Industry USA 11

11 | S E P T E M B E R 20 1 6

INDUSTRY INDUSTRIAL MARKET MAGAZINE

USA

SOURIAU USA'S MIL-DTL-38999 CONNECTORS HAVE BEEN QPL CERTIFIED FOR MORE THAN 30 YEARS

18 BAUMER THE NEW BENCHMARK IN ABSOLUTE HEAVYDUTY ENCODERS

25 CV-X200 : stabilité, KEYENCE précision et vitesse ORCHID ORTHOPEDIC SOLUTIONS uniques

38 50

SMALL, SMALLER, SMALLEST: NEW ULTRA-MINIATURE CONNECTOR IN FISCHER MINIMAXTM SERIES

34

11 | Industry USA | September 2016

INDUSTRIAL MARKET MAGAZINE

SCOTT SAFETY TYCO

BAUMER

5

LEROY-SOMER

8

6 FISCHER CONNECTORS

MEPAX

11

EPLAN

14

12

HAIMER

SOURIAU

16

18

SOFTING AUTOMOTIVE ELECTRONICS GMBH

20

DDPS

HMS

BALLUFF

22

23

24

FISCHER CONNECTORS

BAUMER

25

SIC MARKING

28

26 KENNAMETAL

KEYENCE

30

33 ADVERTISERS: MEPAX 4

www.magazine-industry-usa.com

FISCHER CONNECTORS

34

ARC INFORMATIQUE

36

KEYENCE

38

11 | Industry USA | September 2016

3

OPTIMIZE YOUR INTERNATIONAL PR AND ADVERTISING FOR THE INDUSTRIAL MARKETÂ !

International capability

Outstanding results

Optimized process

80 employees in 35 different countries, ensuring a strong relationship with main local media. Mepax distinguishes itself through its extensive media knowledge and ability to select the best international online/print advertising options. PR can be translated into 35 languages.

25,000 published articles in 2014: EMEA: 45% - Asia: 35% - Americas: 20%. Most of the articles are published in the top 1000 media worldwide.

With a proven process set for more than 70 active customers, we can adapt to all specific client needs with the highest reliability.

We have developed in house the most advanced PR dedicated ERP, enabling transparency and real-time full online reporting. International media management is then made easy, fast, and efficient for optimal results.

www.mepax.com info@mepax.com

THE MOST INNOVATIVE PR AGENCY

@mepaxIntPR

NEWS

AWARD-WINNING VISUALAPPLETS INDUSTRIAL CAMERAS STREAMLINE QUALITY INSPECTIONS IN PHARMACEUTICAL AND ASSEMBLY PROCESSES LX series VisualApplets cameras with integrated image preprocessing are a self-contained camera, lighting, and processing system ideal for quality inspections and error-proofing in pharmaceutical and assembly applications.

B

aumer is pleased to announce that these cameras were honored with the 2016 “Vision Systems Design Innovators Awards Program” Platinum-level award.

The esteemed expert jury of system integrators and endusers considered the cameras as one of the top innovations 2016 in the image processing industry.

These cameras allow even non-expert users without profound FPGA knowledge to implement unique image processing solutions quickly and flexibly directly in the camera’s FPGA using the graphical programming environment VisualApplets by Silicon Software with no need for expensive and complex VHDL programming. At the same time the volume of transmission data is reduced so the PCbased image processing system is not required to perform complex algorithms requiring considerable processor power. This will increase throughput, simplify system design and reduce overall system cost.

About The Vision Systems Design 2016 Innovators Awards Program The Vision Systems Design 2016 Innovators Awards program reviews and recognized the most innovative products and services in the vision and image processing industry.

Honorees were announced at The Vision Show 2016 held in Boston, Massachusetts. Criteria used in the Innovators Awards ranking included: originality; innovation; impact on designers, systems integrators and end-users; fulfilling a need in the market that hasn’t been addressed; leveraging a novel technology; and increasing productivity.

MORE INFORMATION

The new LX VisualApplets cameras integrate global shutter CMOS sensors by CMOSIS and a GigE Vision compliant interface, are available with 4, 12 and 20 megapixel resolutions and allow image acquisition and processing with VisualApplets with up to 74 fps.

More information on LX VisualApplets industrial cameras: www.baumer.com/VisualApplets-Cameras.

About Vision Systems Design Published since 1996, Vision Systems Design is a global resource for engineers, engineering managers and systems integrators that provides comprehensive global coverage of vision systems technologies, applications, and markets.

Vision Systems Design's magazine, website (www.visionsystems.com), email newsletters and webcasts report on and analyze the latest technology and business developments and trends in the worldwide machine vision and image processing industry.

Our product tutorial for LX VisualApplets industrial cameras: Simple Show on YouTube.

11 | Industry USA | September 2016

5

NEWS

SCOTT SAFETY TO DEBUT UK’S FIRST EVER IN-MASK THERMAL IMAGING INTELLIGENCE SYSTEM AT EMERGENCY SERVICES SHOW 2016

Scott Sight, the UK firefighting industry’s first ever in-mask thermal imaging intelligence system from Scott Safety will debut at the Emergency Services Show 2016 on stand B69, 21-22nd September in Birmingham. This ground-breaking system brings the future of firefighting into clear view for those on the front line and is set to revolutionise the industry.

W

ith slogans such as “Choice of the Brave” and “Innovation at First Sight”, the global leader in design, manufacture and supply of respiratory protective equipment, and thermal imaging technology has injected significant investment into the development of the global firefighting industry this year.

MORE INFORMATION

Scott Sight utilises hands-free thermal imaging technology to provide firefighters with a clear, unobstructed view of their surroundings thus improving their situational intelligence and eradicating the need to stop searching or put the hose down to deploy a hand-held camera. In spite of being exceptionally lightweight at 8 ½ ounces, Scott Sight is very powerful producing a 160x120 resolution at 9 frames per second through an infinity lens which ensures a clear picture with no eyestrain.

Longin Kloc, Global Product Manager, Growth Initiatives from Scott Safety, said: “We are extremely proud to launch such an innovative product for the firefighting industry. Scott Sight really is a sophisticated imaging tool - it supplements existing hand-held technology by offering configurable hands-free visibility to the wearer in often inhospitable situations.”

“To create Scott Sight, we worked very closely with firefighters to develop a thermal imaging solution that is more accessible and easier to use. This means that the wearer’s attention can stay focused on the fire, enhancing the ability to spot hazards and locate casualties, while also providing the means to identify a secondary egress in the event of a sudden change in circumstances.”

A further innovation debuting at the show is the Light Decontamination System, a portable airborne and surface decontamination solution with the ability to decontaminate chemical, biological and radiological vapours, liquids and particles simultaneously in as little as five minutes.

11 | Industry USA | September 2016

6

NEWS

Utilising atomisation technology the Light Decontamination System creates a fine mist ensuring an even and consistent coverage, and haptic dry surfaces. Rapidly projecting these droplets in the form of a dense and turbulent mist, the system is capable of delivering CBRN decontaminants to all non-line of sight surfaces. This process drastically reduces both the chemical footprint and time required for effective decontamination. Unlike many traditional decontamination systems which utilise liquids, this new process forces powders to behave like a gas, ensuring that sensitive and electronic equipment is not damaged.

Innovative, industry-first technology from Scott Safety reaffirms its stature as a global leader at the forefront of innovative design, manufacture and supply of respiratory protective equipment and thermal imaging technology.

To find out more about the latest products from Scott Safety, visit stand B69 at the Emergency Services Show 2016.

For further information about Scott Safety, visit www.scottsafety.com/emea

Environmentally friendly and cost-efficient, the Light Decontamination System typically requires only five percent of decontaminant compared to traditional systems due to the gas-like behaviour of the small droplet mist. Easily directed and controlled with a lance hose, the system achieves a projection distance of up to 30 meters and is compatible with a range of chemistries.

MORE INFORMATION

Global Product Manager for Military & Civil Defence at Scott Safety, Dr David Crouch said: “The Light Decontamination System will revolutionise the fire market; it is lightweight, portable and extremely powerful. In validation trials, the system decontaminated anthrax by 99.9999999 percent from a 100mÂł space, in less than five minutes.â€?

11 | Industry USA | September 2016

7

NEWS

ENVIRONMENTALLY-FRIENDLY, ECONOMICAL, RELIABLE AND SIMPLE: PARALLEL HYBRID PROPULSION OFFERS NOTHING BUT ADVANTAGES

Since 1968 NAVE VA have specialised in maritime excursions into the heart of the most beautiful areas of western and southern Corsica, and they want to run their business in an ethical and sustainable way.

Electric propulsion generates no emissions and is extremely user-friendly: the vessels that use it are silent, experience much lower levels of vibration and are easier to handle. Last but not least in terms of its advantages: parallel hybrid represents an attractive economic proposition.

L

eroy-Somer and Control Techniques have been suppliers of marine applications for many years. In association with Mayday Electronics they have now produced a high-performance propulsion system which is at the leading edge of hybrid technology. The system was developed for CNB PRO, a trademark of Construction Naval Bordeaux (Bénéteau Group), and its client, NAVE VA.

MORE INFORMATION

Trusting in CNB PRO’s know-how in the field of passenger transport vessels and the expertise of the naval architects, Bureau Mauric, the Corsican boat excursion company, NAVE VA, recently acquired a new model CNB PRO 20 Hybrid. As specialists in organising visits to protected sites, NAVE VA do not consider this solution to be an option, but rather an environmental duty.

11 | Industry USA | September 2016

8

In low speed mode, for manoeuvring in port or in protected areas, the vessel switches to electric power. “The silence is incredible,” explains Eric Brun of the Mayday company, which designs and supplies the propulsion system for these hybrid vessels. It has a speed of 6 to 8 knots, which is quite sufficient.

A rapid return on investment Parallel hybrid differs from serial hybrid in that the size of the electric motor can be designed to match the desired application, which in the case of NAVE VA is for a 6 to 8-knot low-speed mode. Optimum efficiency is therefore achieved: at low speed, the electric motor is used in its optimum operational range. In addition, the weight of the installation is much less for equivalent endurance. Another advantage is that the internal combustion engines can be stopped when the electric mode is activated. The CNB PRO shipyard, situated in Bordeaux (western France) and part of the Bénéteau Group, has identified a decisive advantage of hybrid propulsion systems: “Diesel engines do not run at optimum efficiency at low speeds. They exhibit low levels of efficiency and are prone to fouling. The fact that the diesel engine can be shut down in order to use the electric

NEWS The LSRPM series from Leroy Somer’s Dyneo® motor range offers high levels of efficiency and an exceptionally compact design.

A technology which is expected to develop “Legislation is changing. Electric power is becoming mandatory for an increasing number of applications, and not just in protected nature reserves. We are developing the hybrid system, in particular the parallel hybrid system, which is ideally suited to ships of less than 30 metres. Its use could be extended to regular ferry services, links between two ports, and river or pleasure navigation,” Pierre Lompech concludes.

The passenger vessel supplied to NAVE VA is equipped with two 800 hp motors, allowing it to achieve a speed of 20 knots in diesel mode. In electric mode it has a maximum speed of 8 knots and an endurance of 6 - 8 hours at a speed of 6 knots.

Recharging takes a maximum of 6 hours, and uses a harbour three-phase supply or the on-board electrical generator.

Hybrid propulsion allows 135 passengers to be ferried on visits to the Scandola nature reserve in Corsica, with no CO2 emissions and the use of batteries eliminating the noise pollution generated by internal combustion engines.

propulsion system helps to preserve it. Its service life can therefore be doubled, depending on the applications,” explains Pierre Lompech of CNB PRO. For the NAVE VA vessel, this would mean changing the engine after 16 years, instead of just 8. In real terms, the replacement of the two diesel engines represents a budget equivalent to the price of the electric propulsion system.

“Despite the system’s advantages there are still very few parallel hybrid systems in use, especially in France. Apart from passenger ferry, we have projects in the field of pleasure boats for ‘super yachts’ and in military applications,” says Eric Brun.

Leroy-Somer and Control Techniques are global specialists in drive solutions, and offer a range of products specifically designed for the maritime world “We chose the Dyneo® range LSRPM series permanent magnet 750 - 3000 rpm synchronous motor because of its high output and exceptionally compact design. We did find more compact motors, but these used separate cooling systems, which complicates installation in the limited space available in the engine room. Furthermore, LeroySomer offered to make the motor suitable for use at sea, in particular by supplying an aluminium housing appropriate to the environmental constraints”, adds Eric Brun.

“The reliability of Leroy-Somer and Control Techniques products is also an advantage. The first vessel equipped with Leroy-Somer motors on a Mayday propulsion system has been in continuous operation since April 2012. This is the Hélios ferry at Marseilles (southern France), designed with the operator, ICARD Maritime, who have made over 2000 sea voyages without any problems. In fact, we chose industrial motors which are tried and tested in manufacturing industry rather than in maritime applications. The motors are only used for a few hours per day, whereas they’re in operation 24-hours a day in some factories,” concludes Eric Brun.

MORE INFORMATION

“The use of an electric propulsion system instead of internal combustion for manoeuvring in port, for berthing and for low-speed travel reduces the length of time that the internal combustion engines are in use during the phases when they are least efficient. In these operating situations, significant reductions in fuel and maintenance costs are achieved. 70 litres of fuel per hour can be saved for each diesel engine, therefore totalling 140 litres per hour. Taking account of the overall added costs of the electrical propulsion installation (about €350k to €400k depending on the capacity of the battery set) and the seasonal use specific to our client, the latter expects to be able to write off this extra cost in less than four seasons, and at the same time increase the service life of the diesel engines while extending their maintenance intervals,” says Pierre Lompech.

The electric propulsion system also provides redundancy, which is essential for passenger vessels.

“The price of electric propulsion could come down even more in the future. The batteries take up a lot of space and are still quite expensive, at about 1 euro per Watthour. Since the installed electrical capacity is 125 kWh, the batteries represent about half the cost of the propulsion system. The remainder is made up of the mechanical drive system, the two electric motors and the variable speed drive units. Ensuring compliance with marine conditions is straightforward. The motors and variable speed drives are installed in dry dock, the fastenings are made of stainless steel and often only minimal environmental adaptations are required, such as adding coats of paint”, explains Eric Brun.

11 | Industry USA | September 2016

9

NEWS

Motor control unit, equipped with Control Techniques Unidrive M.

“The marine market has become a priority for us,” explains Mathieu Hérieau, Marine Business Development Manager for Leroy-Somer: “The maximum amount of power needs to be concentrated in a very restricted space, and our products achieve this through their high levels of efficiency and compact design.” The permanent magnet synchronous variable speed solutions supplied are part of the Dyneo® range. These comprise Leroy-Somer LSRPM motors and the latest-generation of Unidrive M variable speed drives from Control Techniques. The LSRPM motors use patented LeroySomer technology, with a magnet rotor whose innovative design provides significantly increased efficiency, much greater than that required in industry, over the entire speed range of the motor.

MORE INFORMATION

This technology also significantly reduces the size and weight of the motor in comparison with asynchronous technology. The Control Techniques Unidrive M range of universal variable speed drives offer optimised levels of power consumption, reliability and flexibility. In this way, the overall cost of installation and operation can be significantly reduced.

11 | Industry USA | September 2016

10

The strengths of the Leroy-Somer & Control Techniques / Mayday Electronics propulsion solution: - Increased comfort: silence, no fuel odour or CO2 emissions - Operational benefits: reduced fuel consumption, less maintenance, rapid ROI, extension of the propulsion system service life.

- Technology created using drive systems with optimised size, weight and fuel consumption www.leroy-somer.com

NEWS

MEPAX IS ACQUIRING OLIVIER ARNAUD CONSEIL (OAC)

Mepax, the world’s leading international PR and advertising agency for the industrial market, joined forces with OAC, the leading communications agency in France in the same area. OAC manages 2 million euros in advertising budgets in France.

T

he combined organization manages an extensive portfolio of over one hundred clients with an annual turnover of over 5 million euros, half of which comes from France.

Mepax, the world’s leading international PR and advertising agency for the industrial market, joined forces with OAC, the leading communications agency in France in the same area. OAC manages 2 million euros in advertising budgets in France. The combined organization manages an extensive portfolio of over one hundred clients with an annual turnover of over 5 million euros, half of which comes from France.

Customers are managed in more than 60 countries in 35 languages, and Mepax has a network of 80 employees worldwide.

This is a very powerful merger as the cutting-edge solutions of both companies are innovative and complimentary and will drive positive business outcomes for clients who seek to promote their brands globally and maintain a competitive edge. www.mepax.com

MORE INFORMATION

The principal business sectors of Mepax are the manufacturing and processing industries, electronics, IT, transportation and military.

11 | Industry USA | September 2016

11

NEWS

IMFINITY® LIQUID COOLED MOTORS: LC RANGE

The IMfinity® induction motor range developed by Leroy-Somer has now expanded with the Liquid Cooled (LC) series. Designed to withstand harsh environments and meet specific requirements, the LC motor range is a step forward to satisfy the most demanding customer expectations in terms of high reliability, energy savings and ease of integration into their facilities.

A design that enhances performance Based on the success and reliability of the IMfinity platform, the LC motors achieve the highest electrical and mechanical performance, including some innovative characteristics: • The latest generation frame housing, with cast iron or steel flanges for DE and NDE bearings, allowing excellent heat dissipation.

MORE INFORMATION

• A sophisticated cooling system which maintains the thermal efficiency, enabling the motor to be used together with a variable speed drive, for heavy duty applications that require constant torque.

• Reduced noise level, decreased in average by -10 to -20 dB (A) compared to air-cooled motors due to the lack of fan, offering ultimate comfort.

• Improved modularity thanks to its fabricated steel design, providing higher flexibility for retrofit installation.

11 | Industry USA | September 2016

12

The liquid cooling system of LC motors, provided by water circulation over the frame housing, offers additional significant advantages, such as the power-weight ratio (increased power in the same motor frame size) and compactness (saving up to 25% of volume compared to an air-cooled motor for easier and less costly integration within a machine or a system. Moreover, LC technology makes it possible to eliminate external components, such as ventilation equipment.

A design that optimizes energy efficiency Based on the new IMfinity® induction motor range, the LC series has been designed to achieve the efficiency levels defined in IEC 60034-30-1. As standard, LC motors are IE3 Premium from 150 to 1500 kW. Perfectly suited for use in variable speed, the LC motor has been designed to integrate specific features as standard, such as a thermal reserve for maintaining the rated torque over an extended speed range. In order to meet particular requirements, options can be provided upon request,

NEWS

The Liquid-Cooled technology ensures a clean surrounding environment, as there is no pollution associated with airflow.

Moreover, there is no impact on ambient temperature, as the waste heat from the motor is carried away by the cooling circulation. For these reasons, the risk of installation ageing and malfunctioning due to air pollution and high temperatures is considerably lowered.

This reliability ensures easy maintenance of the motor within customer systems.

An easy-to-select and easy-to-install solution, the new LC motors are particularly recommended for plastics & rubber, test stands, industrial refrigeration, marine and nuclear applications, and crushers for the food and animal feed industry. including reinforced winding insulation and insulated bearings. The motor can also be equipped with an encoder for applications that require precise positioning.

Key features:

Variable speed can generate immediate operating profits, such as up to 50% energy savings (depending on the application and operating conditions) or increased productivity as a result of improving the process and reducing machine downtime. The return on investment is consequently extremely quick.

- Frame sizes: 315 to 500 (< 315 and > 500 on request) - Voltage: 400 V for 315 to 450 mm / 690V for 500 mm - Number of poles: 2, 4 & 6 - Power: 150 to 1,500 kW - Frequency: 50 or 60 Hz - Insulation class: F or H - Mounting: B3, B35 and V1 (other position on request) - Double nameplate: DOL + variable speed characteristics

A design giving priority to safety and reliability Benefitting from optional IP56 or IP65 protection to safeguard against external hazards, the LC range is fitted with a water leakage detector to control the water circuit reliability.

www.emersonindustrial.com

Another option, space heaters, ensure safety during motor start-up, while winding and endshield thermal protection control and monitor the motor temperature.

MORE INFORMATION

A design facilitating maintenance Developed to reduce operating costs without compromising industry needs, LC motors are equipped with a patented breathable membrane. This completely waterproof (IP 66 minimum) feature considerably reduces condensates, whose evacuation is achieved by drain plugs.

11 | Industry USA | September 2016

13

NEWS

EPLAN PLATFORM 2.6 NOW AVAILABLE

Current terminal status can be shown with the expanded terminal editor. Manually or automatically defined jumpers can also be easily identified. Accessories can be graphical-ly visualised.

It’s quite the example of an “out of the box” culture of innovation. With the new Eplan Platform version 2.6, users benefit from substantial engineering features that can easily be integrated into everyday work processes, including new functions for terminal design and project data management, the representa-tion of piping in fluid power engineering, and optimised IT integration. Another highlight: Eplan Platform is now also available in Turkish and thus offered in a total of eighteen languages.

E MORE INFORMATION

nglish, German, Japanese and Chinese: Eplan software previously “spoke” just seventeen languages. With the new version 2.6, Turkish has been added to the software languages–after all, Eplan has been running its own affiliate company in Istanbul since 2014. There are also numerous technical upgrades in the newest version. Used accessories can now easily be depicted when processing and managing terminal strips. Furthermore, automatically or manually defined jumpers can also be easily identified.

Users also have the possibility to display the current terminal status as it is represented in the Navigator. Yet another im-provement: a new connection-oriented view quickly shows which terminal connections are still free and therefore available. Aside from these functionalities making designing simpler, they also significantly acceler-ate design engineering processes.

11 | Industry USA | September 2016

14

Managing Projects and Project Data Using the Quick Input Filter for project management makes it even easier to process and manage projects and project data. Subprojects are freely definable and can be saved at will, and there is more flexibility in name allocation. For instance, users can only update the main project instead of storing subprojects with the goal of bringing the main project up to date. In project structure management, certain structures can be searched for and revised throughout the entire project, which considerably simplifies project oversight. The definition of sequencing pages for print or PDF outputs has also been appreciably enhanced–and users also benefit from faster results in this area.

Piping/Hose Lines in 3D For hydraulics and pneumatics, for cooling and lubrication: numerous applications require the use of pipes or hose lines to transport media such as air or oil. Eplan Fluid Professional, including the Eplan Pro Panel add-on, now

NEWS

Function-oriented design with Eplan is a source for increasing efficiency with the Eplan Platform.

With Eplan Preplanning, data from external sources can now be imported. A preview function allows incoming data to be verified before being imported.

offers the possibility to represent piping and hydrau-lic hose lines directly in 3D with complete layout functionality. Design engineers can thus review the layout or for instance the length of the hose lines. An export function is also provided in order to transfer the pipe geometries to an external manufacturing software for pipe bending.

www.eplanusa.com/us MORE INFORMATION

From Preplanning to Detail Engineering Many new functions were optimised to simplify integrating Eplan Platform into customersâ&#x20AC;&#x2122; existing processes.

Eplan Preplanning now allows data from external sources to be imported. A preview function allows incoming data to be verified before being imported. Differences are easy to recognise and even previously deleted objects can now easily be found and removed from preplanning and detail engineering. This represents the next step toward more data consistency and data continuity within design engineeringâ&#x20AC;&#x201C; from preplanning through to detail engineering.

Better IT Integration User management has also become easier: existing users can simply be imported into an IT infrastructure instead of having to create a new user. Eplan user rights management was expanded with support for Active Directory. The use of SQL databases has also been made simpler: a selection list of available SQL databases is available from which to select the correct one.

11 | Industry USA | September 2016

15

NEWS

MAPAL RELIES ON THE SAFE-LOCK™ SYSTEM FROM HAIMER

Within a wide range of markets, such as the aerospace industry, cutting tools from MAPAL have successfully established themselves for high-performance machining operations liketrochoidal milling. In order to offer users even greater protection against tools being pulled out of the chuck during machining operations, and to prevent damaging single workpieces or the machine itself, MAPAL is going to rely on the SafeLock™ pull-out protection system from HAIMER. The two companies recently signed a corresponding licensing agreement.

H

AIMER and MAPAL have reached a partnership and licensing agreement. The toolholding specialist from Igenhausen near Augsburg and the precision cutting tool manufacturer from Aalen are combining their strengths to form a new partnership. In the future, they will work strategically closer together on the progression and further development of technologies and their applications in the manufacturing market.

MORE INFORMATION

The two companies have signed an agreement that has contractually solidified their partnership. “We are proud and happy to have a strong partner at our side in MAPAL that is one of the world's leading tool manufacturers,” emphasizes Claudia Haimer, managing partner of HAIMER. And the managing partner of MAPAL, Dr. Dieter Kress, is also looking forward to the future cooperation. “We value the high-level expertise of HAIMER whose innovative solutions in the 11 | Industry USA | September 2016

16

field of tool holders represent the perfect complement to our high-tech tools.” Through the agreement, MAPAL has acquired a license to HAIMER's Safe-Lock™ technology that is patented worldwide.

“The Safe-Lock™ system has proven itself both in the market and during our in-house trials. Consequently we have decided to use this leading system,” Dr. Jochen Kress, Member of the MAPAL Senior Management, says. “It is very frequently used for modern machining strategies.

With Safe-Lock™ the productivity and tool life can be significantly increased,” Andreas Haimer, Managing Director and President of the HAIMER Group,explains . When it comes to high-speed cutting, absolute safety is especially crucial.

Considering the high value of the single workpiece or an unmanned production, scrap parts and machine downtime have to be avoided in order to guarantee process reliability.

NEWS

From left to right: Dr. Jochen Kress, member of the senior management of MAPAL, Dr. Dieter Kress, managing partner of MAPAL, Claudia Haimer, managing partner of HAIMER and Andreas Haimer, managing director of HAIMER.

Through special drive keys in the tool holder and grooves in the cutting tool shank, the Safe-Lockâ&#x201E;˘ system from HAIMER ensures high accuracy frictional clamping with the security of a form fit between grooves on the cutting tool and the drive keys in the chuck. This prevents the cutting tool from turning or being pulled out of the chuck during machining.

As a first step and starting in October, MAPAL will be offering selected cutting tools for high-performance machining with the Safe-Lockâ&#x201E;˘ shank. As a second step, the MAPAL hydraulic chucks will follow and also be designed for this type of pull-out protection. www.haimer.com

MORE INFORMATION 11 | Industry USA | September 2016

17

NEWS

ESTERLINE CONNECTION TECHNOLOGIES – SOURIAU USA'S MIL-DTL-38999 CONNECTORS HAVE BEEN QPL CERTIFIED FOR MORE THAN 30 YEARS

Esterline Connection Technologies – Souriau's MIL-DTL-38999 and MIL-DTL-26482 aluminum, composite and stainless steel (class K) connectors are QPL certified. The group and its 12 value-added distributors (VAD) based in the USA are able to meet sudden surges in demand whilst maintaining the same high level of service, quality, and on-time delivery.

Exceptional quality Esterline Connection Technologies – Souriau prominently stands out for its high quality and reliability requirements on the production of its ranges of MIL-DTL-38999 and MILDTL-26482 connectors.

MORE INFORMATION

“It has always been a priority of Souriau to comply with MIL qualification procedures, which ensure that connectors are capable of withstanding the harshest and most critical environments”, says Alain Philippe, Souriau Business Development Manager for the aerospace and defense markets. “Our MIL 38999 connectors have been QPL certified since 1983 and we successfully maintain this qualification status every two years. The inserts and shells of our MIL 38999 connectors are manufactured at Souriau plants that have been audited by the US Department of Defense, and no components are sourced in Asia”.

11 | Industry USA | September 2016

18

This standardization of its manufacturing process has allowed Esterline Connection Technologies – Souriau to implement specific production processes and a continual improvement system. “These requirements guarantee that our clients benefit from a high level of quality and a steadily decreasing defect rate of less than 500 ppm (0.05%) whereas this rate elsewhere on the market is 10 times higher”, says Mr. Philippe. “This level of quality is also due to the metal contact-retention clips used on our entire MIL range.

Competing solutions are less durable and require greater care during wiring operations to avoid breaking the plastic clips”.

Outstanding logistics The main components of Souriau connectors — the shells and inserts — are manufactured in-house within a single distribution, production and quality organization that allows the group to quickly respond to market changes and double production capacity within a matter of weeks.

Managing market forecasts and future trends via its S&OP

NEWS

is the linchpin that allows the group to achieve an on-time delivery rate of 98%.

An industrial implementation and a large VAD network in the US Esterline Connection Technologies â&#x20AC;&#x201C; Souriau has a strong presence in the USA thanks to its Paso Robles, California plant and its strong network of value-added distributors (VAD). They are able to assemble MIL-DTL- 38999 connectors on demand and at short notice from their sub-assembly inventories. Souriau VADs are QPL-qualified for the assembly of MIL-DTL- 38999 connectors and regularly undergo audits and requalification. The Paso Robles plant also has a design engineering office that researches and develops specific connectors for the US market.

Innovation on the move Esterline Connection Technologies â&#x20AC;&#x201C; Souriau is a forerunner of MIL-DTL-38999 connectors, invented the bayonet-locking system, and was the first to be MIL qualified for composite and zinc-nickel-plated aluminum 38999 connectors.

MORE INFORMATION

It will continue its innovative roadmap by further developing the 38999 range to include miniaturized shells, titanium shells, compliance with REACH regulations, and integrate optical, power, and high-speed technologies. www.souriau.com 11 | Industry USA | September 2016

19

NEWS

DIAGNOSTIC TOOL SET 8: COMPLETE SOLUTION FOR VEHICLE DIAGNOSTICS WITH MULTIPLE NEW FUNCTIONS AND EXTENSIONS

The new release 11 of Softing's Diagnostic Tool Set is a very effective upgrade: Alongside support for Windows 10 and all other current platforms, consideration of updated automotive standards and the maintenance of authoring systems for ODX and OTX, the engineering tester DTS Monaco in particular features considerable extensions and improvements.

T

he new release now also fully supports Windows 10. For use in embedded systems, smartphones and tablets, the ISO MVCI Server and OTX runtime environment are additionally available for Linux, Android and iOS on request. Under Windows, the relevant programming interfaces and the automation API for manufacturing and test bench applications now all use the Visual Studio 2015 runtime library.

MORE INFORMATION

Taking updated standards into consideration, the delivery scope also includes the protocol template ISO_14229_3_ on_ISO_15765_2 for UDS on CAN. With regard to Euro 5 and 6, the OBD protocol template was extended in compliance with SAE J1979:2014-07. With the DTS project based on this, self-diagnosis for both gasoline and diesel vehicles can be validated and released without vehicle-specific ODX data being required for this purpose.

11 | Industry USA | September 2016

20

In the case of the engineering tester DTS Monaco, the communication status is now visualized for every layout.

When workspaces are opened, the VCI selection can be changed and the status of the connected VCIs verified.

The workspaces can be managed comprehensively. If no connection to the VCI is possible, the simulation can be used temporarily instead. Individual HMI Controls can now also be reused in other layouts or projects. This always involves a consistency check which now can be launched also independently of an import. To analyze bus or symbolic trace recordings, the completely revised Analyzer can now be launched directly from DTS Monaco. The new, more efficient HMI Control Service Table combines and replaces the HMI Controls Data Display used to date for reading out measured values and the IO Control for modifying parameter values. Service configurations of the new HMI Control can be exchanged between users. Two new ultra-efficient HMI Controls are ECU Identification for reading out identification information of individual ECUs or an entire vehicle as well as Tool Quick Test for the fast determination of the vehicle status regarding identification and error memory.

NEWS

Reporting has also been completely revised, standardized and extended. The application security of preconfigured workspaces has been considerably improved for users of the basic license as faulty and unintentional configuration changes are not saved. Users with a valid maintenance and service package for DTS Monaco receive a free upgrade with which layouts and controls can be configured without any limitations and workspaces saved.

With Softing's Diagnostic Tool Set, diagnostic data and sequences can be created, run and tested on the basis of the latest international automotive standards. It helps to ensure that both the diagnostic communication and the actual vehicle diagnostics always work reliably in Engineering, Manufacturing and After-Sales Service.

More details: http://automotive.softing.com/en/DTS8

Users of the ODX authoring system DTS Venice can now select individual ECU variants as well as audiences in filtered exports. The RTF export has also been optimized.

MORE INFORMATION

OTX Studio, the engineering environment for complex diagnostic sequences, now offers to users more convenience and support. Among other features, the interactive help was extended and provided with programming examples.

These help beginners in particular to better understand individual contexts and interrelations as well as areas of implementation. In the Test Case Editor, users can now generate generic diagnostic test cases which can be reused for different ECUs. Test reports can be compared with the integrated differ and the results visualized as statistics. The high-performance OTX runtime environment developed in C++ has been further optimized and now enables the parallel execution of several scripts.

Registered users with a maintenance and service package will receive the upgrade to release 11 free of charge.

11 | Industry USA | September 2016

21

NEWS

DE DIETRICH PROCESS SYSTEMS IS LAUNCHING A NEW EXTERNAL PROTECTION OF GLASS-LINED PARTS

To address the problems of its customers, particularly in pharmaceutical and fine chemicals, sensitive to the risk of contamination of their products by paint chips, De Dietrich Process Systems has developed a new exterior nickel coating for glass-lined parts.

T

his coating is particularly suitable for glass-lined accessories such as manhole covers, protection rings and even some AE reactor covers, or process peripheral such as piping.

To address this risk, De Dietrich Process Systems has developed a nickel coating solution that provides corrosion protection comparable to painting, while eliminating the risk of chipping.

The external protection of process equipment (reactors, piping, etc.) in glass-lined steel is traditionally provided by the paint. These paints have excellent corrosion resistance but may in places be subject to high mechanical stress, and flake.

Indeed, nickel coating has outstanding properties: • Bonds perfectly with the base material • Impact resistant • Easy to clean thanks to a specific surface preparation • Makes it possible to apply homogenous surface coating to components with complex geometries

MORE INFORMATION

The GMP (Good Manufacturing Practices) standards of the pharmaceutical industry prohibit the fact that a paint flake can contaminate the final product.

11 | Industry USA | September 2016

22

www.dedietrich.com

NEWS

IXXAT CAN@NET NT 200–THE MULTI-FUNCTIONAL CAN-TO-ETHERNET GATEWAY

The CAN@net NT (now in new black hou The CAN@net NT (now in new black housing) allows users to connect CAN and Ethernet sing) allows users to connect CAN and Ethernet.

The new IXXAT CAN@net NT 200 is a CAN-to-Ethernet gateway which allows users to connect CAN and Ethernet. Thanks to its two operating modes, CAN@net NT can be used as CAN-Ethernet-CAN bridge and as CAN-to-Ethernet gateway. Equipped with two CAN interfaces, it supports an even wider range of use cases compared to the well-known CAN@net II. Linking of CAN networks One of the key features of the CAN@net NT – which is especially useful in e.g. building automation – is the ability to separate CAN networks that are distributed over large areas.

CAN@net NT couples the CAN networks via a backbone Ethernet system, allowing existing infrastructures to be used. This segmentation also increases the reliability and stability of the overall system.

CAN@net NT supports all CAN baud rates from 5 kBit/s to 1 Mbit/s, as well as simultaneous use of 11 and 29 bit identifiers. The TCP/IP-based protocol ensures that no CAN messages are lost when transmitted over Ethernet. The device configuration is easily made by using a Windows configuration tool.

More variants of the CAN@net NT, with PC interface operation mode, 4 CAN channels and CAN FD support will soon be released.

MORE INFORMATION

Enables remote access Designed for high performance in harsh environments, another common application for CAN@net NT is remote access to CAN networks via Ethernet – e.g. in wind power plants or in the manufacturing sector. CAN@net NT enables service staff to get access to plants all around the world, simplifying control, service and monitoring of CAN-based plants, reducing costs and downtime significantly.

Besides the bridge operation, linking two CAN networks via Ethernet, the CAN@net NT 200 can also be directly accessed from Windows, Linux, VxWorks or QNX based systems as well as from embedded systems, by using a simple ASCII protocol over a standard TCP/IP socket.

More information is available at www.ixxat.com

11 | Industry USA | September 2016

23

NEWS

LEAN SOLUTION FOR TRACK-AND-TRACE

All-in-One RFID Reader BIS M-4008.

T

he BIS M-4008 from Balluff is an All-in-One RFID Reader with integrated processor. The 13.56 MHz reader with IP67 protection and a rugged die-cast zinc housing features a Profinet interface, needs no additional processor and can communicate directly with the control level.

The reader is an ideal choice wherever a lean solution is needed for detecting data carriers on workpieces and workpiece carriers at individual stations. Typical applications include material flow control in production facilities, conveying systems and assembly lines.

MORE INFORMATION

The device is the only all-in-one reader on the market with an integrated 2-port Ethernet switch for constructing simple line- and ring topologies. An integrated webserver provides conven-ient status monitoring from a distance. Highly visible LEDs di-rectly on the device also indicate status.

The new reader supports data carriers conforming with RFID standard ISO 15693. Anyone needing faster data transmission can simply choose Balluff high-speed data

11 | Industry USA | September 2016

24

carriers with a transmission rate of up to 8x faster than the standard and extra-large memory capacities of up to 128 kB. The BIS M-4008 saves the user much time and money in as-sembly and installation. The die-case zinc housing can be in-stalled directly on metal in a variety of ways. Direct connection to Profinet also represents reduced wiring expense and effort. Yet another benefit is the use of costeffective 4-pin, M12 standard cable for the power and Profinet connection.

Device master data are available as a GSDML file for typespecific parameterization. Ready-made function blocks provide for simple S7 programming. www.balluff.com

NEWS

THE NEW BENCHMARK IN ABSOLUTE HEAVYDUTY ENCODERS

Baumer further expands their unparalleled portfolio of HeavyDuty encoders. The new absolute encoder series HMG 10 and PMG 10 are specifically designed to address application needs in the Metal & Steel, Ports, and Mobile Automation industries. These HeavyDuty encoders have been proving their reliability and unrivalled durability for decades.

B

test of time under harsh HeavyDuty conditions for more than a decade. The patented revolution counter of the latest generation is powered by the energy generated by the encoder shaft rotation. Gearless and without battery, the counter is absolutely immune to wear, dust and magnetic fields. Ultimate long-term protection against corrosion is another hallmark for the outstanding high robustness of Baumer HeavyDuty encoders.

An extremely resilient housing, optimally spaced fixed/ floating bearings on both sides, and generously sized hybrid ball bearings are the cornerstones for the unrivalled long service life and reliability of Baumer HeavyDuty encoders.

The robust magnetic precision sensing supplies a signal quality which is nearly identical to that of optical sensing principles - but withstanding dust, dirt and condensation.

Even at high temperatures up to +100°C and in adverse environments the shock-and vibration resistant sensing technology ensures high-precision signals for maximum processing accuracy and control quality in the application.

Where required, besides the absolute position information the encoder provides at a specific measuring point up to two galvanically isolated incremental outputs with zero pulse and integrated speed switch with galvanically insulated switching states. This way, one encoder is sufficient to supply the relevant signals for control, converter and other control loops.

Thanks to consistent component optimization and harmonization, the new series sets an absolute benchmark in HeavyDuty encoder technology. But even more robust, highly efficient and with a signal quality previously achieved by optical sensing only.

Centerpiece in the new series is MicroGen technology, the energy harvesting approach which has been standing the

MORE INFORMATION

aumer HMG 10 and PMG 10 encoders merge in their revolutionary design the practice-proven concept of bearings on both sides, innovative high-precision sensing and the patented Baumer energy harvesting technology MicroGen which has been standing the test of time for more than 10 years. Furthermore they continue the Baumer encoder success story with even further enhanced performance.

More information: www.baumer.com/HMG10 11 | Industry USA | September 2016

25

NEWS

FISCHER RUGGED FLASH DRIVE NOW FIVE TIMES FASTER WITH USB 3.0

Fischer Connectors, the worldwide innovator in push-pull circular connectors and cable assembly solutions, today launched the USB 3.0 version of its ultra-portable, miniature, lightweight and extremely tough Fischer Rugged Flash Drive. This memory stick has been specially designed for the safe transportation and storage of sensitive data in harsh environments.

T

he USB 3.0 Fischer Rugged Flash Drive is even faster, smaller and more user-friendly than the USB 2.0 product introduced to the market in 2011. The read speed is now up to five times faster; standard memory sizes are 32, 64 or 128 GB; the body is shorter; and, in order to guarantee secure access, it is now available not only with the Fischer UltiMateTM Series interface, but also with the Fischer MiniMaxTM Series interface. The activity LED is a further feature of the new product to improve usability.

Miniature – the size of a key ring – and lightweight, the Fischer Rugged Flash Drive has proven to be the durable solution for people on the go who need to download and securely transfer confidential data, images or videos from devices used in extreme environmental conditions or in hard-to-reach areas. It is perfectly adapted for applications where data security and confidentiality are critical, such as the defense and security, financial, medical, industrial, energy, underwater, motor and extreme sport sectors, e.g. for civil or military UAVs, ROVs, test & measure equipment or rugged computers.

MORE INFORMATION

Main technical specifications • IP68 sealed even unmated • Unique Fischer UltiMate (size 07) and MiniMax (size 08) interfaces • Up to 100 MB/s read speed • 6High speed USB 3.0 • Memory sizes: 32, 64, 128 GB • R esists corrosion, vibration, shock and extreme temperatures 11 | Industry USA | September 2016

26

NEWS

The Fischer Rugged Flash Drive USB 2.0 on UltiMate size 08 and new versions UltiMate size 07 and MiniMax size 08 with USB 3.0.

Safe AND secure The Fischer Rugged Flash Drive is both safe and secure. Its rugged casing provides full protection against extreme environmental conditions. The flash drive is waterproof down to 120 meters and is resistant to extreme operating temperatures (-40°C to +85°C). Thanks to the unique proprietary Fischer Connectors’ circular connector interface combined with a durable encapsulation technique, it guarantees data security in case of loss or theft.

More information: • Web page: http://www.fischerconnectors.com/global/en/fischerrugged-flash-drive-usb-3 • How to contact us: http://www.fischerconnectors.com/global/en/contact-us

“Performance and flexibility” “At times when privacy and confidentiality are of paramount importance, you need the right product to protect your critical information against the elements and the potential risk of loss or theft,” explains Wim Vanheertum, Product Manager at Fischer Connectors. “Technology moves fast, and both performance and flexibility are required when designing high-speed applications using video. The new Rugged Flash Drive increases data transfer speed by five, and its flexible modular design, which includes a large selection of body styles, sizes, contact configurations and memory capacities, offers high customization.”

MORE INFORMATION

Showcased as world premiere at Eurosatory tradeshow The new Fischer Rugged Flash Drive is showcased for the first time, along with the company’s new electrical and optical connectivity solutions, at the Eurosatory tradeshow in Paris from 13 to 17 June 2016, at Fischer Connectors’ booth no. G 497, Hall 6. The Fischer Rugged Flash Drive will be commercially available in July.

11 | Industry USA | September 2016

27

NEWS

SCRIBING TECHNOLOGY

Precise, Reduced Noise Marking.

S

SIC Marking's product range runs from standard machines to custom engineered solutions. All systems are created with careful attention to bring functional design, quality, innovation, and performance to manufacturing lines. Every site, every job, and every customer is unique.

Also called “drop and drag” or “scratch marking,” scribing technology is an ideal choice for applications where noise level limitations are imposed. If dot peen markers are considered too noisy when used on steel pipe, for example, a pneumatic scribing machine might be preferred. SIC Marking's scribing technology guarantees a high quality mark and is ideal for requirements that include Optical Character Recognition (OCR) or aesthetics concerns (logos, symbols…).

As an example, one of our customers in the automotive industry has asked our engineers to set up a system adapted for eight of his exhaust pipe’s production lines.

The traceability and identification of exhaust pipes can be a complicated task since the parts are hollow. Our customer’s main issue was compliance with the noise limits which is the reason why scribing marking systems were chosen.

MORE INFORMATION

cribing is a marking process whereby the mark (text or logo) is produced by a carbide or diamond tip that penetrates and indents the surface. This produces a deep groove that forms continuous lines across round, concave, flat, or arched surfaces, and on almost any material.

Our i113s marking systems have been easily integrated and implemented on each work station. Thanks to the reliability and flexibility of SIC Marking’s scribing systems, our customer was able to adapt the marking head’s position to fit each of his production lines.

New scribing marking machine To complete its scribing range SIC Marking launches a new i63s marking machine. This new scribing marking

11 | Industry USA | September 2016

28

NEWS

head complements the i113s machine dedicated to deep marking on steel and other hard materials. i63s marking system has a compact yet robust design engineered for integration on production lines of all types of industrial environments. The marking quality is excellent with perfect continuous lines and very fast for materials of all kind, from plastic to hardened steel (up to 62 HRC).

The mechanical system is much simpler which has for consequence reduced maintenance. Already equipped with full connectivity (digital I/O, Ethernet TCP/IP, RS232...), our i63s scribing systems also offer many features to interact with all the elements that set up their environment. Our machines can be easily integrated on all production lines using Profinet, Profibus and Ethernet/IP. www.sic-marking.com

MORE INFORMATION 11 | Industry USA | September 2016

29

Stellar Precision owner discusses tooling on the shop floor with production manager Ed Frieze.

NEWS

STELLAR SUCCESS

The mix of machine tools on Stellar’s shop floor is one of continuous improvement and adoption of new technology.

This solid ceramic endmill might feel like plastic in your hand, but its cutting performance in nickel-based alloys is often twenty times that of carbide tools.

Solid ceramic endmills from Kennametal help this aerospace job shop meet a critical delivery date.

MORE INFORMATION

M

ost shops evaluate new cutting tools in an effort to reduce machining time, increase tool life, or improve part quality, and sometimes all three.

Stellar Precision Components Ltd., a Tier II aerospace supplier in Jeanette, Pennsylvania, did it for an entirely different reason. “We’d just taken an order for some Inconel parts,” says production manager Edward Frieze. “None of us were really worried at that point about tool life or making a profit on the job—our only concern then was how the heck could we get them shipped in eight weeks.”

“We started out doing a lot of overload work from other larger shops in the area, but that evolved into direct support of several nuclear programs because of my father’s experience in this area,” says daughter Lori Albright, now owner and president of Stellar Precision. “We’ve since become a key supplier to a number of prime aerospace and defense contractors including Boeing, Lockheed, and Raytheon, as well as various nuclear and medical customers, and have over 70 employees and sales revenues of nearly ten million dollars US.”

Opening Doors Four decades earlier, Mike Vucish Sr. was working for a manufacturer of naval nuclear components when he saw an opportunity to go into business for himself. He bought some equipment, invited a few students from the technical school where he taught shop class at night, and opened the doors of Stellar Precision in 1978. He continued to work at his day job until his fledgling company was firmly established, but in the meantime brought some family members on board to help out.

Stellar prides itself on continual updates to its equipment list, and has an eclectic mix of CNC machine tools from Haas Automation and Okuma, although that balance is steadily tipping in Haas’ favor as the shop’s older machines go into retirement. Albright says not only is the Haas equipment less expensive than its foreign-built competition, but that “Made in America” resonates with many of Stellar’s customers. “This approach also lets us replace our equipment on a more regular basis, which in turn keeps us current on technology.”

Key equipment includes an Okuma LB-45 lathe able to turn 36 in. diameter parts up to 120 in. long (91 mm x 305 cm), and a Haas VF-11 5-axis machining center with 10 ft.

11 | Industry USA | September 2016

30

NEWS Hot stuff. Kennametal’s full ceramic end mills operate at spindle speeds up to 10 times faster than carbide and provide far greater tool life.

of X-axis travel (305 cm) and a table load capacity 4000 lb.

(1814 kg). Stellar also has several wire EDMs, a dozen or so 3, 4, and 5-axis machining centers and mill-turn lathes, and offers value-added services such as non-destructive testing, welding, heat treating, and Teflon coating.

Not Too Tough Stellar is used to meeting demanding requirements. Recent projects include components for RAM Block II anti-ship missiles, the CCtCap crew transport vehicle, 155mm Long Range Land Attack Projectile (LRLAP) advanced gun system, rocket motor cases for the Atlas Five launch vehicle, and others. Their newest project, however, would be one to test the mettle of machinists and management alike.

Nor was tolerance an issue. Frieze points to one recent titanium part that called out a 0.005 in. (0.127 mm) profile tolerance over its 12 in. length (304 mm), the equivalent of holding “a couple tenths” in parts that cost over $5000 apiece before machining. Meeting the relatively wide open tolerances on the Inconel part was not a concern.

Seminar Payoff Earlier that year, Frieze and several of his coworkers had attended a learning event sponsored by a local chapter of the National Tooling and Machining Association (NTMA), and hosted at the Kennametal technical center in the nearby town of Latrobe. There he met product manager Matthieu Guillon, who introduced him to a cutting tool that Frieze was initially skeptical of. “It looked and felt like a plastic toy end mill,” he laughs.

That tool was Kennametal’s series of 4 and 6-flute high performance full ceramic end mills. Constructed of SiAlON KYS40 grade ceramic and designed specifically for roughing in nickel-based high-temperature alloys, these end mills often out-produce carbide by up to 20 times. Says Guillon, “We recommend a starting speed of 825 SFM up to 3300 SFM (250 to 1000 m/min) and feedrates starting at around 0.001 IPT (0.03 mm) depending on the tool diameter and other conditions. Despite the far higher cutting speeds, we have some customers who have reported 2 to 3 times greater tool life than carbide.”

>>>

MORE INFORMATION

Frieze explains that Stellar had just received a purchase order for a handful of Inconel 625 prototypes. The raw material blanks for the job measured 18 in. square x 3 in. thick (457 x 457 x 76 mm), and weighed nearly 300 lb. each (134 kg). The project team suffered little indigestion over the tough material’s poor machinability; Stellar routinely cuts Inconel and other nickel-based superalloys, as well as tungsten, maraging steels, 60 Rc 4340 (300M), and tool steel.

The problem was one of raw material removal: when finished, the Inconel plates weighed in at a svelte 30 lb. (13.6 kg), 90-percent lighter than their starting weight. Frieze knew there weren’t enough hours in the day to remove that much material using conventional carbide tooling, not if he were to meet the deadline. He needed a better solution.

11 | Industry USA | September 2016

31

Lori Albright in an early morning strategy discussion with Kennametal product manager Matthieu Guillon.

NEWS

“The tools aren’t inexpensive,” he says. “At one point, Lori had around $20,000 worth of end mills sitting in her office and we were starting to question the investment. But once you calculated in the machine costs and reduced cycle time, we figured it was three to four times more cost-effective to go this route. Each end mill gave us one half hour of cut time, at which time we replaced it whether it was worn or not. The process was so predictable we were able to run lights out. It was a drastic savings.”

Young people and fresh ideas are two of Stellar’s biggest assets, says owner Lori Albright.

Stellar didn’t have any immediate use for the ceramic tools, but after making some quick feed and speed calculations, Frieze knew they would be an effective solution given the right application. Several months later, that application arrived with the Inconel plates. He called Guillon to say he might have a good use for those ceramic cutters they were talking about, and wondered how soon he could get some.

Skeptic to the Last Frieze remained skeptical. He’d tried indexable ceramic cutting tools on both milling and turning jobs in the past and had mediocre results. In this case, however, he was willing to try anything if it meant meeting the customer’s deadline. When Guillon arrived a few days later with the ceramic end mills, Frieze followed Kennametal’s feed and speed recommendations to the letter, crossed his fingers, and pushed cycle start.

MORE INFORMATION

“We weren’t certain what would happen so started out with a block of test material,” he says. “You don’t use cutting fluid with ceramic—only an air blast—and everyone in the shop was crowded around the machine saying, ‘Wow, look at that!’

There was fire shooting everywhere. It was something we’d never seen before. But within the first hour, we knew it was going to work.”

11 | Industry USA | September 2016

32

Enjoying the Heat Best of all, Stellar delivered the parts on time with zero scrap, and is now quoting a second, even larger order. Owner Lori Albright was quite pleased with the outcome. “This type of situation is the nature of our business. We have to react to our customers’ needs and employ the best technology available to do so. That’s one of the reasons why Kennametal is so welcome here. We work together as a team to solve challenges.”

Looking forward, Albright anticipates continued growth.

Having expanded Stellar’s existing facility six times, she figures it might be time to put up an entirely new building on nearby property. She also looks forward to bringing additional young people to the machining trade. “We have apprenticeship programs with several of the area schools, one of which my father used to teach at,” she says. “I find that it’s often our younger people that drive our innovation. It's too easy to keep doing things the old way and not invest in tooling and equipment, or pursue new technology. The days of high volume, round-the-clock fender clip manufacturing are gone, and it’s only by continually improving their manufacturing processes that companies can succeed and grow. For us, Kennametal is part of that success.” www.kennametal.com

NEWS

KEYENCE CLAMP-ON FLOW SENSOR RECEIVES INNOVATION AWARD

KEYENCE’s FD-Q Clamp-On Flow Sensor has been recognized by New Equipment Digest as the 2016 Innovation Award winner. The success of the FD-Q can be directly attributed to its impact on American Manufacturing.

T

he FD-Q, released in the summer of 2015, introduced ground-breaking technology for liquid flow monitoring in the factory automation industry.

As opposed to conventional models that require pipe modifications, this sensor clamps directly to the outside of any pipe, and monitors any liquid flow without intrusion.

What sets the FD-Q apart?

The FD-Q is easily installed with a Phillips screwdriver.

Since no pipe modification is necessary, it can be installed without downtime, extra costs, or added risk. The unit can reliably sense the flow of liquid through metal or resin pipes ranging from ¼” to 2”. Lines previously considered too costly or difficult to monitor are a perfect fit for this innovative solution.

About New Equipment Digest For the past 80 years, New Equipment Digest has been the leading source for the latest manufacturing equipment news and trends. As part of Penton’s Manufacturing & Supply Chain group, NED prides itself on publishing the latest and greatest industrial innovations first to help bring manufacturers the tools and technologies they need to do their jobs.

To learn more about NED, visit www.newequipment.com Learn more about FD-Q at www.keyence.com/FDQ_NED_AWARD_201

MORE INFORMATION

This sensor can detect virtually any type of liquid, including: water, deionized water, oils, chemicals, and more. 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.

11 | Industry USA | September 2016

33

NEWS

SMALL, SMALLER, SMALLEST: NEW ULTRA-MINIATURE CONNECTOR IN FISCHER MINIMAXTM SERIES

Fischer Connectors, the worldwide innovator in push-pull circular connectors and cable assembly solutions, today launched an even smaller ultra-miniature connector, MiniMax 06, as an extension of its miniature high-density product range, the Fischer MiniMaxTM Series.

T

he MiniMax 06 connector can include up to 12 power and signal contacts in a footprint of only 10 mm. This corresponds to a density factor* of 0.83 – a unique technological feature for a connector with standard 0.5 mm contacts. The new MiniMax 06 connector also includes a new unique configuration with 2 signal and 2 high-power 1.3 mm contacts for applications needing 10 Amps or more power, doubling the standard 5 Amps current rating of the existing MiniMax product line.

MORE INFORMATION

MiniMax 06 is easy to use and ensures premium performance even in harsh environments. Also available as a pre-cabled solution, it is ideally suited for handheld or body-worn applications when space is limited, in such fields as defense & security, instrumentation, testing equipment, civil or military unmanned aerial vehicles (UAVs), among many others.

11 | Industry USA | September 2016

34

Increased power & miniaturization with continued durability With this new smaller connector, Fischer Connectors continues to drive the evolution towards combined signal and power connectors as a way of making electronics lighter and smaller. MiniMax 06 integrates fully into the ultra-miniature high-performance Fischer MiniMax™ Series, well-known for its use in limited space and lightweight applications, and for meeting the combined needs of multiple signals and power. Tested for high-speed protocols such as HDMI and data transfer up to 10Gb/s, the series also addresses the growing market need for higher data transmission rates.

“This product proves that miniaturization in connectivity can be successfully implemented in rugged high-density connectivity solutions that combine power and signal”, explains Wim Vanheertum, MiniMax Product Manager at Fischer Connectors. “We’ve extended our Fischer MiniMax™ Series to address application engineers’ need to increase the performance of their miniature rugged devices.

Handling more mixed signal and power connections in a unique combination of multiple contacts also means

NEWS

The Fischer MiniMax™ Series: high density, signal & power, miniaturization.

increasing flexibility in meeting specific design challenges in miniaturization.”

MiniMax 06’s main technical specifications • Up to 12 contacts in less than 10 mm diameter • Unique combined power and signal configuration • IP68 mated & unmated • Transfer data up to 10Gb/s • Robust locking systems: push-pull, screw and quick-release • Also available pre-cabled with straight or angled bend relief overmold • 5,000 mating cycles The Fischer MiniMax™ Series connectors and cable assembly solutions allow design engineers to save up to 45% space and to reduce weight by up to 75% compared to standard connectors with a similar contact size. By replacing multiple connectors with only one, they pack more functionality into smaller devices, lowering the total cost of ownership.

mm and 12 mm footprint respectively. Configurations range from 4 to 24 contacts. * Density factor = receptacle diameter divided by the number of contacts available in that receptacle size.

More information: http://www.fischerconnectors.com/global/en/new-ultraminiature-connector-minimax-06 White paper “Miniaturization”: http://www.fischerconnectors.com/global/en/militaryconnectors-miniaturization-white-paper How to contact us: http://www.fischerconnectors.com/global/en/contact-us

MORE INFORMATION

These connectors are also rugged, with IP68 sealing (2m/24h), both mated and unmated, an unbreakable keying system, and over-molded cable assemblies. Available in three locking systems (push-pull, screw and quick-release), they are easy to connect and disconnect up to 5,000 times.

With its new smaller version, the Fischer MiniMax™ Series now comes in two sizes, 06 and 08, with receptacles of 10 11 | Industry USA | September 2016

35

NEWS

PCVUE INTRODUCES PROXIMITY-BASED CONTEXTUAL MOBILITY FOR SCADA

PcVue® is ARC Informatique’s core product, the company is an independent provider in HMI/SCADA software. It has been contributing to the evolution of the automation industry for 30 years by providing a flexible solution for supervising building management systems, industrial processes, utilities, and infrastructure. The BTL listed PcVue Solutions are now entering an uncharted market to provide an innovative mobile offering for SCADA in intelligent buildings.

P

roximity-based services enabled by micro-geolocation for Indoor Positioning Systems (IPS) are growing quickly. The IPS technology market alone is estimated to reach $5 billion in revenues by 2017 and to represent over 200,000 installations of infrastructure equipment, including Wi-Fi hotspots, Bluetooth antennas, and more than 800 million branded applications downloads.

MORE INFORMATION

This technology has made possible the practical deployment of contextual Human Machine Interfaces (HMI). Contextual HMI creates the opportunity for new more efficient work processes for those who rely on Supervisory Control and Data Acquisition (SCADA) and Building Management Systems (BMS) to perform their job.

11 | Industry USA | September 2016

36

Remote access to supervisory systems have typically been accomplished by using internet browsers on laptops. With the increasing adoption of smart mobile devices, technology such as Microsoft Remote Desktop Services (RDS) has been adopted as an alternative for mobile HMI. Navigating an HMI designed for a workstation while using a much smaller mobile device can prove difficult given the reduced screen size and mechanism for managing the mouse. A mobility infrastructure eliminates this problem via the presentation of information and controls in the context of role and place. It provides a dynamic HMI that changes as the worker moves through workplace zones automatically adjusting for job responsibility. In a plant scenario, such a system is aware which floor a worker is on and automatically sends the status and controls of equipment in that worker’s proximity. It is a very pro-active approach that is recognized to improve the efficiency of commissioning, operation and maintenance of automation systems.

NEWS

For safety, it is critical that the Mobility Server knows the current location of workers. With the ready availability of geolocation signals, IPS indoors and GPS outdoors, it is possible to track location by simply archiving the deviceâ&#x20AC;&#x2122;s position over time. Safety and dispatch tracking are natural functions of the Mobility Server which relies on position in order to create contextual HMI. PcVue Solutions are reinventing mobility architectures with smart mobile devices using proximity services in innovative ways to benefit SCADA and Intelligent Building projects throughout the world. www.pcvuesolutions.com

MORE INFORMATION 11 | Industry USA | September 2016

37

NEWS

ORCHID ORTHOPEDIC SOLUTIONS

Instant Measurement Brings Instant Results (and Heavy Traffic) to this Medical Manufacturer (Orchid sees immediate ROI with Keyence.)

K

evin Botta, Continuous Improvement Manager at Orchid Orthopedic Solutions Inc., has been having a hard time keeping people out of the Quality Inspection lab. “I’ve had to chase people out of here because they want to measure everything with the new equipment,” says Botta. “It’s amazing how much faster it is than our legacy inspection methods.”

MORE INFORMATION

He’s talking about the IM, or “Instant Measurement” systems Orchid purchased recently to increase inspection throughput on the small, tight-tolerance components machined at the company’s Arab, Alabama facility. With the ability to simultaneously measure up to 99 dimensions, and do so in less than 3 seconds, the Instant Measurement gives Orchid employees a tremendous increase in the speed and efficiency at which they can measure parts.

It’s a good thing the company bought three of the units; otherwise Quality Control would really have their hands full.

Orchid is a world leader in the design and manufacture of life changing—and life saving—orthopedic implants, surgical instruments, and other medical devices. The company’s mission statement is “To provide an opportunity for people to live a better life.”

That mission pertains to everyone the company touches - the patients treated with Orchid products, the surgeons who use them, their OEM customers, and the employees who make and market a diverse range of spinal screws, fusion cages, fixation plates, hip and femoral stems, as well as the instruments needed to install those components in the human body.

Considering what’s at stake, the company has a strong emphasis on quality, and is registered with the FDA. This is at least part of the reason it partnered with Keyence, as it needed a reliable method of measuring together with a metrology partner that would stand behind its products.

Botta—a self-avowed CMM junkie—says he’s been monitoring vision measurement technology for the past

11 | Industry USA | September 2016

38

NEWS

decade, and made the final decision to go with Keyence during a visit to the 2014 IMTS show.

“I spent an entire day cruising the Metrology hall at McCormick Place. Compared to the other brands, the Keyence has easily twice the measurement accuracy and repeatability. It has the largest measurement stage for ‘‘field of view’’ technology. Also, there are some really neat things about the IM. It has a wide-angle double telecentric lens, so it eliminates the curve you sometimes get when checking a part on an optical comparator. And the programmable ring illumination takes care of any potential lighting problems.”

The news has spread. Botta says he’s been kept busy doing test measurements and pushing the envelope of the system.

“Orchid has purchased some battery-powered carts and made the Instant Measurement mobile. We have integrated the wireless bridge with a mobile power cart solution to optimize the systems mobility on the manufacturing floor.

We worked with the Keyence support staff and our I.T. Department to make this work. Keyence’s support level has been phenomenal. We are able to download part programs and CAD files to the machine, and upload measurement results back to the file server. It’s going to make life very simple for the people on the shop floor.” www.keyence.com/orchid

MORE INFORMATION

Before signing on the dotted line, Orchid sent a test part to Keyence a geared component Orchid was making for a customer in Italy and had previously had trouble getting repeatable inspection results. The Instant Measurement had no problem measuring the spline gear’s pitch, major, and minor diameters, the tooth angle and form, and concentricity, a tall order for many inspection machines.

Based on these results, Orchid placed the order for three IM-6225 “Place-and-Press” Image Dimension Measuring Systems.

the technicians in the lab figured out they could measure multiple parts at a time. The Friday before, our Quality Manager Scott Steelman spent twelve hours measuring a lot of 200 parts. A week later, we programmed the same job on the Keyence system and were able to measure the same 200 parts within 30 minutes. We learned to program and use the machines in only a few short hours.”

“When the machines arrived—and after they were FDA validated—the opportunity to implement this technology exploded,” he says. “Quality planning was asking if we could inspect anything from milled parts to dimensions on laser marking. Our first real big savings happened when 11 | Industry USA | September 2016

39