Industry USA 14

14 | APRIL 2017

INDUSTRY INDUSTRIAL MARKET MAGAZINE

USA

BETA LAYOUT IS OFFERING THE WORLD'S FIRST FREE 3D-MID DESIGN SOFTWARE

5 EC1 SIC MARKING’S NEW DOT PEEN MARKING SYSTEM

9 KEYENCE

CV-X200 : stabilité, BIDMC DIGITAL MICROSCOPE HELPING HEARTS précision et vitesse uniques

22 50

MAYR THE PERFECT OVERLOAD PROTECTION FOR DRIVES WHICH ARE HARD TO ACCESS

20

14 | Industry USA | April 2017

INDUSTRIAL MARKET MAGAZINE

SOFTING AUTOMOTIVE ELECTRONICS

BETA LAYOUT

5

LEMO

8

6 SIC MARKING

HENGSTLER

SOURIAU

9

10

11

KEYENCE AMERICA

12

ESPRIT

MAYR

14

20

KEYENCE AMERICA

22

ADVERTISERS: MEPAX 4

www.magazine-industry-usa.com

INDUSTRY

USA

Contact: Evans ROSS Editor in Chief: editor@magazine-industry-usa.com Send your press releases to: editor@magazine-industry-usa.com

To receive Industry USA magazine free of charge, please subscribe online at www.magazine-industry-usa.com Industry USA is the US-language magazine for engineers, published by IPM (Industrial Portal Media) It contains the latest product and company news for industrial markets.

Industry USA edits its articles with the greatest of care, however we cannot guarantee the accuracy of the information presented in them. Our teams disclaim all responsibility concerning the content of this media or how it might be used.

INDUSTRIAL

PORTALS MEDIA

OPTIMIZE YOUR INTERNATIONAL PR AND ADVERTISING FOR THE INDUSTRIAL MARKETÂ !

International capability

Outstanding results

Optimized process

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

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

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

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

www.mepax.com info@mepax.com

THE MOST INNOVATIVE PR AGENCY

@mepaxIntPR

NEWS

BETA LAYOUT IS OFFERING THE WORLD'S FIRST FREE 3D-MID DESIGN SOFTWARE

Designing circuits on 3D printed components.

The company, renowned for their PCB-POOL® prototype manufacturing service is offering this comprehensive design software for FREE.

T

he latest TARGET 3001! V18 PCB-POOL® edition includes an integrated 3D-MID (Mechatronic Integrated Device) function enabling schematic creation and the ability to place circuitry on already created 3D step file data. This is the first free ECAD software for designing electronic circuits on three-dimensional circuit carriers and is now available to download. www.pcb-pool.com/ppus/info_pcbpool_3d_mid.html www.beta-layout.com

MORE INFORMATION 14 | Industry USA | April 2017

5

NEWS

CAR ASYST APP 2.0 FOR AUDI: MULTI-LANGUAGESUPPORT DIAGNOSTIC TEXTS, OBD SCAN TOOL FUNCTION AND DEMO VERSION

CAR ASYST APP for Audi after-sales service and repair shops now also provides German diagnostic texts (multi-language) in the current Version 2.0. Furthermore, it offers an OBD scan tool function for a wider range of vehicles as well as a free 30-day demo version.

Multi-language support The current Release 2.0 provides users with vehicle data, service information, identification data and error texts as multi-language information. In the first phase, these can be shown in English and German. Other languages (incl.

French, Italian, Spanish, Chinese) are to follow.

OBD scan tool for extended range of use To increase deployment, owners of a released VAS 5054A VCI can now also use the CAR ASYST APP as an OBD scan tool. OBD modes 1, 2, 3, 4, 7, 9, A are supported. This means that users can evaluate the OBD information of vehicles of the VW Group as well as a range of cars from different manufacturers.

MORE INFORMATION

Free 30-day demo version There is also a free 30-day demo version of CAR ASYST Release 2.0. Alongside simulated vehicle data (Audi Q7), direct tests can also be carried out on Audi vehicles using a VIN|ING 600 or VAS 5054 VCI.

14 | Industry USA | April 2017

6

The highlights of CAR ASYST Release 2.0 at a glance • M ulti-language vehicle data, service information, identification data and error texts (English, German, and other languages under development).

• OBD scan tool supports the following modes: 1, 2, 3, 4, 7, 9, A when using VAS 5054 VCI Extended use of vehicles of the VW Group or use for a range of manufacturers • Free 30-day demo version (Audi Q7 simulation mode, direct vehicle test).

Vehicles supported in CAR ASYST Release 2.0 Audi A4, Audi A5, Audi Q5, Audi Q7, Audi Q7 e-tron, as well as additionally (with VAS 5054 release) Audi Q2, Audi A3, Audi TT. Further models are under development.

The CAR ASYT APP is available here [link: https://play.google. com/store/apps/details?id=com.softingapp] in the Google Play Store. All other information on the diverse uses of CAR ASYST and the supported vehicles can be found on the central info site www.car-asyst.com.

NEWS

General company information on CAR ASYST CAR ASYST. The mobile system solution for vehicle communication on smartphones and tablets for Audi repair shops, after-sales service and vehicle testing CAR ASYST is a mobile fast tester (smartphone/tablet) and analysis tool released by Audi. CAR ASYST is a flexible and handy extension to stationary service testers in the repair shop. A smartphone or tablet thus quickly becomes a fast tester which, as a mobile diagnostic tool, enables access to vehicle electronics faster than ever before. CAR ASYST has also been released for the Audi ServicePad VAS 601 301.

MORE INFORMATION

Main areas of implementation for CAR ASYST • Mobile tool for service technicians and repair shops • Fast tester and ECU error reporting • Actuator test (actuator addressing) in repair shops and service • Data logging and fast initial diagnostics • Error detection for stationary vehicles as well as vehicles on the road • Enabling/disabling transport mode • Service & vehicle test on the forecourt • Breakdown service • Engineering and vehicle test • Supports use on the Audi ServicePad VAS 601 301 www.softing.com 14 | Industry USA | April 2017

7

NEWS

NEW S SERIES DESIGN

LEMO launches a new design for the S series connector range.

T

he S series connector is one of the initial designs of the LEMO Push-Pull connector system. The S series product range will now also include a new outershell design using LEMO's famous chocolate bar shape.

The product uses the S series half-moon inserts and is fully compatible with the existing S series sockets on the market.

Both straight plug and free socket use the collet of the B series, thus offering a slightly different cable range than the existing S series.

MORE INFORMATION

www.lemo.com

14 | Industry USA | April 2017

8

NEWS

EC1, SIC MARKING’S NEW DOT PEEN MARKING SYSTEM

Discover the new column-mounted dot peen machine!

I

ntroduced at the IMTS (International Manufacturing Technology Show) tradeshow in Chicago, the new ec1 marking system uses dot peen technology to achieve permanent marking of all industrial components. Dot peen technology provides a reliable and unalterable marking directly into the material.

The ec1 column-mounted machine is extremely precise, marks at high speed and has an excellent robustness, which is perfect for all types of dot peen marking. You can mark data such as texts, logos, 2D codes, QR codes or datamatrix codes.

The ec1 controller features a completely redesigned software for simpler handling and increased intuitiveness.

This software allows to create easily and quickly marking programs directly from the controller. New navigation icons facilitate switching between different menus. The main innovation is the “Edition Menu”: it can be programmed in graphical or in table view (selectable at any time). www.sic-marking.com

MORE INFORMATION

This new machine is ideal for marking small to medium sized parts, from plastics to hardened steel up to 62HRC. Parts of various shapes and surface conditions (flat, concave, convex, circular, raw, machined surfaces...) can be marked.

Thanks to its improved stability, the brand new design of the ec1 makes it more comfortable to use on tabletop.

The system also includes a graduated column for an easier positioning. Its new marking window is bigger (120 x 100 mm) and its controller is equipped with a HD color screen of 95 x 54 mm. Besides, the controller is fully programmable thanks to its new industrial keyboard.

14 | Industry USA | April 2017

9

NEWS

HENGSTLER PAPER CLIP THE PRESENTER ALTERNATIVE Hengstler recently developed and introduced a paper clip as a presenter alternative, when the use of a presenter is not possible due to space availability and limitation inside a kiosk or to keep the cost of the total system as low as possible. The paper clip is a small clip made out of thin metal that can be used for receipt paper, tickets, labels with liner, or other materials. The inexpensive feature that can be ordered either with the printer or as accessory.

M

any kiosk applications use a presenter to prevent vandalism, protect private information, or to keep untaken documents off the floor. Keeping the floor safe: as odd as it may sound, one reason for a presen¬ter, especially in an indoor environ¬ment with a lot of traffic, like a shop¬ping mall, is to prevent untaken printouts from ending up on the floor and becoming a slipping ha¬zard to passersby. A presenter with retract capability would be needed in this case. But with the Hengstler paper clip no additional space is needed for a presenter plus reject bin.

The paper clip holds the paper inside the chute.

With a presenter the printer orientation plays a major role.

The printer can only be mounted horizontally. With the Hengstler paper clip the printout can exit the kiosk; upward, downward, horizontally, at an angle. Printer orientation no longer plays a role.

MORE INFORMATION

The cutter almost always used in kiosk printers, but the type varies depending upon paper. Guillotine cutters are also sometimes configured to make either full cuts, severing the pa¬per completely, or partial cuts, leaving a small tab of paper holding the cut prin¬tout to the roll, on command, allowing one cutter to do both. Another cutter technology is the rotary cutter, where a rotating blade cuts against a flat one. A rotary cutter can only perform a full cut. Full cut is a term that refers to how the paper cutter serves paper. A full cut means that the paper is completely separated from the paper roll when it is cut, so it can fall fre¬ely. The advantage 14 | Industry USA | April 2017

10

of full cut is that the printout is completely free after cutting and can be dropped into a chute or bin for customer access.

This completely prevents vandals from pulling out the entire paper roll by grasping the prin¬tout that is still attached. Full cut is al¬ways used when a presenter is used, because the presenter must move the separated printout via its own paper transport mechanism. If full cut is used, the paper not yet printed can be retrac¬ted back into the printer to save paper on the next printout. The disadvantage of full cut is that the printout can fall to the floor causing clutter and possible slip hazards; it is not caught in a bin or something similar. The construction of such a bin or chute adds cost to the total system.

The Hengstler paper clip provides benefits to the kiosk owner, including reduced paper clutter. Convincing advantages which offer you the highest levels of security and operational ease to suit your application. www.hengstler.com

NEWS

ESTERLINE CONNECTION TECHNOLOGIES – SOURIAU’S HERMETIC 38999 CONNECTORS ARE QPL CERTIFIED Esterline Connection Technologies – SOURIAU's range of hermetic 38999 connectors has successfully obtained QPL certification from the DLA.

The hermetic 38999 connector range ntermateable and interchangeable with standard MILDTL-38999 connectors, these hermetic connectors can be mounted in four different ways (screw, jam nut, weld, and solder) according to the type of use. The qualified versions include 45 layouts and cover an abundance of configurations from 3 to 128 contacts with sizes ranging from 22 to 8 AWG. Esterline Connection Technologies – SOURIAU's hermetic receptacles follow stringent quality control procedures and include helium leak testing to ensure leakage rates of less than 10-7 atm.cm3/s.

Connectors suitable for critical aerospace environments Hermetic 8D connectors are used on many types of equipment where airtight seals are a key factor in protecting electronics from fluid or gas ingress. “Our hermetic 38999 connectors are used on many types of safety-critical components, from pressure sensors, temperature sensors, speed sensors, and vibration sensors, to landing gear actuators and flight control components” says Samuel Tournier, Product Manager for hermetic connectors. “They ensure that these highly critical components operate properly and safely.”

QPL: performance, quality and easy ordering QPL certification of Esterline Connection Technologies – SOURIAU's range of hermetic 38999 connectors demonstrates that they are suitable for use in both critical and severe conditions. Such certification is recognized by the most demanding customers with the most stringent requirements. QPL certification is granted by the DLA (Defense Logistics Agency), a neutral agency of the US Department of Defense. As a result, these connectors can be marked and listed according to an internationally recognized system common to all interconnect qualified manufacturers.

MORE INFORMATION

Excellent control of glass-to-metal sealing “Ensuring hermetic connections is crucial for some of our customers' products and must in no way ever be altered by the addition of an electrical connector” Mr. Tournier continued: “The use of hermetic connectors with glass beads makes guaranteeing such superior seals possible. In addition to our conventional screw or nut connections, our hermetic connectors can also be directly soldered or welded to our customers' interfaces for greater integration.”

The internal hermetic seal of the receptacle between contacts and shell is ensured by a glass insulator instead of plastic insulation. A sintered pad of the same size as the shell and corresponding to the contact layout is inserted and melted at 1000°C in a furnace. The heating and cooling cycles in the process are interspersed with stabilization periods. As a result, the compression of the shell against the glass and the glass against the contacts provide a full hermetic assembly when cooled down.

Customers can now easily order Souriau hermetic 38999 connectors they are accustom to working with and will not be required to change connector part number(s). www.souriau.com 14 | Industry USA | April 2017

11

NEWS

GREENLEE: 3D MEASUREMENT SYSTEMS CAPACITY RELIEF

Greenlee Textron brings easy, accurate measurement to the shop floor.

T

he quality assurance technician is out sick. The backlog for the coordinate measuring machine (CMM) is five jobs deep. The machine operator needs to check a hole position on a rush job. These are common occurrences on any manufacturing floor, ones that cause machine downtime, employee frustration, lost productivity, and bad parts.

Some shops attempt to solve these problems by placing a conventional CMM in the production area. This consumes valuable floor space, however, and often requires a special foundation and plumbing for compressed air. What’s more, most CMMs require lengthy operator training, and are not suitable for the temperature swings and less-than-pristine air quality typical of many manufacturing environments.

MORE INFORMATION

Nathan Blair, plant manager at Greenlee Textron’s Genoa, IL facility, recognized all this, and in the spring of 2016 decided to do something about it. He contacted his local KEYENCE representative and scheduled a demonstration of the metrology provider’s newest addition to its shop floor lineup, the XM Series handheld probe coordinate measuring machine.

14 | Industry USA | April 2017

12

“Greenlee has been around for more than 150 years,” says Blair. “We became part of Textron Inc. in 1986, and primarily serve the electrical industry. Our facility has 63,000 square feet of manufacturing space, with 80 employees working two shifts. We machine and assemble several Greenlee products at this location, including electric and hydraulic benders, cable pullers, cutters and strippers, and several hydraulic tools such as impact wrenches and drills, chainsaws, and orchard pruners.”

With that many products and employees, Blair needed a fast and simple to use measurement solution. The XM proved to be just that. Using a combination of high-resolution camera and unique, handheld probe, it guides the operator through a series of steps—simply touch the workpiece with the stylus, select the measurement parameters, and follow the on-screen guide to measure points, surfaces, circles, ellipses, and a variety of 3D shapes, including freeform surfaces.

The XM also allows recording of positions obtained while checking, a feature that greatly simplifies creation of work instructions. It uses “augmented reality” to visually overlay measurement points and anticipated geometry on top of and alongside the workpiece image. This makes it easy for

NEWS

anyone to walk up and start using the XM, with no need for lengthy training or knowledge of measurement principles.

“The XM was purchased to relieve capacity constraints on our larger production CMMs,” says Blair. “We mounted the system to a cart that allows us to roll it anywhere on the shop floor that a setup is taking place, and can begin measuring a part as soon as it’s removed from the machine.

This is a big improvement from our past program prove-out experiences, in which we would need to break into the CMM schedule of normal production parts in order to perform first article inspection and complete the machine setup—all while the CNC sits idle waiting for the inspection report so the operator can make the necessary offset modifications. It also greatly reduces the time needed for the manufacturing engineering and/or quality department to diagnose a quality issue.”

Ernest says the transition to shop floor measuring has been easy due to the high level of support from KEYENCE, as well as the system’s ease of use, robustness, and flexibility.

“Installation was quick and pain-free, and the training very helpful and straightforward. KEYENCE has really done a great job streamlining the entire process with easy-tounderstand instructions and training exercises. They’ve been great about answering our questions, and helping with the transition from the training material to programming our own production parts. The XM is proving to be a very useful tool that provides immense value to our facility. www.keyence.com/GREENLEE

MORE INFORMATION

Shop supervisor Derek Ernest agrees. “The XM’s capabilities are an important part of Greenlee’s move into the digital manufacturing era. Not only is it a key player in managing part quality, but the XM also makes statistical process control (SPC) easier with its Cp and Cpk tracking capabilities. This helps to put our operators at ease with the whole idea of SPC, which in the past has been a very manual, pain-staking ordeal that can now be completed behind the scenes automatically.”

14 | Industry USA | April 2017

13

NEWS

ESPRIT PROFITTURNING™ A Technical Overview.

Traditional Turning Limitations Taking the Plunge in Turning Operations When using traditional turning methods on heat-resistant and hard materials such as superalloys large engagement angles and inconsistent chip load can occur at both tool entry and exit. Employing traditional plunge methods on such workpieces may also result in uneven rest materials with irregular surfaces.

1 See Sandvik Coromant Tips film: Grooving – trochoidal turning at https://youtu.be/sJnQnsz0cN8 2 See CAM Programming Tip: Trochoidal Turning Sandvik Coromant at https://youtu.be/HRtSpY0SdBY

Furthermore, Traditional Turning methods can cause adverse effects during the cutting process, such as heavy tool load, high and irregular cutting forces, vibration and poor chip control (1). A key factor when high-speed machining these hard materials is maintaining a constant chip load, which remains vital when machining quality parts and prolonging tool life. In particular, if a chip load is too low or too high, that may cause the tool to wear faster causing many unwanted outcomes. These unwanted outcomes may include chips so large that they cannot get out of the cutter's way fast enough. For example, if a tool is cutting deep down in a slot the chips will have a hard time getting out of the way quick enough, which may cause the tool to break. Another adverse outcome of a low chip load is a rubbing effect, which prevents the machine from making clean chips, and will also heat up both the tool and the material, drastically reducing tool life. Therefore, maintaining a constant chip load is crucial in the manufacturing process.

3 See Sandvik Coromant Tips film: lead/entering angle round inserts at https://youtu.be/9CCr78Z60U4 4 TMAC, Tool Monitoring Adaptive Control, Caron Engineering is available at https://www.caroneng.com 5 See Negative basic shape inserts in Sandvik Coromant – Turning tools 2012, available at http://www.sandvik.coromant.com/sitecollectiondocuments/downloads/global/catalogues/en-gb/turning/turn_a.pdf 6 See Engineered solutions for the aerospace industry in Sandvik Coromant – Application Guide – Heat resistant super alloys.pdf, available at http://www.sandvik.coromant.com/sitecollectiondocuments/downloads/global/technical%20guides/en-us/c-2920-034.pdf

14 | Industry USA | April 2017

14

Figure 2 - ProfitTurning™ divides motion into a number of segments made up of feed rate, roll-in, parallel move, and roll-out. (2)

Figure 1 - Traditional Plunge cutting methods create large engagement angles, irregular cutting forces, and uneven remaining materials.

ProfitTurning™ Capabilities ESPRIT features a new and innovative lathe roughing strategy, ProfitTurning™ which helps eliminate the adverse effects of traditional turning methods. ProfitTurning™ is a high-speed cutting method added as an additional cutting strategy in ESPRIT’s existing Roughing and Grooving cycles.

ProfitTurning™ is a productive and secure cutting method that enables manufacturers to make more efficient cuts with consistent chip loads and cutting forces, thereby reducing tool wear and decreasing cycle time. This is achieved using a toolpath algorithm based on an engagement control strategy, which allows for consistent cutting forces universally, and achieves the highest level of productivity.

Cut small, tricky areas with ease Not all cutting areas are as smooth and easy to reach, such as the one featured in Figure 3. Fortunately, ProfitTurning™ provides cutting strategies for all small and uneven areas.

These areas are often defined by part profiles, roll-in/out arcs, and the minimum trochoidal radius. The minimum trochidal radius is determined by users to limit the size of trochoidal moves in small corners where a cutting tool cannot easily fit.

Another challenge in these difficult to reach areas is to keep constant tool engagement, so that the roll-in arc radius is not too large. To handle this challenge, ProfitTurning™ employs full trochoidal cutting inside these small areas until the tool reaches the “minimum trochoidal radius” as defined by the user. The minimum trochoidal radius then sets the size of the nonmachinable area at sharp corners, and the stepover is reduced to maintain constant tool engagement.

MORE INFORMATION

Engagement control: Make reduced and constant engagements throughout the entire pass Another way to eliminate negative effects in traditional plunging is to maintain reduced and consistent tool engagement. ProfitTurning™ breaks the cutting surface into manageable pieces, and uses round inserts to roll in and out of the cut to control the engagement at both tool entry and exit. With smooth roll-in movements and a smaller feed rate, the cutting force at tool entry can be significantly reduced and maintained at a constant level. The feed rate is also maximized during these straight line movements called – parallel moves – maintaining constant engagement, and then reducing engagement when exiting the cut.

Figure 3 - The depth of cut of ProfitTurning™ toolpath in small areas progressively gets smaller.

>>> 14 | Industry USA | April 2017

15

NEWS Figure 4 - “Alternate Cut Direction” is activated and “Smooth Transitions” is inactivated.

Alternate cut direction and smooth transitions ProfitTurning™ allows users to alternate the direction of the cut to eliminate retract moves (Figure 4).

“Smooth Transition” replaces bridge moves in alternating toolpath with smooth arcs. Too large blend arc in corners can be replaced by this segment as well.

Benefits of ProfitTurning™ ProfitTurning™ uses round inserts or the full radius of groove tools to achieve higher feeds rates, in order to maintain a constant or near constant chip load. This is referred to as the chip thinning effect. In addition, ProfitTurning™ reduces vibration and irregular cutting forces, which can result in poor surface finish and cutting tool damage by using round inserts with engagement control. In turn this makes ProfitTurning™ ideal for cutting hard materials and super alloys with thin walls, as displayed in Figure 6 and Figure 7.

In (Figure 6) half of the diameter of the insert, the feed rate per tooth and chip thickness are identical for a round insert.

This is similar to a 90 degree cutter. As the lead angle of the cutter changes and depth of cut decreases (Figure 7), feed rate can be increased in order to maintain the proper chip thickness. Where depth of cut is lacking, users can make up for in an increased feed rate, which results in increased productivity. (3)

Figure 5 - Both “Alternate Cut Direction” and “Smooth Transitions” are activated.

Figure 6 - At half diameter of the round insert, feed rate per tooth is equal to chip thickness for a round insert. (3) Figure 7 - As the depth of cut decreases, the feed rate increases. (3)

Put to the Test!

Comparative testing of ESPRIT ProfitTurning™ was completed against conventional turning methods in collaboration with ESPRIT machine tool partners. The baseline for the test was established using a conventional ZigZag cutting strategy, and then compared to ESPRIT’s ProfitTurning™ strategy. The results were successful indicating a 25% reduction in cycle time using ProfitTurning™ as opposed to conventional cutting methods.

Another goal of the test cut was to evaluate tool life compared to traditional cutting strategies using ESPRIT ProfitTurning™. One part with two identical features was used in the test cut. One feature was cut with the traditional ZigZag technique and the other feature was cut with ProfitTurning™. During the test cut, TMAC (4) (Tool Monitoring Adaptive Control) from Caron Engineering, was used to monitor the horsepower of the spindle. Caron Engineering has over 30 years of experience in monitoring and controlling CNC machines, and TMAC is just one of their products. TMAC operates on the principle that the power required to cut a part increases as the tool life decreases.

With the support of TMAC, we measured the difference in horsepower between ProfitTurning™ and conventional ZigZag strategies. For each strategy, we started with an air cut, then measured the horsepower for each pass. That data was then averaged together to show the overall horsepower value for each groove.

MORE INFORMATION

In Figure 8, the orange bars display a gradual, yet consistent, 5% increase in horsepower between each groove, using the conventional ZigZag method. (Note: As the tool wears, the machine uses more horsepower to make the cut). This same data was collected for ProfitTurning™ – illustrated with the blue bars. When comparing the two cutting strategies the work over eight parts using ProfitTurning™ is 10.26%, while the work using the Conventional ZigZag method is 31.3%.

The results shown by the graphs trendlines show that, by 14 | Industry USA | April 2017

16

Figure 8 - Tool work comparisons between ProtTurning™ and the conventional ZigZag method.

Figure 9 - An example of ProtTurning™ applications – deep grooving.

comparison to the conventional ZigZag method, users will experience a three times increased tool life, and tooling inserts will need to be replaced less often using ESPRIT’s ProfitTurning™.

likely to produce harmonics during the cut, allowing for higher productivity. For example, Aerospace components are usually large, with increased radii and blending profiles designed to eliminate high stress points, which allows for round inserts to be used with ease.

ProfitTurning™ Tool Selection

Benefits of round inserts: • The entire insert perimeter can be used when cutting.

• The cutting direction can be alternated.

• Effective engagement control with roll-in and out techniques.

• Stronger cutting edge for tough materials.

• Higher feed rates.

• Side loaded cutting.

In addition, when machining rigidity is also a factor when comparing round inserts to square inserts. Generally speaking, round inserts are more stout, making them the strongest inserts available, which also means they are less

MORE INFORMATION

ProfitTurning™ uses round inserts or the full radius of groove tools. When using these round inserts, the entire cutting edge perimeter can be used when cutting, and the direction of the toolpath can be alternated to maximize the tool usage with higher efficiency, and to prolong tool life. Furthermore, round inserts can also tackle side loaded jobs, in which regular square inserts usually fail to accomplish. In addition, round inserts are suitable for materials with hardness levels of ISO-S and H (5), such as heat-resistant superalloys.

ProfitTurning™ Applications In Figure 9, an example of ProfitTurning™ applications is illustrated when deep grooving and profiling, where long slight tools are required. In the diagram disc and spool components are featured with deep cavities that need to be machined from a solid or finished after welding.

When machining these typical components there is a high 14 | Industry USA | April 2017

17

tendency toward vibration with a huge depth to width ratio. By adopting ProfitTurning™ users can optimize these difficult machining applications with maximum rigidity and minimized vibration allowing for increase productivity.

Additional examples of ProfitTurning™ applications are featured in Figure 10. (6) Test Results The first test cuts were made at the Mazak Technology Center in Gardena, California. The goal of this first test cut was to verify that the original toolpath motion worked properly with the proper feeds/speeds. The results showed that both the OD groove/contour and face groove were machined with the “alternate” parameter turned on when cutting the face groove. The OD cutting conditions and final results proved successful, and the surface finish was consistent with a high speed roughing cycle.

Equations of Business In today’s manufacturing world a lot of money is spent on adopting and investing in new technologies. However, there still remains a decision on when to adopt those new technologies versus continuing to use traditional methods. Adopting ESPRIT’s ProfitTurning™ can increase cutting speeds and decrease cutting time, but what is the investment cost to use this new technology compared to traditional methods? We used a Sandvik Turning calculator to show users just that by setting priorities when choosing a cutting strategy. We calculated the cost per part using ESPRIT ProfitTurning™ and round inserts (Table 1), and in parallel used a similar cost evaluation using the traditional ZigZag cutting method (Table 2) with the same round tool insert and holder. The final results showed that the unit price to cut one part using ProfitTurning™ costs 60% less than the unit price of using the traditional ZigZag cutting method.

Conclusion The ProfitTurning™ cutting strategy in ESPRIT features a toolpath that maintains consistent chip load and cutting forces, allowing cutting speeds to be significantly increased.

By employing controlled engagement techniques using round inserts, the ProfitTurning™ toolpath also reduces vibration and residual stresses, making it particularly useful for thin walls or hard materials, such as superalloys. This innovative cutting strategy results in significantly reduced machine cycle time and cost per part, allowing for increased productivity and making it the ultimate turning solution.

The Sandvik Coromant Turning Calculator is available at www.sandvik .coromant.com/en- gb/k nowledge/ calculators_and_software/apps_for_download/Pages/ turning-calculator.aspx MORE INFORMATION

www.espritcam.com

14 | Industry USA | April 2017

18

Figure 10 - Some more examples of ProtTurning™ (6)

Test Results - Example 1-2

MORE INFORMATION 14 | Industry USA | April 2017

19

NEWS

THE PERFECT OVERLOAD PROTECTION FOR DRIVES WHICH ARE HARD TO ACCESS

The EAS®-reverse with patented disengagement mechanism is a disengaging clutch which re-engages again simply through slow backwards rotation – ideal for drives which cannot be accessed for re-engagement purposes.

EAS®-reverse – the disengaging torque limiter with automatic re-engagement.

W

ith their EAS®-reverse, mayr® power transmission has developed a new, disengaging torque limiter on which all functional processes can be automated through the drive. It is easy to handle, permits long run-out times and re-engages again through slow backwards rotation. A housing also makes the clutch resistant to dust or spray water – and thus ideal for use in heavy mechanical engineering.

In case of rough operating and ambient conditions such as dust, dirt, spray water, heat or cold, the drive lines, particularly in heavy mechanical engineering, are frequently encapsulated and therefore hard to access. But these machines in particular require reliable overload protection.

Therefore, mayr® power transmission as a leading specialist for clutches, couplings and brakes has now developed with the EAS®-reverse a robust, disengaging torque limiter which can withstand both high loads and which automatically re-engages – which is ideal for drives without access possibilities for re-engagement.

MORE INFORMATION

Residual torque-free separation on overload On the EAS®-reverse torque limiter, all functional processes can be automated via the drive alone. In case of overload, if the torque exceeds the value set on the clutch, a patented disengagement mechanism separates the input and output almost residual torque-free with high switch-off and repetitive accuracy. The kinetic energy from the rotating masses stored in the system can slow down freely. After responding, the clutch can withstand long drive run-out times. Through slow reverse rotation, the EAS®-reverse torque limiter re-engages automatically without the use of pneumatics or hydraulics.

14 | Industry USA | April 2017

20

NEWS

The EAS®-reverse is easy to handle and permits long run-out times. A housing also makes the clutch resistant to dust or water spray.

MORE INFORMATION

Simple and flexible The new EAS®-reverse torque limiter by mayr® power transmission transmits the torque with exceptionally low wear (< 0.05°) and features hardened functional parts. It is easy to handle and represents adaptable, branch-optimised solutions with its numerous versions and additional characteristics. In this way, for example, the combination with an elastomer coupling permits easy separation of the drive line by loosening a few screws, without the motor or gearbox having to be displaced. In addition, applications with load-holding outputs can also be combined with a brake disk on the output side. The EAS®-reverse can also easily be integrated into a solid housing with standard IEC or NEMA dimensions. It is thus protected against dust and spray water and resistant to adverse ambient conditions. The new torque limiter already covers the first three construction sizes with a torque range from 80-2500 Nm, and this range is now to be extended with a fourth construction size up to 5000 Nm and a bore diameter of up to 100 mm. The EAS®-reverse provides permanent protection for machines and protects them reliably against overload damage, thus ensuring operational safety and maximum productivity. www.mayr.com

14 | Industry USA | April 2017

21

NEWS

BIDMC: DIGITAL MICROSCOPE HELPING HEARTS

Researchers at Harvard University get a better look at heart disease and other ailments with fluorescent microscopy from KEYENCE.

T

he genetic disorder Noonan syndrome (NS) causes a host of problems in humans. Growth and musculoskeletal abnormalities, distinctive facial features, issues with the lymphatic system, bruising and bleeding are all associated characteristics of NS, but the most serious complication is congenital heart disease, which manifests itself through a narrowing of the pulmonary valve or through weakening of the heart muscle itself.

MORE INFORMATION

Fabrice Jaffré, an Instructor in Dr. Maria Kontaridis’ laboratory at Beth Israel Deaconess Medical Center and Harvard Medical School, Boston, MA, is working on elucidating the mechanisms associated with causing this disorder. He and others in the Kontaridis lab study the cardiac defects in NS patients, as well as those associated with a rarer, allelic variant disorder called Noonan Syndrome with Multiple Lentigines, formerly known as LEOPARD syndrome.

“By understanding how abnormal signaling pathways lead to heart defects in these patients, we can begin to assess how specific and targeted drug or gene therapies can work to ameliorate the disease” Jaffré says.

14 | Industry USA | April 2017

22

One possible treatment for these and other genetic diseases may come through the use of induced pluripotent stem cells (iPSCs). As Jaffré explains, these cells are cultivated from the patient’s own body—typically from the skin or blood—and de-differentiated into iPSCs, which have the potential to then re-differentiate and become virtually any type of cell in the human body, including nerve, bone, and muscle; in Jaffré’s case, they are become cardiomyocytes, the cells responsible for making the heartbeat.

Jaffré says that the analysis of these cells would be more difficult if not for a fairly recent addition to the Kontaridis lab’s equipment list, one that greatly expands its capabilities: a KEYENCE BZ-X700 All-in-One Fluorescence Microscope.

“I might place a bunch of cardiac cells in a specimen dish and use antibodies to perform immunofluorescence,” he says.

“The KEYENCE BZ-X700 helps you to identify many different proteins that are expressed in cardiomyocytes with high resolution. It also does automatic measurement of cell size, and cell number in each sample. These tasks would be more difficult or at least more time consuming without it.”

NEWS

measurement of large sample sizes, and image stitching.

“We can do most anything we want for microscopy with the KEYENCE BZ-X700,” he says.

The BZ-X700 is KEYENCE’s publication-quality imaging and analysis solution for researchers throughout the life sciences.

It uses a high-sensitivity CCD camera to capture low-noise color or monochrome images, even when fluorescent signals are weak. The integrated software provides a range of features such as image stitching, 3D measurement, optical sectioning and more, and does so with an intuitive interface that requires very little training to operate.

“We get excellent resolution in both still images and video,” Jaffré says. “It’s also quite user friendly. Even if you’re unfamiliar with microscopy, you’ll be able to operate the device easily.”

Jaffré is also pleased with some of the other features the KEYENCE BZ-X700 brings to the lab, such as the flexibility to use a variety of well plates and dishes, automatic

Jaffre is close to releasing a paper on his research, one that will include images obtained from the KEYENCE BZ-X700.

For lab director Dr. Maria Kontaridis, an Associate Professor of Medicine at Harvard Medical School and the interim Director of the Basic Cardiovascular Research Program at Beth Israel Deaconess Medical Center, this is always welcome news. “We purchased the KEYENCE BZ-X700 nearly two years ago,” she says. The images are stellar and its capabilities have proved helpful to everyone in the lab. For instance, the ability to show real-time hypertrophy in individual cardiomyocytes has been invaluable to Fabrice, and we have additional postdoctoral fellows in the lab who are also working on understanding the mechanisms associated with end stage heart failure. In this case, the KEYENCE BZ-X700 is used to automatically quantify the percentage of fibrosis in each of the mouse heart tissue samples, something we also utilized in a recently published manuscript with the Journal of Clinical Investigation. “We’ve also recommended the KEYENCE BZ-X700 to other institutions here at the medical school complex as well. Overall, we’re very happy with its capabilities.”

MORE INFORMATION

Aside from automatic cell counts, area and linear measurement, and other types of specimen analyses, the KEYENCE BZ-X700 is used by the lab for time-lapse motion tracking, a function particularly valuable to Jaffré.

“Cardiomyocytes form monolayers, or sheets of cells that beat together, just like in the human heart. We use the KEYENCE BZ-X700 to measure contractility, and the number of beats per minute at the cellular level. By analyzing the differences between the cardiomyocytes of NS patients and those of control subjects, we’re able to identify defects in the patient-derived cells.”

iPSC research such as this may one day provide individualized therapy for treating common patient ailments, Jaffré points out. For example, it may be possible to extract cellular material from a heart attack victim and use it to generate iPSCs that can then be reintroduced to repair those that were damaged by the event.

www.keyence.com/BIDMC 14 | Industry USA | April 2017

23