Industry USA 12

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INDUSTRY INDUSTRIAL MARKET MAGAZINE

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COG RESIST® THE NEW HIGH-TECH FFKM COMPOUNDS FROM COG

6 SCOTT SAFETY LAUNCHES NEW DURAFLOW POWERED AIR RESPIRATOR WITH REALTIME AIRFLOW CONTROL

20 CV-X200 : stabilité, KENNAMETAL précision et vitesse PCD PERFORMANCE uniques

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WIDIA HIGH TEMP TOUGH

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INDUSTRIAL MARKET MAGAZINE

ESPRIT

COG

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DE DIETRICH PROCESS SYSTEMS

7 LEROY-SOMER CONTROL TECHNIQUES

KEYENCE AMERICA

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KENNAMETAL

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STAHL

BALLUFF

HENGSTLER

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16 HMS INDUSTRIAL NETWORKS AB

SCOTT SAFETY - TYCO

EPLAN

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WIDIA

HAIMER

SIC MARKING

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ADVERTISERS: MEPAX 28

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DP TECHNOLOGY CONTINUOUSLY FORGES PARTNERSHIPS WITH ACADEMIA TO ACCELERATE SMART MANUFACTURING

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

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

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

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

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

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

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

NEWS DP Technology application engineers provided training in ESPRIT CAM programming

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

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

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

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

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

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

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

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

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

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

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

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

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COG RESIST® THE NEW HIGH-TECH FFKM COMPOUNDS FROM COG

In all sectors and applications, the requirements are continuously becoming more complex: Not only must seals be resistant to temperature; they must also be able to withstand a wide variety of chemicals and be resistant not only to vapour, but also to solvents. Or they need to be able to resist changes in media, plus high pressure.

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n these situations, a high quality perfluorelastomer (FFKM) seal really is a must. Precisely for these applications, COG has developed a new range of FFKM materials: COG Resist®.

The FFKM product family launches with four compounds: two universal materials, a special FFKM compound for use in the oil and gas industry and a compound for the food and pharmaceutical industry. The two all-round materials, COG Resist® RS 75 AL and COG Resist® RS 80 AL demonstrate outstanding resistance to chemicals and acids, as well as possessing excellent mechanical properties. COG Resist® RS 75 AL is therefore heat resistant at temperatures of up to +325°C, and COG Resist® RS 80 AL is heat resistant up to +260°C. Both FFKM compounds demonstrate low gas permeability and extremely low levels of swelling.

The COG Resist® RS 92 AED seal material was developed especially for applications where resistance to explosive decompression is required, and has been tested to NORSOK standard M-710 and NACE TM 0297. Wherever seal materials are exposed to high pressure and aggressive media, COG Resist® RS 92 AED provides the security you need. The

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compound combines extraordinary chemical resistance with excellent thermal resistance. These properties, along with its low compression set, mean that it is especially suitable for meeting the high demands made by the oil and gas industry in particular, for example, for use in deep sea valves, pumps or compressors.

COG Resist® RS 75 HS can be used with even the very highest demands of the food, medicine and pharmaceutical industries. It has excellent resistance to CIP and SIP procedures and is free from animal-derived ingredients (ADI free). This compound has the approvals/certificates for USP Class VI up to +121 °C, FDA 21. CFR 177.2400 and CFR 177.2600 as well as 3-A Sanitary Standard. The extraordinary material properties that the COG Resist® FFKM seals demonstrate enable a longer service life in an extremely wide range of demanding industrial applications. www.cog.de

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THE VERTICAL DRYER IS AN ADVANTAGEOUS ALTERNATIVE TECHNOLOGY

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

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

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

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

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

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DUDEK AND BOCK: INSTANT MEASUREMENT SYSTEMS MORE THAN QUALITY

Inspection bottlenecks jeopardize on-time delivery and hurt the company’s bottom-line, so how did Dudek and Bock Spring Manufacturing Company instantly solve their inspection problems?

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visit from a key customer’s engineering group is something that many in the contract manufacturing world dread; in some cases, however, that visit reaps great rewards for supplier and customer alike. This was recently the case with Chicago-based Dudek and Bock Spring Manufacturing Company, a leading supplier of metal products to the automotive, appliance, building construction, energy products, and virtually any industry that uses springs, stampings, wire forms, or assemblies.

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One of Dudek and Bock’s customers is a global provider of automotive seating solutions. The Tier 1 manufacturer works closely with its suppliers, not only to assure high quality products, but also in the role of continuous improvement (CI) support on the production floor. Vice-president of Quality Assurance Eipe Varghese became directly involved in one of these CI projects when it was discovered that machine tools were sitting idle for long periods of time during first-article inspection.

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“The team was working on improving the changeover time on one of our wire forming lines,” says Varghese. “This involved single minute exchange of die (SMED) and other Lean practices designed to make the line more efficient while also assuring continued part quality. The problem was that it was taking way too long to inspect the parts and provide the necessary dimensional feedback to the operator so he could make the correct machine adjustments.”

The inspection process for this particular part is intense. The workpiece—a wire form for a headrest locking mechanism referred to by shop employees as “the zigzag part”—has dozens of complex angular, linear, and radial dimensions that were being measured on an optical comparator, each one requiring the time-consuming series of knob turning, crosshair alignment, and manual result recording most quality people are painfully familiar with.

“Each 30-piece sample was taking around 8 hours to measure,” Varghese says. “If there was a problem, they’d have to go back and make adjustments, and then start the process over again. We knew there had to be a better way.”

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The customer’s Global CI Director, who is typically more focused on production improvements rather than metrology, remembered seeing a digital comparator demonstration several years earlier at a spring and wire show in Dusseldorf, Germany. He suggested Varghese contact KEYENCE. “They have an office nearby and were at our facility the next day,” says Varghese. “Once we saw what the machine was capable of, we bought it on the spot.”

The machine? KEYENCE’s IM Series: A digital comparator that uses a high-resolution CMOS camera and intelligent patternmatching algorithms to measure up to 99 dimensions on 100 different workpieces simultaneously. There’s no need for fixtures or clamps—just set the part on the stage and push the measure button. Within seconds, the data is collated, analyzed, and the results displayed on the screen, recorded to a database, and can be printed out immediately for use on the shop floor.

The IM Series may make Luberda’s life easier, but it’s those on the shop floor who appreciate it the most. That’s because the Dudek and Bock quality procedure mandates that two pieces be inspected every time a job is setup. Before the KEYENCE, this took an average of two hours to complete, during which the machine sat idle.

“If we’ve run the job before, they’re in and out of here in a few minutes,” Luberda says. “The other cool thing is that, even if I’m in the middle of a program or something, it’s easy to break in and check a dimension for one of the operators.

I don’t even have to write a report; I just hand him the printout with the results. The IM’s a huge timesaver for all of us. I love it.”

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Quality Manager Casey Luberda was the lead on the new piece of equipment. Luberda jumped right in with the new system, and had the IM largely mastered within a few days.

“It’s pretty simple to operate,” he says. “The person that does the training for KEYENCE in this area has been back several times since, and on each visit shows me little tricks I can do to make my life easier. They’ve been very good to work with.”

Luberda now writes all the programs for the IM and has trained others how to operate it. Compared to an optical comparator, he says it takes roughly one-fourth the time to layout a new part, and “around fifteen seconds” to measure once the program is done. Oftentimes, however, he doesn’t bother writing a program. “For down and dirty measurements, dimensional verifications and such, I find it’s faster on the IM Series than on the mechanical comparator.

You don’t have to worry about positioning the part, you can just throw it up there and tell the computer to check from here to there and you’re done.”

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

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

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

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

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

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

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

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

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Mentor MP420A4R DC drive rated at 420 Amps continuous.

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

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

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

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

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

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

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

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PCD PERFORMANCE

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Marshall recommends presetting the KBDM offline using an optical or video style presetter. A small amount of lubricant should be applied to the adjustment and locking screws, and also the wedge side of the pocket. Turn the axial adjustment screw until the insert is 0.0004 - 0.0006 in. (0.010 - 0.015 mm) below the final set height, tighten the locking screws to 31 in/lb. (3.5 Nm)—don’t overtighten—then adjust each insert 12 | Industry USA | November 2016

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Among the principal advantages is the connection concept of the AX73, which allows the routing of cabling and the

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

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

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

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

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AVAILABLE NOW: EPLAN SMART WIRING “AS EASY AS CAN BE”

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

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

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

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

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

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

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

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

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

Eplan at the SPS IPC Drives Hall 6, Stand 210

MORE INFORMATION 12 | Industry USA | November 2016

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NEWS

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

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

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

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

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

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

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

For further information, please visit www.scottsafety.com

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ANYBUS WIRELESS BOLT CONNECTING DEVICES WIRELESSLY

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

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

www.anybus.com/products/wireless-index/anybuswireless-bolt MORE INFORMATION

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

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

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NEWS

HIGH TEMP TOUGH

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Success with superalloys takes more than a good carbide grade, however. Sperhake also recommends increasing the cutting fluid concentration, and using a high-pressure coolant pump wherever possible. Selecting the right cutter 12 | Industry USA | November 2016

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HEAVY DUTY MACHINING BUT SAFE

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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NEWS

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

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

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

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

HAIMER Safe-Lock™ grooves were subsequently added on similar solid carbide tools, but the application would be run 12 | Industry USA | November 2016

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

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

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

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

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

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

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

www.haimer-usa.com

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

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

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

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

However, the increased cutter engagement and cutting 12 | Industry USA | November 2016

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SIC MARKING CARRIES ON ITS INTERNATIONAL EXPANSION

An increasing worldwide network.

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IC Marking, leader in marking and traceability solutions keeps on going global. This innovative company sells its marking machine in the whole world, thanks to its strong international network composed of 5 subsidiaries in the USA, Canada, Germany, China and since June, South Korea. SIC Marking is also working with 47 distributors, to cover as many countries as possible and to be able to meet customer’s needs everywhere.

Germany succeeds in Europe SIC Marking Germany has welcomed Mr. Endemann last year as the General Manager. One year after, results are very positive and the German company is succeeding. It has even hired three salesperson, to handle different zones and replace sales agents (in Austria and Germany). Figures indicate a double digit growth in the first half of the year, compared to previous year, showing that SIC Marking is able to succeed everywhere.

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New subsidiary in South Korea The 1st of June 2016, SIC Marking, has opened new offices in South Korea, in the south of Seoul. This country has turned itself into an attractive investment destination for foreign investors and has a huge business potential for SIC Marking Group. Indeed, South Korea is the 5th largest car manufacturing for 11 years and has produced 4.14 million units in 2015. Famous car brands such as Kia, Hyundai, Daewoo, Renault Samsung and Ssang Yong represent several dozen of modern plants. South Korean industry is very strong, particularly in shipbuilding, heavy industry, aerospace and defense. South Korean offices will contribute to the expansion of SIC Marking business in South East Asia and will allow the company to be closer of Asian customers.

All information are available on sic-marking.co.kr ‌

SIC Marking USA moves in bigger buildings Following the international growth of SIC Marking, US subsidiary has moved in new offices in Pittsburg, PA (Pennsylvania). New buildings are bigger (4400 sq foot) and more comfortable. This was much needed since US team is getting new employees. Mr. MEJALI, the latest arrived in the team, is the new operations director who will bring his technical expertise in marking machine to answer the increasing market.

www.sic-marking.com

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