analysis, by using this bimodal hybrid mode it is possible to reduce the emissions by up to 40 %. www.bonfiglioliusa.com
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INDUSTRY INDUSTRIAL MARKET MAGAZINE
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0 9 i s s u e w il l be pu b l ished J A N UA R Y 2016... MORE INFORMATION 08 | Industry USA | November 2015
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