13 | J A N UA R Y 2 0 1 6
Industry
Asia Pacific THE INDUSTRY MAGAZINE FOR ASIA
OLDHAM NEW 5 YEAR LONG LIFE OXYGEN SENSOR
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PORTESCAP NEW ULTRA HIGH TORQUE 22ECT BRUSHLESS SLOTLESS MOTOR
6 HMS INDUSTRIAL NETWORKS PRESENTS NEW SOLUTIONS FOR THE INDUSTRIAL INTERNET OF THINGS
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JUNGHEINRICH INTRODUCES NEW PANTOGRAPH REACH TRUCKS, SETTING SIGHTS ON NON-EUROPEAN MARKETS
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13 | Industry Asia Pacific | January 2016
THE INDUSTRY MAGAZINE FOR ASIA
OLDHAM
PORTESCAP
5
6 SECO TOOLS
8 DE DIETRICH PROCESS SYSTEMS
EMERSON INDUSTRIAL AUTOMATION
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16
VERLINDE
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PEPPERL +FUCHS FACTORY AUTOMATION
7 HMS INDUSTRIAL NETWORKS AB
DE DIETRICH PROCESS SYSTEMS
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14 BUREAU VERITAS
18
JUNGHEINRICH
NORD
OLDHAM
20
22
25
PROSOFT ASIA PACIFIC
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www.industry-asia-pacific.com
VERLINDE
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NEW 5 YEAR LONG LIFE OXYGEN SENSOR
Oldham launches a new long life Oxygen sensor for the OLCT 100.
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he OLCT 100 is a 4-20 mA analog gas transmitter designed for industrial applications in hazardous locations.
The new design is lead free and has an operational life of five years. The range is from 0 to 30% vol. O2 and the sensor operates from -40째C to 50째C continuously allowing new opportunities in low temperature applications. This new Oxygen sensor completes the range of our current 2 year life O2 sensors and carries a full 4 year warranty. For more information, please see the pages for the OLCT 100 on our website www.oldhamgas.com
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NEW ULTRA HIGH TORQUE 22ECT BRUSHLESS SLOTLESS MOTOR
Portescap introduces the newest addition to our Ultra EC™ mini motor platform, the 22ECT brushless motor, designed specifically to deliver ultra high torque in a compact size.
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ith the unique coil technology and a patent pending multipolar rotor design, the 22ECT has been developed to be one of the most advanced and highest performing brushless slotless motors in its class. The 22ECT is specifically optimized for high continuous torque at low to medium speeds, maximizing power between 10 K and 20 K rpm. These motors are capable of delivering 2 times higher continuous torque than comparable BLDC motors of same size over the entire low speed range when used with gears.
Portescap succeeds in providing a high quality, long lasting & high performance brushless motor by optimizing the electro-mechanical motor design and material selection for 22ECT. Due to the multipolar design, these motors possess the torque capabilities of much bigger motors. The advantages of the 22ECT make it a good choice for geared applications because of its minimal speed drop and low motor heating under load. Their low inertia design makes them an exceptional option for applications requiring fast stopping, starting and acceleration.
The 22ECT is constructed with an enhanced high efficiency magnetic circuit that significantly reduces both iron and joule losses, the primary causes for motor stator heating. The result is the new 22ECT stays cooler and offers greater power density than equivalent models within its target operating zone. With maximum continuous torque up to 98.5 mNm and higher stall torque, 22ECT motors are ideally suited for use in applications such as Industrial automation, power tools & robotics.
The 22ECT is available in 60 and 82 mm length versions, with hall sensors and 3 different coils to match your speed and voltage requirements. Upon request, Portescap can provide options for customization including gearboxes, encoders, coil variations and mechanical interface modifications. Portescap is globally ISO 9001:2008 certified, and our production site in India is also ISO 13485, ISO14001:2004 and OHSAS 18001:2007 certified. www.portescap.com
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UMB800
The UMB800 from Pepperl+Fuchs is the world's smallest ultrasonic sensor in solid stainless steel. It is made entirely from FDA-compliant materials. With its large detection range and highly compact design, it opens up new automation possibilities in hygienic applications.
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he new sensors in the UMB800 series feature hygienic housing that is made entirely from V4A stainless steel. The surface roughness of the housing is less than 0.8Âľm, minimizing the risk of microbial contamination. The outer skin is hermetically sealed and free from gaps. The sensor can withstand steam jet treatment and aggressive cleaning agents. It features IP68/IP69K degrees of protection and ECOLAB certification. No cleaning processes need to be changed when the sensor is installed in existing systems. At 18mm in diameter and 55mm in length, the UMB800 is the world's smallest ultrasonic sensor in solid stainless steel. The compact design does not reduce its performance: It provides an exceptionally wide measuring range from a dead band of only 70mm and a detection range of 800mm.
The UMB800 series is primarily designed for use in hygiene applications (food and pharmaceuticals). It demonstrates its strengths when used in applications in aggressive environments, such as in the chemical or vulcanization industry. The same is true for systems in which robust cleaning methods are used. Typical applications include packaging food in thermoformed trays and measuring the fill level in receiving tanks, as well as applications in car tyre production or processes in electroplating and painting systems, e.g., to detect parts moving into and out of an acid bath. www.pepperl-fuchs.com
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The sensor complies with the guidelines of the European Hygienic Engineering and Design Group (EHEDG). All materials are FDA-compliant. The certification covers its specially developed hygienic mounting bracket. No tools are
required for assembly. The sensor is resistant to significant temperature fluctuations and remains functional at a continuous operating temperature of up to 85°C.
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MACHINING SUCCESS REQUIRES A PRODUCTIVE BALANCE
In producing a vast range of parts from widely differing workpiece materials, manufacturers utilise a variety of machining processes. Regardless, the common goal of all manufacturers is to create a certain number workpieces of a desired quality, in a specified amount of time and at an appropriate cost.
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any manufacturers achieve that goal by following a narrow-perspective model that begins with tool selection and application and solving problems on a reactive basis. Reversing that approach, however, can reduce costs and increase efficiency. Instead of waiting for problems to arise and then making adjustments to individual machining operations, manufacturers should focus first on proactive preplanning aimed at eliminating rejected parts and unplanned downtime. After a stable and reliable process has been established, applying the concepts of production economics can help manufacturers find a balance between production rate and manufacturing costs. Then, building on the foundation of secure, economically strong operations, manufacturers can select tools and cutting conditions that will fully optimise the machining process.
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Production economics Prior to taking steps to optimise metal cutting, it is essential that the processes are secure and reliable, minus defective parts or unplanned downtime. Achieving process security requires creation of a stable production environment. The areas manufacturers must analyse include machine tool maintenance, CAM programming, tool holding systems and coolant application. Work handling automation such as 13 | Industry Asia Pacific | January 2016
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pallet or robotic part load/unload systems could be part of the evaluation as well. The art and science of production economics focuses on assuring maximum security in, and predictability of, the manufacturing process, while maintaining highest productivity and lowest production costs. When the metal cutting process and environment are secure and predictable, production economics becomes a two-dimensional pursuit: finding a balance between production output and manufacturing costs that is appropriate for a manufacturer’s specific situation. For example, in mass production of simple parts, maximising output at minimal costs may be the primary consideration. On the other hand, in high-mix, low-volume manufacturing of valuable complex parts, the emphasis must be on total reliability and accuracy before addressing manufacturing costs. Minimising unplanned downtime Maximum utilisation of manufacturing resources requires the minimisation of downtime, which, most simply, is the period when the machine tool is not making chips. Some downtime is necessary and planned. This includes the time spent programming and maintaining the machine tool,
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installing fixturing, loading and unloading workpieces and changing tooling. Manufacturers account for planned downtime in their production schedules. However, production of unacceptable parts results in unplanned downtime. When a rejected workpiece must be remachined, the time consumed originally machining it represents unplanned downtime and is wasted. Traditionally, shops take a reactive approach to reducing unplanned downtime. When a problem halts production, the search for a solution begins. Rather than waiting to react to a negative situation, a better approach is proactive planning that recognises key targets for the operation and steers the process toward them from the beginning. Most shops spend 20 percent in preparation efforts followed by 80 percent implementation and testing. The ideal would be to invest 80 percent in preparation and the rest in implementation and adjustments if necessary.
Micro versus macro The traditional approach to maximising metal cutting output involves a narrow-perspective micro model based on optimisation of individual tools in individual operations. Macro models, on the other hand, consider manufacturing processes from a broader perspective. These models concentrate on the total floor-to-floor time required to produce a given workpiece. The relationship between the micro and macro economic models can be compared to an artist’s perspective when creating a painting. The micro model concentrates on individual details, in the same way that an artist would concentrate on individual brush strokes. The macro model steps back and views the part production process overall, as in viewing a painting in its entirety. It is clear that attention to detail is necessary, but not at the price of ignoring the overall purpose of the effort.
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In preparing for a machining operation, a shop should analyse its targets and develop reliable processes to achieve them. The primary target is not always increased production rates. Although some manufacturing situations, such as automotive part production, remain true examples of high-volume mass production, manufacturing in general is moving more towards high-mix, low-volume scenarios.
In mass production, losing 50 or 100 parts when developing a machining process that will turn out hundreds of thousands of parts over a long period of time represents a tiny percentage of the overall volume and can easily be absorbed. However, in a high-mix, low-volume situation, the process must be as fully developed as possible before partmaking even begins. High-mix, low-volume scenarios can involve small batches, single-digit lot sizes or even custom one-part runs. In these cases, rejection of a few parts represents the difference between a profit and a loss.
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Hidden costs Exaggerated fixation on detail can distract attention from the final outcome of the process. For instance, it is a disadvantage to reduce cutting time by ten seconds when it is achieved with an extra tool that adds ten minutes in setup and indexing time. Similarly, working to achieve product quality beyond customer requirements will increase costs and production time. Almost seriously, one could ask, “How long would it take, and how much would it cost, to produce the worst workpiece possible, which is still functionally acceptable?” Operating costs Models for machining costs can also represent microand macro-perspectives. Micro-models consider cutting processes from a narrow viewpoint, linking cutting conditions directly to cutting costs. Macro-economic models work from a broader perspective, emphasising the overall time required to produce a given workpiece. Manufacturers measure production rate in various ways, from workpieces completed over a period of time to the total length of time required to finish an operation. Many factors affect production rate, including workpiece geometry requirements and material characteristics, product flow throughout a facility, personnel input, maintenance, peripheral equipment and environmental, recycling, and safety issues (see sidebar).
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Some elements of manufacturing costs are fixed. Workpiece complexity and material generally dictate the type and number of machining operations required to make a part. The costs of acquiring and maintaining a facility’s machine tools and the power to run them are basically fixed costs. Labor costs are somewhat more flexible, but are effectively fixed for at least the short term. These costs must be offset with revenue from the sale of machined components. Raising production rate – the speed at which workpieces are converted into finished products – can offset fixed costs. 13 | Industry Asia Pacific | January 2016
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Individual optimisation After the overall productivity and cost efficiency picture of a process is balanced and optimised on a macro basis, manufacturers can achieve further improvements by careful optimisation of individual operations. Cutting conditions – namely depth of cut, feed rate and cutting speeds – play a key role in balancing productivity and costs. Any or all of the three can contribute to reductions in machining time, but the impact of each on reliability of the process varies widely. Depth of cut essentially has no effect on tool life. Feed rate affects tool life slightly. However, the impact of cutting speed on tool life, as well as on the reliability of the cutting process, is significant. Many shop managers believe that simply increasing cutting speeds will produce more parts per period of time and thereby reduce manufacturing costs. Usually that is true, but tradeoffs are involved. In general, the faster an operation runs the less stable it becomes. High speeds generate more heat that affect both tool and workpiece. Tool wear occurs faster and is less predictable, and tool wear or vibration can cause part dimensions to vary and surface finish to decline. A tool may break and mar the workpiece. In addition, a process operating at the outer boundaries of reliability is typically unable to run untended or semi-tended, eliminating a potential source of labor savings. Extremely high cutting speeds and aggressive machining parameters can increase machine maintenance costs and even downtime resulting from machine failures. Recognising these issues, American mechanical engineer F.W. Taylor, at the beginning of the 20th century, developed a model for determination of tool life. The model shows that for given combination of depth of cut and feed there is a certain window for cutting speeds where tool deterioration is safe, predictable and controllable. Taylor’s model makes it possible to quantify the relationship between cutting speed, tool wear and tool life, balancing cost efficiency and
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productivity and providing a clear picture of the optimum cutting speed for an operation. In general, manufacturers should select the largest depths of cut and highest feed rates possible for each operation, subject to the stability of the tool clamping, workpiece fixturing and machine tool, as well as the machine tool’s power. Operational safety, in regards to chip formation and evacuation, vibrations and workpiece deformation, also must be considered. A balanced approach involves reduced cutting speeds matched with proportional increases in feed rate and depth of cut. Utilising the largest depth of cut possible reduces the number of cutting passes required and thereby reduces machining time. Feed rate should be maximised as well, although workpiece quality and surface finish requirements can be affected by excessive feed rates. In most cases, increases in feed rate and depth of cut while maintaining or lowering cutting speeds will produce metal removal rates equal to that achieved by higher cutting speeds alone. Production costs are the sum of tool costs and machine costs. With increasing cutting speeds, machining times become shorter and machine costs decrease. However, from a certain point overall costs rise because shorter tool life increases the cost of tooling and tool change times enough to surpass the savings in machine cost. When a stable and reliable combination of feed rate and depth of cut has been reached, cutting speeds can be used for final calibration of the operation. The target is a higher cutting speed that reduces machine time costs but does not excessively raise cutting tool costs via accelerated tool wear. Non-cutting issues Environmental and safety issues represent increasingly important factors in production economics. Manufacturers are under pressure to conserve energy. Use and disposal of coolants and cutting oils is increasingly regulated and expensive. A balanced approach to cutting conditions can help manufacturers deal with these and similar concerns. Lower cutting speeds combined with increased feed rate and smaller depths of cut reduce the amount of energy required to remove metal. Balanced conditions also increase tool life, reducing tool consumption and disposal issues. Lower energy consumption results in reduced generation of heat, offering opportunities for minimal- or zero-coolant machining.
www.secotools.com By: Patrick de Vos, Corporate Technical Education Manager, Seco Tools
The benefits of viewing machining processes from a macro perspective extend beyond individual metal cutting operations. A broad view considers the interrelation of all the steps in production. A simplified example involves two machine tools employed in a series to produce a component. If machine tool A is optimised to boost its output but the results from machine B can’t be improved, parts from the first machine will sit waiting for the second as semifinished inventory, increasing costs. In this case, simply optimising cutting costs (rather than output) on the first machine would lower machining cost overall while maintaining output. On the other hand, in a situation where machine B sits idle waiting to process parts from machine A, increasing the output of the first machine will increase total output. Much depends on whether the shop’s production flow is organised in a line, batch or parallel sequence. Machine tool acquisition costs can also be evaluated relative to a manufacturer’s business overall. A typical situation involves a shop running a milling machine fully loaded 40 hours a week and deciding to replace it with a more expensive, more sophisticated, higher-speed machine. However, when the new machine is up and running, it spends half the time standing idle. The shop faces the challenge and expense of finding more work to keep the new machine busy and justify the investment in it. Further, work that takes full advantage of the new machine’s capabilities may not be a good fit with the rest of the shop’s operations or markets. The better path would have been to first examine the bigger picture and anticipate what would result from the new machine’s greater output. A less expensive, less advanced machine may be a better match with current and anticipated part requirements and production volumes. Paired with the older machine, a more carefully chosen machine tool could also provide expanded flexibility and redundancy to handle scheduled or unscheduled machine downtime. Taking a comprehensive view of process optimisation can also involve very basic, simple actions and analysis. Examination of used tools provides a broad view of what is going on in a workshop. For example, if a shop generally uses inserts with 12-mm-long cutting edges but wear patterns on the tools only reach 2 mm or 2½ mm, the shop is probably using inserts that are much too big for what they do. Tools with 6-mm cutting edges would be more than sufficient, and a tool with 6-mm long cutting edges is significantly cheaper than a tool with a 12-mm cutting edge. Such a simple observation can reduce tool costs by 50 percent without affecting productivity.
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Conclusion Adopting production economics concepts requires making an overall analysis of the machining environment and accepting ways of thinking that are counter to many established metal cutting practices. But, carrying out the recommended strategies can improve cost savings and workpiece quality and enable more environmentally friendly production, while at the same time maintaining productivity and profitability in a stable and reliable manufacturing process overall.
FACILITY-WIDE PERSPECTIVE
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HMS INDUSTRIAL NETWORKS PRESENTS NEW SOLUTIONS FOR THE INDUSTRIAL INTERNET OF THINGS
HMS Industrial Networks presents a number of new industrial communication innovations for the Industrial Internet of Things. The new solutions and prototypes enable communication between operational technology (OT) on the factory floor and Information Technology (IT) resulting in unprecedented efficiency gains.
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The benefits of Industrial IoT Building on 25 years of experience in industrial communication, HMS’s Industrial IoT solutions are a gamechanger for many machine builders and plant owners. For example, they allow machines to communicate their operation status to IT systems enabling predictive maintenance. They also allow machine builders to become service providers and sell maintenance as a service. IT systems can analyze information from real-time industrial systems and present KPIs and statistics from previously unattainable OT systems.
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IT/OT Bridging solutions New “edge connectivity gateways” enable access to OT information from the IT-level giving business intelligence systems unprecedented access to live information from production facilities. Among other things, HMS presents new gateways for connecting PROFINET and PROFIBUS to .NET on the IT level. Another piece of news is an “embedded IIoT” solution where integrated Anybus chips, bricks and modules open a direct channel to the IT level making the host machine “IIoT-ready.” Cloud solutions HMS’s proven and trusted Netbiter solution already connects thousands of drives, generators, UPSs and other OT-machines to the cloud where they can be monitored and controlled remotely. HMS now presents new solutions for connectivity to 3rd party clouds such as Thingworks, Oracle and SAP. Connection to these clouds can be made using HMS’s new IT/OT bridging solutions.
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PROFIBUS/PROFINET to .NET gateways and solutions for embedded IIoT.
Industrial Networking HMS’s current product portfolio for industrial networking is already connecting more than 3 million automation devices around the world. Many of these devices get connected to some kind of controlling system – a basic form of IIoT. At the SPS/IPC/Drives fair, HMS also presents a new OPC UA solution for the German “Industrie 4.0” initiative meaning that an OPC UA server is offered inside the Anybus communication solutions providing data from the factory floor.
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“For us at HMS Industrial Networks, the Industrial Internet of Things is nothing new,” says Jörgen Palmhager, COO, at HMS Industrial Networks. “We have been ‘Connecting Devices’ for more than 20 years and enabled millions of machines to communicate with controlling networks. Through our HMS Labs initiative, we have been working with Industrial IoT for several years and while other companies are still discussing IIoT roadmaps, we are presenting actual prototypes, products and solutions – innovations which will provide substantial value as users can do predictive maintenance, KPI-follow-up, machine analytics, data mining, big data processing, production statistics and much more. Industrial IoT will be a game-changer for many automation companies and HMS is technologically very well positioned to help customers realize the promises of IIoT. ” www.hms-networks.com
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DE DIETRICH® EMBRACES GREEN CHEMISTRY AND ESTABLISHES A PARTNERSHIP WITH SAS PIVERT Designing sustainable and competitive chemical processes.
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n April 2015, De Dietrich® and SAS PIVERT signed a partnership agreement to equip the BIOGIS Center and to combine the resources of both companies to develop innovative plant-based chemistry solutions. This partnership allows both companies to share their expertise and industrialize new processes using bio-based raw materials, particularly oilseed biomass. “Sustainable development is a value shared by both of our companies. We are very pleased to initiate this partnership.” declared De Dietrich® President and CEO Daniel Steck at the time. “Research advances in catalytic chemistry require adaptable equipment capable of working in diverse conditions in order to develop sustainable and competitive solutions. We work towards this goal with De Dietrich, to develop innovative plant-based chemistry solutions.” declared SAS PIVERT CEO Gilles Ravot.
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The BIOGIS Center is equipped with a complete and innovative reaction and distillation system which is entirely remote controlled (utilities and automation), allowing distillations and reaction mixtures (homogenization, suspension, dispersion, crystallization...) to be performed on a variety of oilseed biomasses.
Within this partnership, De Dietrich® contributes its particular expertise in managing projects and studies up to their market release, as well as carrying out user training. The new processes designed within the BIOGIS Center will allow SAS PIVERT's industrial partners to be at the cutting edge of innovation in plant-based chemistry. Thanks to this partnership, new molecules and new processes stemming from research will be available for industrial use. Opening up innovation, from plants to chemistry BIOGIS Center is a unique technological platform dedicated to the development of plant chemistry products and processes designed to valorise the entire plant. Operational since autumn 2015, it includes several thematic labs including a catalytic chemistry lab operated under the aegis of the partnership. The processes developed are guided by the principle of sustainable development, using a renewable raw material that is both promising and competitive: oilseed biomass. Drawing on its expertise and experience, De Dietrich® has developed solutions and equipment aiming on the one hand to transform plant-based material and on the other hand to optimize the energy consumption of this type of material. www.dedietrich.com
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DE DIETRICH EXPANDS ITS ENAMELLED PIPING RANGE!
By reorganizing its product range, De Dietrich aims to become a major player on the piping market for the chemical and pharmaceutical industry.
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s a key leader in the enamelled equipment sector, particularly in reactors, De Dietrich relies on its technical expertise to propose a standard range of enamelled piping, which is both attractive and available at short notice. In order to meet the market's objectives, the company has made a stock of over 12,000 items available, covering the whole range of the sector's standard needs. The process peripherals (piping, pumps, valves, columns, gaskets, etc.) are components that are as important as the “heart” of the system. The De Dietrich glass-lined piping range thus benefits from the same quality of enamel as used for the reactors. A distinctive feature of De Dietrich's enamel is that it is manufactured on-site, in France, allowing control over the quality of the Group’s whole range of equipment.
Corrosion-resistant, non-adhesive, pure, easy to clean and without catalytic effect, the components of De Dietrich piping are used by over 200 clients worldwide, in a quality that has made the company's success. Another distinctive feature is the company's engineering and consultancy skills, allowing it to take part in large-scale projects. Worldwide, clients can rely on the group's expertise in selecting the standard product best suited to their needs in order to optimize the operating life and the dimensioning of the equipment. De Dietrich can additionally provide tailor-made solutions when required. MORE INFORMATION
The current piping range is particularly suitable for transporting acid and alkaline fluids, abrasive solutions and high-temperature fluids in atmospheric or pressure conditions and in vacuum-high vacuum application in combination with temperature. In that last case the plastic lining have problems with accidental collapse.
Our range is designed for projects of all sizes and types: new installations or maintenance, always respecting the requirements of the most demanding markets.
Finally, the glass-lined piping range is offered at highly competitive prices, making it the most attractive offer in terms of cost-performance ratio. www.dedietrich.com
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POWERDRIVE FROM EMERSON HELPS WIDER YACHTS ACHIEVE 20% FUEL SAVINGS
A luxury yacht manufacturer is using Powerdrive MD2 modular drives from Emerson as part of a unique power management system.
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he application forms part of a bespoke system which delivers a 20% reduction in fuel consumption and allows the yacht to travel further between refuelling.
WIDER Srl, based in Castelvecchio di Monte Porzio, Italy, specialises in the design and construction of composite and aluminum pleasure craft with a strong focus on outstanding performance combined with low fuel consumption. The company’s Superyacht Division, where yachts up to 165ft are manufactured in aluminium, is located at the company’s satellite facility in nearby Ancona, which offers direct access to the sea.
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The vessel, which features diesel-electric propulsion, is equipped with four MAN engines. Each engine is connected to an alternator to produce 350 kW of power that drives azimuthal pods. “The power generated can be stored in lithium polymer battery banks, allowing the yacht to cruise completely
under electric power and in total silence,” said Tilli Antonelli, founder and CEO of WIDER Srl. “Importantly, the propulsion system is managed by the proprietary Wider Management System (WMS), which was developed conjointly by WIDER’s engineering team and Emerson.” Four variable speed generators deliver electrical power to the super yacht, with diesel engine speed controlled by the WMS featuring Powerdrive MD2 modular drives. This ensures the engines run at best efficiency in any cruising conditions to optimise overall consumption and maximise comfort for those sailing on the vessel. A DC variable voltage switchboard with a working range of 500-750V distributes the generated electrical power. Here, power levels are adapted instantly to the requirements of the system with the support of a battery pack. Of significant note is the fact that the super yacht can spend an entire night at anchor without ever having to start a generator as the entire hotel load can be run from the batteries, offering clear benefits in terms of fuel savings and comfort on board. “Traditional yachts run the generators at a constant speed and produce a fixed output,” explained Mr Antonelli. “This is often too much or too little for the yacht’s needs, and as
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a result they are in frequent need of services and overhauls. The same is true of a yacht’s engines – these run at varying speeds according to requirements, consuming vast amounts of fuel and demanding regular attention and service.” The diesel electric system on board the WIDER 150ft super yacht is different. By connecting MAN engines to alternators they can be employed as variable speed generators, producing only as much power as necessary at any given time. This results in greater efficiency from the engines – the engineering team at WIDER estimates fuel savings of up to 20% are achievable (depending on usage) compared with the same boat using traditional twin screw propulsion. At 11 knots it gives the super yacht a range of 4,200 nautical miles between refuels, a substantial distance for a vessel with a fuel capacity of 45,000 litres.
voltage stabiliser, thus eliminating voltage spikes that can be harmful to appliances. The battery banks are connected to a DC distribution bus that works at a nominal 675V DC, guaranteeing considerable power to the vessel but also allowing enormous flexibility in the way that the power is managed. Everything is controlled by the power management system, which governs power generation, flow and storage. The number of generators that are running and their speed is checked constantly against the vessel’s requirements for safety, the demand for power and the state of the battery banks. A power management strategy can even be adopted to cater for specific requests from the yacht owner, such as noise reduction, high performance, zero emissions or night mode. Each profile can be selected manually.
“The Powerdrive MD2 drives help make this possible, with power from the generators or the battery banks converted into what is needed at the time,” said Mr Antonelli. “This always assures the best performance in terms of consumption and efficiency – taking into account the overall demand for power on board.”
“We are the first yacht builder in the world to offer luxury yachts in this size range with diesel-electric propulsion combined with azimuthal pods,” said Mr Antonelli. “In fact, the 150ft model is the first super yacht produced by WIDER and the entire range (including 125ft and 165ft models) will be powered by Emerson solutions.”
Powerdrive MD2 is a range of high power, compact and userfriendly modular drives. The combination of power modules and choice of cooling methods make it possible to achieve multiple optimised configurations: six-pulse, low frequency harmonics, regenerative or DC bus solution. Powerdrive MD2 provides high performance motor control, making it the ideal choice for any industrial or commercial variable speed application up to 2,800 kW.
“Emerson is now a dedicated and trusted partner of WIDER and was instrumental in the development of the power management system,” added Mr Antonelli. “They recognised our needs and developed an innovative solution that provides us with a distinct competitive advantage.” www.emerson.com
A further benefit of the greater efficiency achieved on the WIDER super yacht through the use of variable speed generators and the power management system, is that it produces less noise and vibration. This results in greater enjoyment on board, which is the basis of WIDER’s philosophy to yachting, as well as longer intervals between maintenance.
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“As a result of running efficiently, maintenance such as checking for exhaust build and dirt/grime on the generator valves is reduced,” said Mr Antonelli. “Additionally, although we have four generators, it is likely that most of the time only one or two will be used, together with the batteries, which means less hours/miles on the clock and less maintenance. It should even be possible to extend intervals between standard maintenance tasks such as oil and filter changes as the engine hours are managed more efficiently than on a standard yacht.” Another important and beneficial feature of the design is that the Powerdrive MD2 drives convert the power from AC at the generators, to DC at the battery banks, and back to AC again when it powers the azimuthal pods or the appliances on board. This guarantees the greatest possible efficiency for the propulsion system, but also acts as a 13 | Industry Asia Pacific | January 2016
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ISO 9001 AND 14001 2015 REVISION: BUREAU VERITAS LAUNCHES INNOVATIVE OFFER TO HELP COMPANIES WORLDWIDE GAIN CERTIFICATION
The second half of 2015 sees revisions to ISO 9001 and ISO 14001, the globally recognized standards in quality and environmental management systems. Following the new revision, and with the deadline for transition set for 2018, Bureau Veritas is launching a suite of tools to help companies achieve the new standards and retain certification, or target certification for the first time.
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ureau Veritas has created LEAD: a unique offer and approach to support companies all over the world in the three-year transition process. LEAD was developed in collaboration with clients, following a worldwide survey to fully understand their needs. It includes an all-in-one service pack, a cost-effective way to help clients move through the process with confidence. New, innovative tools enable clients to train themselves and assess the gap between their current situation and the future standard they want to reach, via e-learning courses and an online gap analysis tool.
Companies can choose between different levels of support: the essentials pack helps them prepare the first steps of their transition, while the complete pack enables them to manage all their transition and certification needs with Bureau Veritas. Companies will gain support in analyzing their requirements worldwide, and have access to advice, training sessions and audits on a country-by-country basis, thanks to Bureau Veritas’ network of experts around the world.
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As part of the LEAD project, the Group has also created a dedicated website, www.revision2015.com, providing clear information on the new standards, and the steps that companies currently certified to ISO 9001 or ISO 14001 should take to retain certification. More than 80,000 Bureau Veritas clients have already visited the website, which will be continually updated with news and information on the revision.
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Bruno Ferreyra, Executive Vice President for Industry and Facilities at Bureau Veritas, said: “The new revision is the clear proof of the continuous improvement in the standards. With the LEAD offer, Bureau Veritas aims at helping clients to make the most of the changes and set the stage for a long-term growth” Commenting on the revision, Sébastien Fox, Head of Bureau Veritas Certification, said: “The 2015 revision offers some significant benefits, including the ability to integrate quality and environmental management systems, more flexibility in use of documentation, and less directive requirements. Its emphasis on risk-based thinking also helps identify opportunities and targets long-term customer satisfaction and improved environmental performance.
www.revision2015.com www.revision2015.com/wp-content/themes/bureau_ veritas_site_iso/pdf/LEAD_brochure_web.pdf www.revision2015.com/category/watch-our-videos-andread-the-interviews-with-our-certification-experts/
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As a trusted partner, Bureau Veritas is working alongside its clients to enable them to move through the transition process with confidence. Our LEAD offer, with its innovative set of solutions, enables companies to meet the demands of the revised ISO 9001:2015 and ISO 14001:2015 standards in the way that best suits their organization: via a turnkey solution, or customized support.” The service packs are already available. Services such as training, gap analyses and audits are also available separately. 13 | Industry Asia Pacific | January 2016
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JUNGHEINRICH INTRODUCES NEW PANTOGRAPH REACH TRUCKS, SETTING SIGHTS ON NON-EUROPEAN MARKETS
Compact design for narrow drive-in racks / Adjustable fork carriages provide for high residual capacity / Intuitive operation, thanks to ergonomic Multi-Pilot control handle / Assistance systems guarantee high rate of efficiency.
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hese days Jungheinrich has launched two new series 2 pantograph reach trucks – vehicles which sport a particularly compact design and a lifting capacity of up to 1,600 kilogrammes, tailored specifically to the requirements of the North American market. Developed by the Jungheinrich Design Centre in Houston, Texas, this type of truck is also suited to numerous applications in other markets, including South America, the APAC region and the Middle East. These ETR 230 and ETR 235 trucks complement the existing 3 series with lifting capacities of up to 2,000 kilogrammes.
For High Throughput Even in Tightest of Spaces In contrast to conventional reach trucks, where the mast moves along the baselegs when handling pallets, the ETR mast is permanently fixed to the chassis. A movable fork carriage in the form of a pantograph performs the reaching and tilting functions. This makes the truck highly compact and, owing to its fixed mast which serves as a counterbalance, gives it a high residual lifting capacity – even at high lift heights. The driver can manoeuvre comfortably in narrow aisles and drive up extremely close to the racks to load and unload pallets quickly and safely.
“Our ETR 2 pantograph reach trucks are designed primarily for North America, but also for other important nonEuropean markets,” explains Philipp Tielmann, Product Manager at the Jungheinrich Lift Truck Corporation in Houston. He continues: “Our clients in these regions are increasingly going over to compact vehicles with high residual lifting capacities. Their pallet sizes are also different from the ones used in Europe, so they consequently require adjustable baseleg widths.”
Jungheinrich has given its ETR 2 pantograph reach trucks an even more compact design to facilitate manoeuvring in tight spaces. The result is that the minimum working aisle width is now more than 30 millimetres smaller than before. “The new masts are around 50 millimetres narrower,” remarks Tielmann, “making the pantograph reach truck ideal for applications in extremely narrow drive-in aisles.” A new, extra-narrow battery compartment – optional for the ETR 230 – further reduces the working aisle width by an additional 50 millimetres.
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battery recharge is required. To adapt the forklift to specific applications the driver can make numerous settings in advance. “The comfortable, user-friendly features of this pantograph reach truck make the operator’s job easier and are beneficial to health and safety,” says Tielmann, adding that this was also “indispensable” to helping the operator increase the truck’s level of throughput. Assistance Systems and Numerous Options Enhance Safety and Efficiency By providing a large selection of assistance systems Jungheinrich has further facilitated the operator’s work. The “SNAP” function for example involves the semi-automatic preselection of rack height. By “snapping” out the control element the truck automatically recognises the targeted rack position; it is no longer necessary to manually select the height.
High Rate of Efficiency for Intensive Operations As with all Jungheinrich pantograph reach trucks, the powertrain components in the ETR 230 and ETR 235 are ideally harmonised and designed for maximum efficiency. A high-performance 36-Volt three-phase AC motor provides for powerful acceleration at travel speeds of nearly 12 kilometres per hour. “With a lift speed of 0.6 metres per second and lift heights of up to 7.6 metres, the truck provides for fantastic productivity,” reports Tielmann. The vehicle also possesses a high rate of energy efficiency, running for two shifts on a single battery charge, making the ETR “ideal for intensive, extended applications”, according to Tielmann.
Jungheinrich ranks among the world’s leading companies in the material handling equipment, warehousing and material flow engineering sectors. The company is an intralogistics service and solution provider with manufacturing operations, which offers its customers a comprehensive range of forklift trucks, logistics systems, services and advice. Jungheinrich shares are traded on all German stock exchanges. www.jungheinrich.com
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Ergonomic, State-of-the-art Workstation In designing the new pantograph reach trucks, Jungheinrich also placed a premium on ergonomics in order to reduce premature driver fatigue. The entry step is substantially lower and the driver’s cabin is generously dimensioned. Using the Multi-Pilot function the driver can safely and intuitively operate the vehicle. This multifunctional lever combines all the driving and hydraulics functions in a single control handle. All controls can be easily activated without needing to grip around the handle, with the operator’s hand resting comfortably on the ergonomic grip. The control handle also allows the driver to simultaneously activate the various hydraulic functions.
Numerous optional features are available for the ETR 2 pantograph reach truck series to guarantee the ideal tailoring to the relevant application profile. This includes 17 different base leg openings, ranging from 839 to 1,245 millimetres and eight different load wheel configurations. In addition the customer can select from among seven different mast heights of 4,953 to 7,595 millimetres. A fork camera facilitates safe load handling from any pallet position. And Jungheinrich also has a comprehensive optional package of features for refrigerated warehouse operations.
Sporting a total of six soft keys, the new high-grade colour display provides the driver with all the key operating data – for example indicating the remaining time until the next 13 | Industry Asia Pacific | January 2016
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DRIVE SYSTEMS PROVIDE CONVEYING POWER IN GRAIN MILL
Managing director Walter Arnreiter greatly values ecologically sound business practices.
Arnreiter products: rye/maize flour and rye/maize extrudates.
Gone are the days when mills depended on a strong stream of water or steady wind to power their wheels. In today’s mills, electric drives carry out various tasks, ensuring efficient and reliable performance. A special challenge lies in the fact that grinding is bound to create dust atmospheres that call for safe, explosion-proof drive configurations.
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he manufacturer NORD DRIVESYSTEMS has decades of experience in the industry and, drawing on a complete range of mechanical, electric, and electronic drive components, can swiftly provide suitable systems for any of the various applications in a grain mill, for instance fans and bucket elevators.
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Based in Wallern in Austria, Arnreiter Mühle processes grain, malt, and oilseeds mostly for the baking and food industry. The family-owned mill has a history of nearly 200 years. Since the early 20th century, it has been continuously modernized and expanded. 2009 saw the most recent exhaustive modernization. A high-capacity mill with separate, stateof-the-art grinding technology and refining facilities was erected. The new building accommodates a wide range of processes that are carried out with a high degree of automation. Grist shape and characteristics are modified by means of steaming, flaking, crushing, grinding, extruding, roasting, cooling, drying, and husking. Thereby, shelf life, 13 | Industry Asia Pacific | January 2016
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digestibility, and baking properties are improved and bitter constituents are reduced. Parallel and integrated processes The Arnreiter mill has a 1,400 kW connected load. Up to 80 tons of grain can be ground daily. In addition, the refining facilities have a capacity of up to 20 tons per day. All processes, from raw produce storage to bagging and loading, are automated. There is control level access to all applications via Profibus. “We need highly flexible facilities,” says Walter Arnreiter, managing director of the mill. “First of all, they must enable variable and parallel processes with separate product flows and additives that can be released from one source into different lines. And we must also ensure product flow with minimal residues.” The main raw materials are temporarily stored in silos located in the upper stories. Geared motors from NORD DRIVESYSTEMS drive the belt and bucket elevators that transport the materials from there. Consecutively, the major part of all product
Geared motors drive the belt and bucket elevators that are used to transport raw materials from the silos.
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Micro proportioning unit: NORD drives ensure that the precise amount of specific ingredients are added to the product stream.
transport takes place in the extensive pipe system that has a total length of 2,500 meters. Free-flowing and non-flowing products are volumetrically dispensed by means of a great number of rotary dischargers, all of which need reliable geared motors. “NORD systems carry out many different tasks in our machines,” says Arnreiter. Explosion protection is prerequisite Mill operators must implement a proven, absolutely reliable explosion protection regime since the dust atmospheres prevalent in many areas pose a high risk. NORD DRIVESYSTEMS can supply explosion-proof versions of all drive components, geared motors as well as mechatronic units and cabinet inverters. More than 1,500 explosionprotected drive systems leave NORD production facilities every month. This includes dust explosion protected systems for zone 21 (device category 2D/zone 21) as well as gas atmosphere systems for zone 1 (device category 2G/ zone 1 and 2, and 3G/zone 2). Arnreiter employs category 3D drives in zone 22.
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Clean application The machines used in the Arnreiter mill are mostly systems made by Swiss process engineering specialist Bühler who has been working with NORD for many years and who installs NORD drives in a great number of machines. Separators and aspirators from Bühler are used to clean and classify granular products such as wheat, rye, barley, oat and maize. Air-recycling aspirators remove dust and husks etc. A radial fan creates an air current to lift the medium and blow the low-density particles into a special separator from where they are discharged by a screw conveyor driven by a NORD helical geared motor. The clean heavy product is discharged from the machine through finger valves.
A great number of explosion-proof NORDBLOC.1 helical geared motors drive rotary dischargers, for instance after the scale that tallies the grinding yield.
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Additional rotary dischargers are employed in the flour silo, e.g. after weighing.
Automatic separation: A NORD helical geared motor drives the screw conveyor that removes low-density particles.
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Sustainable management “Food safety, product quality, and ecological as well as economical sustainability are all crucial and equally important for us,” says managing director Walter Arnreiter. “All processing steps are subject to strict controls and are continuously being documented. We buy most of the raw materials from regional producers or suppliers and process them in a resource-conserving fashion. Part of the energy for our production facilities is generated in our own water mill. We furthermore recycle a lot of the waste heat by means of a rotation heat exchanger and reuse it for heating. Since we carry out various processes in-house, further processing elsewhere is hardly ever necessary, which helps reduce road transportation.” Production is compliant with food and ecological standards. Ingredient traceability according to HACCP is ensured for all batches. “All raw material shipments are strictly quality-controlled,” Arnreiter says. Naturally, the technology partners are expected to demonstrate a similar commitment to sustainability. “We rely on low-maintenance drives from NORD which we employ in continuous operation mode. They perform reliably. If we eventually do need to repair or replace a product, we can simply call our NORD contacts directly, and they will promptly get the job done,’ says Martin Rachbauer, maintenance manager at Arnreiter. www.nord.com
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The pipe system has a total length of 2,500 meters.
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NEW CO2 DETECTOR
Oldham is pleased to announce the launch of the new CTX 300 CO2 detector.
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he CTX 300 is a 4-20 mA analog detector designed for industrial applications in areas without explosion hazard classifications. The detector can connect to more than 30 different factory pre-calibrated sensors to prevent exposure to highly toxic and/or corrosive gases. Designed to detect toxic gases, oxygen and refrigerant gases, the CTX 300 uses a new sensor for CO2 detection over three different ranges: 0-5000 ppm, 0-5% vol. and 0-100% vol.
For versions without displays, the operating temperature range is from -40째C to +50째C, allowing for new applications in extreme cold areas. For more information, please see the pages for the CTX 300 on our website www.oldhamgas.com
The output signal is now open-path over the three measurement ranges, without the need for a supplementary processing card. A version with a display is also available, and accessories for the standard CTX 300 are compatible with the CTX 300 CO2. MORE INFORMATION 13 | Industry Asia Pacific | January 2016
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OFFSHORE RANGE
VERLINDE's Offshore lifting equipment range is designed to be used in maritime areas, on oil rigs, cargo vessels or wind farms. The range includes all types of lifting equipment together with their components: jib cranes, electric chain or wire rope hoists, winches, overhead crane components, etc...
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s the unique source of hoisting resource supplies, VERLINDE is able to ensure total coherency and compatibility of equipment you choose to operate. Most models are also available as EX ATEX compliant. The very tough but light materials, combined with the facility of running the equipment, simplifies maintenance of the Offshore range and also reduces the number of operators required for servicing. Made up of non-corrosive materials, most models' protection is enhanced by additional powder coatings (epoxy, polyester or epoxy-polyester) specific to maritime environments or an aluminium oxide ceramic coating or a combination of both. Much of the equipment is also available as EX ATEX compliant.
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The manual hoists, of compact design, are designed for vertical handling manoeuvres with no horizontal travel. Models ZHR (500 to 20,000 kg) and ZHV (500 to 50,000 kg) are scaled down in size and weight. Ideal for construction, assembly and maintenance applications. An EX version of them is available with ATEX certification and also a 100% stainless steel version.
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As for hoists combined with travelling trolleys, they are designed for the vertical and horizontal handling of loads. The very compact short headroom design for the combined hoist and trolley unit enables lifting height optimisation in confined spaces. They have a 50 µm epoxy powder coating applied as standard, their hoisting chain is in grade 80 alloy steel with a black oxide corrosion resistant finish, while the hand chain is galvanized. The travel trolleys (500 to 100,000 kg) can be associated with the electric and manual hoists to provide horizontal travel in addition to vertical travel for the manoeuvring of loads. They have a 50 µm epoxy powder coating applied as standard and an aluminium oxide ceramic surface treatment as optional. The treatment consists of applying a fine layer (roughly 3 µm) on components in order to increase surface hardness by some 30GPa (tolerated pressure of 3 metric tons per mm2). In addition to reducing friction between parts to increase their life span, it reduces oxidation and corrosion and ensures electrical insulation. These trolleys are also available with a travel jamming system activated by the hand wheel, a highly practical and safety assurance solution
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to prevent any unsolicited travel of the hoist/trolley unit or of the load in the event of any pitching or rolling motion for vessel-borne installations. Travel jamming system activated by the hand wheel For vertical travel handling, with or without horizontal travel, electric hoists are the most appropriate. The powered mechanism enables more significant loads to be lifted (up to 80,000 kg). A flame proof version of the electric hoist (EUROCHAIN EX) for loads from 125 to 10,000 kg is available. Protection rating as standard is Zone 1, EEx de IIB T4 in compliance with EN/DIN. A flame proof version of the electric wire rope hoist (EUROBLOC VT) is also available. It is rated Ex II 3G c IIB T3 for use in Zone 2. Electric wire rope hoist and jib crane for offshore heliport applications As for EUROSTYLE jib cranes, they are typically used in conjunction with lifting/travel systems. These framing systems enable loads to be shifted during rotation along runways. MORE INFORMATION
www.verlinde.com
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FIRST METRO LINE IN SUZHOU ROLLS ON, THANKS IN PART TO PROSOFT TECHNOLOGY’S MODULES
Picturesque gardens dot the city of Suzhou, in eastern China’s Jiangsu province. Some of these gardens, known as the Classical Gardens of Suzhou, date back as far as the 11th century, and were designed by some of China’s renowned scholars. Nearby, numerous canals crisscross the city that is known as the Venice of the East. Forty-two percent of the city is covered in water through its canals and waterways.
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Suzhou City is one of the most famous tourism cities in China,” said Gary Zhang Zhen Hua, ProSoft Technology China Sales & Technical manager.
“The Metro Line I is the first Metro Line in Suzhou, which goes from west to east, and connects two economic development zones and the downtown,” Gary Zhang Zhen Hua said.
But while the area is likely one of the more picturesque in the world, thanks to its gardens and canals, it is also highly populated with more than 10 million people and is largely industrial. Like many cities in China, automobile congestion is a problem. The city needed to install its first subway system to help alleviate its traffic congestion.
More than 150 ProSoft Technology Modbus to ‘C’ Programmable communication modules were installed in the Metro Line’s Building Automation System, which plays a vital role in the underground tunnels and stations that make up the subway.
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After more than four years of construction, the Suzhou Metro Line I opened in April 2012. It encompasses 24 stations that connect the east side of the city to the west side over about 16 miles. The line extends from the Mudu station in the eastern portion of the city to Zhongnan Jie station in the west, near Suzhou Industrial Park. Metro Line I is the start of a larger subway system in Suzhou. Later this decade, the city will construct Metro Line II, which travels north and south.
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The modules allow Rockwell Automation ControlLogix and FLEX I/O systems to communicate and gather data from ventilation systems, air conditioners, as well as monitor the overall environment inside the subway system. Most people think of a train speeding down an underground tunnel when they think of a subway. A Building Automation System is likely the last thing that comes to mind, but without this critical piece, a subway would not be able to operate.
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“The ProSoft Technology solution is a good one,”said Jianshui Gan, the Building Automation System engineer working on the Suzhou Metro Line I. “We chose ProSoft Technology’s product because they are the communication adapter between field devices and the ControlLogix controller.” More than 200,000 people per day, tourists and Suzhou residents alike, now use the Metro Line to get from one end of the city to the other and avoid automobile congestion. The train rolls on – in part thanks to ProSoft Technology’s modules. For more information and success stories visit our website www.psft.com/AzA
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EUROCHAIN VR16 AND VR25
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VERLINDE’s new range of electric chain hoists, EUROCHAIN VR, has been widened with VR16 and VR25 to cater for loads for up to 5000kg. With its new, entirely ergonomic design, EUROCHAIN VR offers numerous innovations ensuring best safety and productivity levels while facilitating maintenance. EUROCHAIN VR25 hoist EUROCHAIN VR is designed to ensure maximum user safety. The standard version is fitted with a new hoist load wheel concept with intermediate teeth for the drive chain, 2 lifting speeds, a Start/Stop palm button on the control box, a torque limiter, a hoist disc brake, a very low voltage control system (48V), a variable speed travel motor, an electric safety limit switch for high and low positions, and it complies with the EC machinery directive.
EUROCHAIN VR boosts productivity. All models offer a wide range of speeds, 25% faster than that of the previous generation. Furthermore, the standard version of the hoist motor is two-speed providing more flexible operability. EUROCHAIN VR's lifting capacity is up to 2.5 tonnes on one fall (with a 2m classification of mechanism [FEM]) providing the ability to increase lifting heights while reducing chain collector dimensions thus increasing the lifting unit’s compactness.
EUROCHAIN VR16 and EUROCHAIN VR25, latest additions to the range, are high power models. VR16 is designed for handling loads of from 1250 to 3200 kg. 7 x 20 mm or 9 x 27 mm chains are available with 1 or 2 falls and a 12 m or 20 m chain collector. As for the VR25, its lifting capacity ranges from 1600 kg to 5000 kg. 9 x 27 mm or 11.3 x 31 mm chains are available with 1 or 2 falls and a choice between a 12 m or 30 m chain collector.
Lubricated for life to reduce maintenance, the EUROCHAIN VR hoist gear reducer was designed for very long operating periods of up to 3200 hours. High precision machining on the gear trains, moreover, ensures a very low noise pollution level when running. The clutch system is easy of access for occasional maintenance operations and its location in the gear box ensures the load is securely held by the brake whatever the operating conditions of the equipment.
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EUROCHAIN VR16 hoist Numerous options are available on EUROCHAIN VR16 and EUROCHAIN VR25: gear limit switch, second brake on the hoist motor mounted with a lug replacing the top hook, automatic closing of lifting hook, travel limit switch, short headroom trolley, curved track trolley, 2-speed travel trolley (20 & 5 m/min), etc. These two new models will soon be available equipped with EUROCHAIN VARIO variable speed control lifting, fitted as standard with ESR (Extended Speed Range). This option allowing a reduction of cycle time (faster return speed for empty returns) enables it to be graded in a lower classification of mechanism (FEM). This recent feature allows lift speed and motor torque to be dissociated: speed - for the reduction of cycle time to enhance hoist station productivity when running empty, and motor torque - for lifting when loaded to ensure precision travel with a maximum power margin. For more information, visit www.verlinde.com MORE INFORMATION 13 | Industry Asia Pacific | January 2016
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