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Industry
Asia Pacific THE INDUSTRY MAGAZINE FOR ASIA
SCOTT SAFETY TO DEBUT UK’S FIRST EVER INMASK THERMAL IMAGING INTELLIGENCE SYSTEM AT EMERGENCY SERVICES SHOW 2016
4 EXTRA SMART FOR INDUSTRY 4.0 - THE INNOVATIVE THIN CLIENT SOLUTION FROM PEPPERL+FUCHS
17 NORD DER ANTRIEB IS IN CONTROL
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KOLLMORGEN HIGH IMPACT CUSTOMIZED SOLUTIONS INTERCONNECTED ENGINEERING SERVICE
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THE INDUSTRY MAGAZINE FOR ASIA
FLUKE PROCESS INSTRUMENTS
SCOTT SAFETY
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MEPAX
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6 LEROY-SOMER
HMS
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12 PEPPERL +FUCHS PROCESS AUTOMATION
BUREAU VERITAS
EPLAN
EMERSON INDUSTRIAL AUTOMATION
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KENNAMETAL
KOLLMORGEN
NORD
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FLUKE PROCESS INSTRUMENTS
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www.industry-asia-pacific.com
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SCOTT SAFETY TO DEBUT UK’S FIRST EVER IN-MASK THERMAL IMAGING INTELLIGENCE SYSTEM AT EMERGENCY SERVICES SHOW 2016
Scott Sight, the UK firefighting industry’s first ever in-mask thermal imaging intelligence system from Scott Safety will debut at the Emergency Services Show 2016 on stand B69, 21-22nd September in Birmingham. This ground-breaking system brings the future of firefighting into clear view for those on the front line and is set to revolutionise the industry.
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ith slogans such as “Choice of the Brave” and “Innovation at First Sight”, the global leader in design, manufacture and supply of respiratory protective equipment, and thermal imaging technology has injected significant investment into the development of the global firefighting industry this year.
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Scott Sight utilises hands-free thermal imaging technology to provide firefighters with a clear, unobstructed view of their surroundings thus improving their situational intelligence and eradicating the need to stop searching or put the hose down to deploy a hand-held camera. In spite of being exceptionally lightweight at 8 ½ ounces, Scott Sight is very powerful producing a 160x120 resolution at 9 frames per second through an infinity lens which ensures a clear picture with no eyestrain.
Longin Kloc, Global Product Manager, Growth Initiatives from Scott Safety, said: “We are extremely proud to launch such an innovative product for the firefighting industry. Scott Sight really is a sophisticated imaging tool - it supplements existing hand-held technology by offering configurable hands-free visibility to the wearer in often inhospitable situations.” “To create Scott Sight, we worked very closely with firefighters to develop a thermal imaging solution that is more accessible and easier to use. This means that the wearer’s attention can stay focused on the fire, enhancing the ability to spot hazards and locate casualties, while also providing the means to identify a secondary egress in the event of a sudden change in circumstances.” A further innovation debuting at the show is the Light Decontamination System, a portable airborne and surface decontamination solution with the ability to decontaminate chemical, biological and radiological vapours, liquids and particles simultaneously in as little as five minutes.
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Utilising atomisation technology the Light Decontamination System creates a fine mist ensuring an even and consistent coverage, and haptic dry surfaces. Rapidly projecting these droplets in the form of a dense and turbulent mist, the system is capable of delivering CBRN decontaminants to all non-line of sight surfaces. This process drastically reduces both the chemical footprint and time required for effective decontamination. Unlike many traditional decontamination systems which utilise liquids, this new process forces powders to behave like a gas, ensuring that sensitive and electronic equipment is not damaged.
innovative design, manufacture and supply of respiratory protective equipment and thermal imaging technology. To find out more about the latest products from Scott Safety, visit stand B69 at the Emergency Services Show 2016. For further information about Scott Safety, visit www.scottsafety.com/emea
Environmentally friendly and cost-efficient, the Light Decontamination System typically requires only five percent of decontaminant compared to traditional systems due to the gas-like behaviour of the small droplet mist. Easily directed and controlled with a lance hose, the system achieves a projection distance of up to 30 meters and is compatible with a range of chemistries.
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Global Product Manager for Military & Civil Defence at Scott Safety, Dr David Crouch said: “The Light Decontamination System will revolutionise the fire market; it is lightweight, portable and extremely powerful. In validation trials, the system decontaminated anthrax by 99.9999999 percent from a 100m³ space, in less than five minutes.” Innovative, industry-first technology from Scott Safety reaffirms its stature as a global leader at the forefront of 16 | Industry Asia Pacific | September 2016
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NONCONTACT TEMPERATURE MONITORING IN HAZARDOUS AREAS
The MI3 system minimizes costs per measuring point: two intrinsically safe MI3 sensors can be used with one power supply and communication box installed up to 15 m away.
Proven MI3 sensors now with Ex i certification.
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ll models from Fluke Process Instruments’ versatile MI3 infrared sensor series are now also available as intrinsically safe versions for use in hazardous environments. The intelligent miniature sensors are fully ATEX and IECEx certified for use in Zones 1 and 2 (gas) and Zones 21 and 22 (dust). The manufacturer supplies a complete intrinsically safe package including the sensor, a communication box, and an Ex power supply. All three components are IP65-rated, and each can be easily exchanged in the field without re-calibration of the entire system. One or two intrinsically safe MI3 sensing heads can be powered by one power supply. The sensor cables can be up to 30 m long in total, providing high flexibility for setting up safe monitoring scenarios.
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Featuring a stainless steel housing with integrated electronics, the rugged MI3 pyrometer is the smallest stand-alone digital infrared temperature sensor for fixed installation on the market today. The MI3 series comprises pyrometers for various spectral ranges and applications, including the 1M and 2M short wavelength models with an excellent 100:1 resolution and 10 ms response time, which are suitable for monitoring temperatures up to +1,800 °C. Each intrinsically safe MI3 sensing head is labeled with the Ex i certification. In the case of the MI3100, this also covers the 16 | Industry Asia Pacific | September 2016
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laser sighting function for easy positioning and aiming. MI3 sensors have excellent EMC characteristics and can be used in ambient temperatures up to +180 °C. Communication boxes are available with RS485, Modbus, Profibus, Ethernet, and Profinet IO interfaces and with four galvanically isolated analog outputs. Automatic head detection and digital communication between sensor and box enable plug and play. The ATEX and IECEx certifications open up many additional areas for the MI3 series, for example steel industry processes using hydrogen atmospheres such as galvanizing, annealing, plating, and coating; hydrogen reduction in the solar industry; petrochemical applications such as sulfur recovery and monitoring boilers, reactors, pipes, and flare control; manufacture and storage of various chemical and agricultural products such as vinyl, fertilizer, starch, alcohols, and flour; fire detection; monitoring mining equipment and conveyors; hazardous waste disposal; and sewage treatment. Contact for sales in Asia: india@flukeprocessinstruments.com www.fluke.com
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MEPAX IS ACQUIRING OLIVIER ARNAUD CONSEIL (OAC)
Mepax, the world’s leading international PR and advertising agency for the industrial market, joined forces with OAC, the leading communications agency in France in the same area. OAC manages 2 million euros in advertising budgets in France.
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he combined organization manages an extensive portfolio of over one hundred clients with an annual turnover of over 5 million euros, half of which comes from France. Mepax, the world’s leading international PR and advertising agency for the industrial market, joined forces with OAC, the leading communications agency in France in the same area. OAC manages 2 million euros in advertising budgets in France. The combined organization manages an extensive portfolio of over one hundred clients with an annual turnover of over 5 million euros, half of which comes from France.
Customers are managed in more than 60 countries in 35 languages, and Mepax has a network of 80 employees worldwide. This is a very powerful merger as the cutting-edge solutions of both companies are innovative and complimentary and will drive positive business outcomes for clients who seek to promote their brands globally and maintain a competitive edge. www.mepax.com
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The principal business sectors of Mepax are the manufacturing and processing industries, electronics, IT, transportation and military.
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ENVIRONMENTALLY-FRIENDLY, ECONOMICAL, RELIABLE AND SIMPLE: PARALLEL HYBRID PROPULSION OFFERS NOTHING BUT ADVANTAGES
Since 1968 NAVE VA have specialised in maritime excursions into the heart of the most beautiful areas of western and southern Corsica, and they want to run their business in an ethical and sustainable way.
Electric propulsion generates no emissions and is extremely user-friendly: the vessels that use it are silent, experience much lower levels of vibration and are easier to handle. Last but not least in terms of its advantages: parallel hybrid represents an attractive economic proposition.
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eroy-Somer and Control Techniques have been suppliers of marine applications for many years. In association with Mayday Electronics they have now produced a high-performance propulsion system which is at the leading edge of hybrid technology. The system was developed for CNB PRO, a trademark of Construction Naval Bordeaux (Bénéteau Group), and its client, NAVE VA.
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Trusting in CNB PRO’s know-how in the field of passenger transport vessels and the expertise of the naval architects, Bureau Mauric, the Corsican boat excursion company, NAVE VA, recently acquired a new model CNB PRO 20 Hybrid. As specialists in organising visits to protected sites, NAVE VA do not consider this solution to be an option, but rather an environmental duty.
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In low speed mode, for manoeuvring in port or in protected areas, the vessel switches to electric power. “The silence is incredible,” explains Eric Brun of the Mayday company, which designs and supplies the propulsion system for these hybrid vessels. It has a speed of 6 to 8 knots, which is quite sufficient. A rapid return on investment Parallel hybrid differs from serial hybrid in that the size of the electric motor can be designed to match the desired application, which in the case of NAVE VA is for a 6 to 8-knot low-speed mode. Optimum efficiency is therefore achieved: at low speed, the electric motor is used in its optimum operational range. In addition, the weight of the installation is much less for equivalent endurance. Another advantage is that the internal combustion engines can be stopped when the electric mode is activated. The CNB PRO shipyard, situated in Bordeaux (western France) and part of the Bénéteau Group, has identified a decisive advantage of hybrid propulsion systems: “Diesel engines do not run at optimum efficiency at low speeds. They exhibit low levels of efficiency and are prone to fouling. The fact that the diesel engine can be shut down in order to use the electric
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The LSRPM series from Leroy Somer’s Dyneo® motor range offers high levels of efficiency and an exceptionally compact design.
A technology which is expected to develop “Legislation is changing. Electric power is becoming mandatory for an increasing number of applications, and not just in protected nature reserves. We are developing the hybrid system, in particular the parallel hybrid system, which is ideally suited to ships of less than 30 metres. Its use could be extended to regular ferry services, links between two ports, and river or pleasure navigation,” Pierre Lompech concludes. The passenger vessel supplied to NAVE VA is equipped with two 800 hp motors, allowing it to achieve a speed of 20 knots in diesel mode. In electric mode it has a maximum speed of 8 knots and an endurance of 6 - 8 hours at a speed of 6 knots. Recharging takes a maximum of 6 hours, and uses a harbour three-phase supply or the on-board electrical generator.
Hybrid propulsion allows 135 passengers to be ferried on visits to the Scandola nature reserve in Corsica, with no CO2 emissions and the use of batteries eliminating the noise pollution generated by internal combustion engines.
propulsion system helps to preserve it. Its service life can therefore be doubled, depending on the applications,” explains Pierre Lompech of CNB PRO. For the NAVE VA vessel, this would mean changing the engine after 16 years, instead of just 8. In real terms, the replacement of the two diesel engines represents a budget equivalent to the price of the electric propulsion system.
“Despite the system’s advantages there are still very few parallel hybrid systems in use, especially in France. Apart from passenger ferry, we have projects in the field of pleasure boats for ‘super yachts’ and in military applications,” says Eric Brun. Leroy-Somer and Control Techniques are global specialists in drive solutions, and offer a range of products specifically designed for the maritime world “We chose the Dyneo® range LSRPM series permanent magnet 750 - 3000 rpm synchronous motor because of its high output and exceptionally compact design. We did find more compact motors, but these used separate cooling systems, which complicates installation in the limited space available in the engine room. Furthermore, LeroySomer offered to make the motor suitable for use at sea, in particular by supplying an aluminium housing appropriate to the environmental constraints”, adds Eric Brun. “The reliability of Leroy-Somer and Control Techniques products is also an advantage. The first vessel equipped with Leroy-Somer motors on a Mayday propulsion system has been in continuous operation since April 2012. This is the Hélios ferry at Marseilles (southern France), designed with the operator, ICARD Maritime, who have made over 2000 sea voyages without any problems. In fact, we chose industrial motors which are tried and tested in manufacturing industry rather than in maritime applications. The motors are only used for a few hours per day, whereas they’re in operation 24-hours a day in some factories,” concludes Eric Brun.
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“The use of an electric propulsion system instead of internal combustion for manoeuvring in port, for berthing and for low-speed travel reduces the length of time that the internal combustion engines are in use during the phases when they are least efficient. In these operating situations, significant reductions in fuel and maintenance costs are achieved. 70 litres of fuel per hour can be saved for each diesel engine, therefore totalling 140 litres per hour. Taking account of the overall added costs of the electrical propulsion installation (about €350k to €400k depending on the capacity of the battery set) and the seasonal use specific to our client, the latter expects to be able to write off this extra cost in less than four seasons, and at the same time increase the service life of the diesel engines while extending their maintenance intervals,” says Pierre Lompech. The electric propulsion system also provides redundancy, which is essential for passenger vessels.
“The price of electric propulsion could come down even more in the future. The batteries take up a lot of space and are still quite expensive, at about 1 euro per Watthour. Since the installed electrical capacity is 125 kWh, the batteries represent about half the cost of the propulsion system. The remainder is made up of the mechanical drive system, the two electric motors and the variable speed drive units. Ensuring compliance with marine conditions is straightforward. The motors and variable speed drives are installed in dry dock, the fastenings are made of stainless steel and often only minimal environmental adaptations are required, such as adding coats of paint”, explains Eric Brun.
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Motor control unit, equipped with Control Techniques Unidrive M.
“The marine market has become a priority for us,” explains Mathieu Hérieau, Marine Business Development Manager for Leroy-Somer: “The maximum amount of power needs to be concentrated in a very restricted space, and our products achieve this through their high levels of efficiency and compact design.” The permanent magnet synchronous variable speed solutions supplied are part of the Dyneo® range. These comprise Leroy-Somer LSRPM motors and the latest-generation of Unidrive M variable speed drives from Control Techniques. The LSRPM motors use patented LeroySomer technology, with a magnet rotor whose innovative design provides significantly increased efficiency, much greater than that required in industry, over the entire speed range of the motor.
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This technology also significantly reduces the size and weight of the motor in comparison with asynchronous technology. The Control Techniques Unidrive M range of universal variable speed drives offer optimised levels of power consumption, reliability and flexibility. In this way, the overall cost of installation and operation can be significantly reduced.
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The strengths of the Leroy-Somer & Control Techniques / Mayday Electronics propulsion solution: - Increased comfort: silence, no fuel odour or CO2 emissions - Operational benefits: reduced fuel consumption, less maintenance, rapid ROI, extension of the propulsion system service life. - Technology created using drive systems with optimised size, weight and fuel consumption www.leroy-somer.com
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IXXAT CAN@NET NT 200–THE MULTI-FUNCTIONAL CAN-TO-ETHERNET GATEWAY
The CAN@net NT (now in new black hou The CAN@net NT (now in new black housing) allows users to connect CAN and Ethernet sing) allows users to connect CAN and Ethernet.
The new IXXAT CAN@net NT 200 is a CAN-to-Ethernet gateway which allows users to connect CAN and Ethernet. Thanks to its two operating modes, CAN@net NT can be used as CAN-Ethernet-CAN bridge and as CAN-to-Ethernet gateway. Equipped with two CAN interfaces, it supports an even wider range of use cases compared to the well-known CAN@net II. Linking of CAN networks One of the key features of the CAN@net NT – which is especially useful in e.g. building automation – is the ability to separate CAN networks that are distributed over large areas. CAN@net NT couples the CAN networks via a backbone Ethernet system, allowing existing infrastructures to be used. This segmentation also increases the reliability and stability of the overall system.
CAN@net NT supports all CAN baud rates from 5 kBit/s to 1 Mbit/s, as well as simultaneous use of 11 and 29 bit identifiers. The TCP/IP-based protocol ensures that no CAN messages are lost when transmitted over Ethernet. The device configuration is easily made by using a Windows configuration tool. More variants of the CAN@net NT, with PC interface operation mode, 4 CAN channels and CAN FD support will soon be released.
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Enables remote access Designed for high performance in harsh environments, another common application for CAN@net NT is remote access to CAN networks via Ethernet – e.g. in wind power plants or in the manufacturing sector. CAN@net NT enables service staff to get access to plants all around the world, simplifying control, service and monitoring of CAN-based plants, reducing costs and downtime significantly.
Besides the bridge operation, linking two CAN networks via Ethernet, the CAN@net NT 200 can also be directly accessed from Windows, Linux, VxWorks or QNX based systems as well as from embedded systems, by using a simple ASCII protocol over a standard TCP/IP socket.
More information is available at www.ixxat.com
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IMFINITY® LIQUID COOLED MOTORS: LC RANGE
The IMfinity® induction motor range developed by Leroy-Somer has now expanded with the Liquid Cooled (LC) series. Designed to withstand harsh environments and meet specific requirements, the LC motor range is a step forward to satisfy the most demanding customer expectations in terms of high reliability, energy savings and ease of integration into their facilities. A design that enhances performance Based on the success and reliability of the IMfinity platform, the LC motors achieve the highest electrical and mechanical performance, including some innovative characteristics: • The latest generation frame housing, with cast iron or steel flanges for DE and NDE bearings, allowing excellent heat dissipation.
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• A sophisticated cooling system which maintains the thermal efficiency, enabling the motor to be used together with a variable speed drive, for heavy duty applications that require constant torque. • Reduced noise level, decreased in average by -10 to -20 dB (A) compared to air-cooled motors due to the lack of fan, offering ultimate comfort. • Improved modularity thanks to its fabricated steel design, providing higher flexibility for retrofit installation. 16 | Industry Asia Pacific | September 2016
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The liquid cooling system of LC motors, provided by water circulation over the frame housing, offers additional significant advantages, such as the power-weight ratio (increased power in the same motor frame size) and compactness (saving up to 25% of volume compared to an air-cooled motor for easier and less costly integration within a machine or a system. Moreover, LC technology makes it possible to eliminate external components, such as ventilation equipment. A design that optimizes energy efficiency Based on the new IMfinity® induction motor range, the LC series has been designed to achieve the efficiency levels defined in IEC 60034-30-1. As standard, LC motors are IE3 Premium from 150 to 1500 kW. Perfectly suited for use in variable speed, the LC motor has been designed to integrate specific features as standard, such as a thermal reserve for maintaining the rated torque over an extended speed range. In order to meet particular requirements, options can be provided upon request,
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The Liquid-Cooled technology ensures a clean surrounding environment, as there is no pollution associated with airflow. Moreover, there is no impact on ambient temperature, as the waste heat from the motor is carried away by the cooling circulation. For these reasons, the risk of installation ageing and malfunctioning due to air pollution and high temperatures is considerably lowered. This reliability ensures easy maintenance of the motor within customer systems. An easy-to-select and easy-to-install solution, the new LC motors are particularly recommended for plastics & rubber, test stands, industrial refrigeration, marine and nuclear applications, and crushers for the food and animal feed industry. including reinforced winding insulation and insulated bearings. The motor can also be equipped with an encoder for applications that require precise positioning.
Key features:
Variable speed can generate immediate operating profits, such as up to 50% energy savings (depending on the application and operating conditions) or increased productivity as a result of improving the process and reducing machine downtime. The return on investment is consequently extremely quick.
- Frame sizes: 315 to 500 (< 315 and > 500 on request) - Voltage: 400 V for 315 to 450 mm / 690V for 500 mm - Number of poles: 2, 4 & 6 - Power: 150 to 1,500 kW - Frequency: 50 or 60 Hz - Insulation class: F or H - Mounting: B3, B35 and V1 (other position on request) - Double nameplate: DOL + variable speed characteristics
A design giving priority to safety and reliability Benefitting from optional IP56 or IP65 protection to safeguard against external hazards, the LC range is fitted with a water leakage detector to control the water circuit reliability.
www.emersonindustrial.com
Another option, space heaters, ensure safety during motor start-up, while winding and endshield thermal protection control and monitor the motor temperature. MORE INFORMATION
A design facilitating maintenance Developed to reduce operating costs without compromising industry needs, LC motors are equipped with a patented breathable membrane. This completely waterproof (IP 66 minimum) feature considerably reduces condensates, whose evacuation is achieved by drain plugs.
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EPLAN PLATFORM 2.6 NOW AVAILABLE
Current terminal status can be shown with the expanded terminal editor. Manually or automatically defined jumpers can also be easily identified. Accessories can be graphical-ly visualised.
It’s quite the example of an “out of the box” culture of innovation. With the new Eplan Platform version 2.6, users benefit from substantial engineering features that can easily be integrated into everyday work processes, including new functions for terminal design and project data management, the representa-tion of piping in fluid power engineering, and optimised IT integration. Another highlight: Eplan Platform is now also available in Turkish and thus offered in a total of eighteen languages.
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nglish, German, Japanese and Chinese: Eplan software previously “spoke” just seventeen languages. With the new version 2.6, Turkish has been added to the software languages–after all, Eplan has been running its own affiliate company in Istanbul since 2014. There are also numerous technical upgrades in the newest version. Used accessories can now easily be depicted when processing and managing terminal strips. Furthermore, automatically or manually defined jumpers can also be easily identified. Users also have the possibility to display the current terminal status as it is represented in the Navigator. Yet another im-provement: a new connection-oriented view quickly shows which terminal connections are still free and therefore available. Aside from these functionalities making designing simpler, they also significantly acceler-ate design engineering processes.
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Managing Projects and Project Data Using the Quick Input Filter for project management makes it even easier to process and manage projects and project data. Subprojects are freely definable and can be saved at will, and there is more flexibility in name allocation. For instance, users can only update the main project instead of storing subprojects with the goal of bringing the main project up to date. In project structure management, certain structures can be searched for and revised throughout the entire project, which considerably simplifies project oversight. The definition of sequencing pages for print or PDF outputs has also been appreciably enhanced–and users also benefit from faster results in this area. Piping/Hose Lines in 3D For hydraulics and pneumatics, for cooling and lubrication: numerous applications require the use of pipes or hose lines to transport media such as air or oil. Eplan Fluid Professional, including the Eplan Pro Panel add-on, now
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Function-oriented design with Eplan is a source for increasing efficiency with the Eplan Platform.
With Eplan Preplanning, data from external sources can now be imported. A preview function allows incoming data to be verified before being imported.
offers the possibility to represent piping and hydrau-lic hose lines directly in 3D with complete layout functionality. Design engineers can thus review the layout or for instance the length of the hose lines. An export function is also provided in order to transfer the pipe geometries to an external manufacturing software for pipe bending.
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From Preplanning to Detail Engineering Many new functions were optimised to simplify integrating Eplan Platform into customersâ&#x20AC;&#x2122; existing processes. Eplan Preplanning now allows data from external sources to be imported. A preview function allows incoming data to be verified before being imported. Differences are easy to recognise and even previously deleted objects can now easily be found and removed from preplanning and detail engineering. This represents the next step toward more data consistency and data continuity within design engineeringâ&#x20AC;&#x201C; from preplanning through to detail engineering.
Better IT Integration User management has also become easier: existing users can simply be imported into an IT infrastructure instead of having to create a new user. Eplan user rights management was expanded with support for Active Directory. The use of SQL databases has also been made simpler: a selection list of available SQL databases is available from which to select the correct one.
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BUREAU VERITAS LAUNCH NEW OIL CONDITION MONITORING ASSET MANAGEMENT SOFTWARE IN AUSTRALIA Bureau Veritas, global leaders for testing, inspection and certification services, have launched the exclusive Lube Oil Analysis Management System (LOAMSSM) software at their Adelaide Oil Condition Monitoring (OCM) laboratory.
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ureau Veritas has been providing lubricant and oil analytical services in Australia for over 25 years, assisting maintenance managers in the industrial, heavy duty equipment and aviation markets to predict failures and prevent catastrophic maintenance events. The organisation is now looking to leverage this experience and increase the level of support so that clients can make timely, informed decisions that can improve machine reliability, reduce maintenance and repair costs and significantly extend equipment life.
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The continuing global expansion of the OCM program within the Bureau Veritas network has now provided the Adelaide laboratory with access to the LOAMS software, whereby clients will have access to one application that brings equipment testing and analysis data together from locations around the world. The LOAMS software provides online tools that bring clarity and meaning to complex laboratory results, maintenance recommendations that improve production and save money, and programs and support that foster collaborative customer partnerships.
“The launch of the LOAMS platform confirms our commitment to support client needs for lubricant and oil analysis services,” said Steve Edmondson, Business Development Manager for Bureau Veritas Oil & Petrochemicals in Australia. “In addition to our local experience, the Bureau Veritas network has over 55 years of global experience in OCM, so our clients can benefit from the expertise in OCM testing, data interpretation and advisory services.” Used oil analysis identifies trends in wear and contamination and monitors changes in the physical properties of lubricants and hydraulic oils. Laboratory data analysts can then pinpoint equipment problems in their earliest stages and make informed recommendations to customers. “Bureau Veritas is committed to investing in our network to ensure we are the global provider of choice for oil condition monitoring services. Increasing our capabilities in Australia is integral to our global expansion strategy and will provide our customers in this region with industry leading expertise,” said Matt Hopkinson, Senior Vice President, Global Oil & Petrochemicals of Bureau Veritas’ Commodities Division. Bureau Veritas will be demonstrating the LOAMS platform at Booth #207 at the 2016 Australian Petroleum Production & Exploration Association (APPEA) Conference and Exhibition on June 5-8 at the Brisbane Convention and Exhibition Centre. www.bureauveritas.com.au
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EXTRA SMART FOR INDUSTRY 4.0 - THE INNOVATIVE THIN CLIENT SOLUTION FROM PEPPERL+FUCHS
VisuNet GXP with RM Shell 4.1. The smart solution for applications in Zone 1 and 21.
The goal is to offer users solutions that meet all the challenges of Industry 4.0.
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ith this in mind, Pepperl+Fuchs continues to lead the way in developing innovative technologies. The most recent example is now being shown at the Hannover Messe trade fair: the smart thin client solution VisuNet RM GXP with new RM Shell 4.1. Solutions for Industry 4.0 must allow Pepperl+Fuchs direct horizontal and vertical access to information from the production system. In addition to communication within the production process, this enables access across all hierarchical levels, right down to the sensor. What exactly this means will be demonstrated by the company at the Hannover Messe trade fair using a smart thin client-based remote monitor with RM Shell 4.1 firmware.
With the remote maintenance mechanisms of the VisuNet Control Center, the administrators can connect to each smart remote monitor with RM Shell 4.1. Even from a distance, users can be supported directly on site to correct faults quickly and cost-effectively. The smart VisuNet GXP HMI system with RM Shell 4.1 therefore uses the advantages of Industry 4.0 for the process industry, even in Zone 1 and 21. MORE INFORMATION
The Internet of Things offers a wide range of new opportunities that can be used to their fullest advantage with this smart HMI system: It communicates with the process control system or the MES (which can be located in the cloud) and allows convenient control and monitoring of the process plant. The VisuNet GXP can also access sensors via a web browser for the purposes of commissioning, configuration, or maintenance tasks.
A real highlight of the exhibit is the additional VisuNet Control Center software for remote management of smart thin client-based remote monitors. With its IP-based communication, these can be set up, configured, and monitored from a central workstation. Engineers no longer need to be physically present in the hazardous areas or clean room, and this saves time and costs.
www.pepperl-fuchs.com
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INDIANA EVOLUTION
The Chip Breaking Effect: Direct delivery of cutting fluid to the work zone together with a variety of application-specific chipbreakers provides the Beyond Evolution™ grooving and cut-off system robust chip control while substantially extending tool life.
Manufacturing engineer Ian Dotson keeping an eye on machining progress with Beyond Evolution™ grooving and cut-off system from Kennametal
A job shop in the Midwestern US State of Indiana cuts insert costs in half and triples tool life with Beyond Evolution™ grooving and cut-off tools from Kennametal.
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ince the day some ingenious machine tool engineer first mounted a metal tube on an engine lathe, machinists have been looking for a better way to cut off parts. From hand-ground bits to high speed steel blades to indexable carbide inserts, cut-off tool technology has continued to improve over the years, increasing metalcutting efficiency and lowering operational expenses along the way. One large step in that evolution came with the development over recent years of multi-purpose cut-off tools able to switch hit as grooving, turning, and profiling tools, giving manufacturing companies the ability to simplify setups and shorten production cycles, and in some cases keep fewer tools in the crib.
Searching for simplicity One such company is EMC Precision, a family owned and operated precision machining job shop headquartered in Elyria, Ohio. Since 1925, EMC has provided prototype to production machining and value-added services to a range of industries including fluid management, hydraulic fluid & power, automotive, recreational, and other OEMs. Ian Dotson, manufacturing engineer at EMC’s Sheridan, Indiana facility says he was happy with the tool life and performance of his existing cut-off solution, and was only looking for a reduction in his tooling costs when he called his local Kennametal distributor, CCA Inc.
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The salesperson there introduced him to Kennametal’s Beyond Evolution™, a single-sided grooving and cut-off system with multidirectional turning capability, through the tool coolant, proprietary chip control, and “Triple V” secure seating geometry. Dotson admits he wasn’t too concerned about the bells and whistles, as long as the tool performed as well as what he was already using, and saved the company some money. He was pleased with the results. “We were using a 0.118 in. wide (3 mm) PVD-coated insert to cut off 0.75 in. diameter (19 mm) 4140 steel hydraulic 16 | Industry Asia Pacific | September 2016
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Many options through multiple ports Don’t have the right adapter or hose? It’s not a problem with Beyond Evolution™ toolholders, which are ported for KM, VDI, and virtually all machine platforms, and is capable of pressures up to 350 bar (5076 psi).
The Fan Effect Specially designed coolant delivery channels in the Beyond Evolution™ system separate and direct cutting fluid to where it’s needed most, underneath the chip and into the work area.
actuators,” he says. “We swapped out the old tool for a Kennametal Beyond Evolution cut-off and kept the feeds and speeds the same. After several runs, we determined tool life was essentially identical, so from a performance perspective there was no difference, at least not on this job. But the Beyond Evolution inserts are dramatically less expensive, roughly 40 percent of what we were paying for our legacy tools. It was a clear win for us.” Triple time The next win came on a job Dotson was running on one of EMC’s Daewoo Lynx 220 CNC lathes, a transmission gear shaft made of 1-1/4 in. (32 mm) 8620 steel, and using a 0.236 in. wide tool (6 mm) to back turn a journal on the left side of the part prior to cut-off. In this application, insert cost was still a concern, but Dotson’s primary goal was tool life improvement.
This is reality for many shops Even without high pressure coolant, Beyond Evolution™ increased tool life three to one compared to EMC’s legacy cut-off system
cutting speed a bit, from 350 to 400 sfm, and bumped up the feedrates by about 30 percent. Even so, tool life increased threefold, to just over 2600 pieces per insert. I’m confident we could have cranked up the feeds and speeds even more, especially if we had plumbed the tool for coolant through, but there was no need. This operation supplies another machine, and that one was already running as fast as it could go. The big thing for us was getting more parts between tool changes, and that’s exactly what the Beyond Evolution did. It’s an excellent product at a very competitive price point.” www.kennametal.com
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“The Daewoo isn’t equipped with high pressure cutting fluid, and the standard pump was unable to generate enough pressure for us to utilize coolant through the tool on our old cut-off system,” he explains. “Because of this, we’ve been stuck with flood coolant, and have always had some chip control issues as a result—the chip would roll back on itself and starve the cutting edge of coolant.” Despite the less than perfect cutting conditions, the Beyond Evolution performed beyond expectations. “We achieved very good results,” says Dotson. “This time we increased the 16 | Industry Asia Pacific | September 2016
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HIGH IMPACT CUSTOMIZED SOLUTIONS INTERCONNECTED ENGINEERING SERVICE INCREASES PRODUCTIVITY AND CREATES TANGIBLE ADDED VALUE
The linear axis can be positioned exactly using an AKD & AKM one-cable package (incl. control unit).
MEquadrat AG is a start-up that has been providing highly specialized solutions for four years as a mechatronics service provider, particularly in the laboratory and medical areas. Interdisciplinary thinking plays a fundamental role in this company’s product development activities. Original ideas related to implementation, efficient development and customized support also characterize the collaboration they had with drive specialist Kollmorgen on their new production module for the medical sector. Kollmorgen’s backlash-free direct drive solution allows exact synchronicity and concentricity with maximum precision up to 2 µm, and is more cost-effective.
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ne of the founding concepts of the service company MEquadrat AG, situated in the municipality of Root in Lucerne, is networked thinking and the creation of new machines and systems that meet its customers’ needs through consistency in the software used, the sophisticated mechanical and electronic components, and the associated increase in the degree of automation.
One thing is clear for Stefan Nyffenegger, a member of the executive management team at MEquadrat AG: “The interlock between the mechanics, electronics, and software is the key to innovative products and higher productivity. We also break new ground with our unconventional approach, as can be seen with the current project for a machine module that is designed for processing thin-walled material in the medical sector”. A difficult objective: Precise clamping despite high levels of rotation The two-sided and torsion-free clamping of highly sensitive glass and aluminum tubes is a particular challenge for the production module developed and constructed in Root. The product diameter ranges from between around
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Stefan Nyffenegger and Martin Zimmermann in front of the machine module. Nyffenegger emphasizes: “With the KBM kit motor solution from Kollmorgen we have found the perfect solution for us, and the overall drive concept really was customized to our needs.” Zimmermann: “The team from MEquadrat knew exactly what they wanted. We were able to make concrete proposals based on their input in order to get there. This allowed us to develop the best solution together.”
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Detailed view of Kollmorgen’s KBM Kit Motor. The delicate product can be guided through the drive in a fluid process as a result of the large hollow shaft. Absolute precise synchronization up to 2 µm is central to this.
one millimeter to 20 mm, with very thin wall thicknesses of around one-tenth of a millimeter. Cutting and joining processes are carried out on the sensitive hollow rod material. The high speed for the material clamped on both sides in the process requires absolute precision in terms of the synchronicity. Developing the overall module in such a compact manner in accordance with the customer’s strict specifications required a highly meticulous and extremely precise drive system for the spindles in the workpiece feeder mechanism and for the relevant process steps with the clamped product. Stefan Nyffenegger highlights: “With the KBM kit motor solution from Kollmorgen we have found the perfect solution for our needs, as the product can be guided through the drive in a fluid process thanks to the large hollow shaft.”
But tt became apparent that a rotor and a stator with the full functionality of a servo drive should be used as a result of the compact packing density and complexity of this assembly. In the end, the company decided the best
Aside from the time pressure and the extreme requirements related to precision in the functional specifications, there was another additional crucial challenge related to the medical technology: “The drive solution must be free from abrasion and lubricant, and we weren’t able to carry out any experiments at the implementation and commissioning stages for the mechanics and software”, says Nyffenegger. All of the components provided in this machine module therefore had to be tested and shown to be absolutely reliable.
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Collaboration on an equal footing for unconventional solutions The engineers at MEquadrat already had the idea of selecting a direct drive as they were designing the drive system. heir intention was to use an existing modular design in order to meet the precision requirements and to guarantee implementation on a time and cost-efficient basis.
solution was from Kollmorgen. The experts at the drive manufacturer were ready for any special requests. Decisions at the implementation stage for this project were made very quickly, as the experts from both companies collaborated witheach other on an equal footing. The synchronicity however remained a problem. But a few ideas were developed for this and the product selection was narrowed down during some initial telephone discussions. The Key Account Manager at Kollmorgen, Martin Zimmermann, and his colleagues providd their full support: “When MEquadrat only requested the rotor and the stator for the feeder unit in this project, we knew that a mechatronics engineer would need to focus on the motor in greater detail. You have to have confidence when trying new things like in this project, which requires mutual and absolute trust”.
The interaction of the direct drive with AKD Drives and the controllers from National Instruments (NI) enables 16 | Industry Asia Pacific | September 2016
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The linear axis can be positioned exactly using an AKD & AKM one-cable package (incl. control unit). The KBM Kit motor which is responsible for synchronization of the tubes fed through sits on top of this.
extremely precise positioning. The cycle times in the current regulator are around 670 ns, and are just 62.5 µs in the speed regulator. Nyffenegger stresses: “This allows us to achieve optimum synchronicity in line with these high dynamic requirements. As such this drive combination represents the optimum price-performance ratio.” Precise positioning with plug-and-play solutions The crucial thing here that the two synchronized axes achieve extremely precise concentricity of 2 µm. Nyffenegger adds: “We’re talking about accuracy ranges that are otherwise only seen in spindle axes in large production plants.” The high speed was another of the major challenges in this project. There are systems on the market that “can indeed clamp sensitive products such as these at the required level of accuracy, but they often lose their clamping force from 500 rotations per minute. I haven’t seen any comparable product on the market that maintains its full clamping force at 3000 rpm!”, highlights Nyffenegger.
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The “AKM” drive with single-cable solution and SFD feedback were selected for the linear axis in the machine design. The components now just needed to be put together and everything fitted perfectly. The resolver method as a single-cable solution is one of the drive expert’s specialties aimed at making optimum use of the robustness of the resolver. Nyffenegger stresses: “The wiring required in the AKM motor is also minimal here as a 16 | Industry Asia Pacific | September 2016
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The direct drive permits extremely precise positioning. The cycle time for the current regulator is 670 ns, while for the speed regulator it is 62.5 µs.
result. Highly compact cable carriers can also be used which really are sensational for tight spaces.” Summary: Achieving the objective using collaboration based on trust The AKD one-cable package (controller & servo motor) is used for the components in the liner drive for the feeder mechanism. The major benefit with this is that the system comes from one source. Nyffenegger emphasizes: “This way I don’t need to worry about any screw fittings or pins that do not fit. We just had to plug it in and get started, which also made the implementation time very short.” Integration of the precise drive technology in the precise mechanics was therefore the central element in the very close and focused collaboration for this project. Keeping an eye on the costs–despite the required level of speed accuracy, the bearing and form tolerances for the mechanics and the fact that everything fits right from the word go, required a lot of mutual trust for both sides. Martin Zimmermann adds: “Our specific part in the project related in particular to our comprehensive recommendation as to how the customer can achieve its objective in an optimized and most costeffective manner.” One thing is clear for Stefan Nyffenegger: “We were also able to discuss ideas directly with the Kollmorgen product developers, and put forward our requests related to the shaft and hub connections. Sitting down at a table and discussing in order to find solutions, or discussing the design details on
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The AKD servo amplifiers are fast, flexible, are suitable for a wide range of functions with Ethernet-based communication, and can therefore be integrated quickly and easily into any application.
the phone, provided us with the assurance that everything would work correctly with the drive, and that we would be able to get things right the first time on this project.” The design phase alone for the machine took just three months, which is extremely efficient. “The Kollmorgen part such as the installation of the axes and connection of the motor with full configuration and testing was completed within two days. This drive concept which was really customized to our needs worked out brilliantly for us. It fulfilled its objective, worked straight away, and met all of the requirements that we set ourselves for our customer.”
AKM standard synchronous servo motors with permanent magnets. The powerful synchronous servo motors from the AKM series, which includes more than 500,000 standard models, are available in different fastening, connection, speed, and feedback versions and with lots of additional options. KBM frameless kit motors (modified by the customer in order to fit into the module). KBM frameless kit motors for rotary direct drive applications. The wide selection of frameless fit motors in the KBM series is the latest direct drive technology. They meet all of the requirements from machine constructors in terms of flexibility, power density, dynamics, lifespan, and simple installation. AKD & AKM one-cable package for easy integration. AKD servo controllers and AKM servo motors can be used in any application and are particularly cost-efficient one-cable solutions. The AKD servo amplifiers are fast, flexible, are suitable for a wide range of functions with Ethernet-based communication, and can therefore be integrated quickly and easily into any application. AKD enables plug-and-play commissioning and interfaces with all parts of the machine without barriers.
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Benefits of Use: • High flexibility of the coordinated components • Integrated hollow shaft for special application predestines integration of a clamping system which maintains its clamping force even at 3000 rpm • Direct drive without any play or redundant mechanical parts allows exact synchronization and concentricity with the utmost precision up to 2 µm and is thereby hardwearing • EtherCAT on board for simple implementation and integration (hardware and software)–also in LabVIEW • Excellent, comprehensive support from Kollmorgen from design through execution to commissioning • Easy conversion to different diameters • High process stability when increasing the degree of automation, achieving higher productivity levels, leading in turn to increased profitability
Products used: The following Kollmorgen motors (with a 1-cable system) and drives are used in the project:
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DER ANTRIEB IS IN CONTROL
Networking in today’s production environments: smart drive units process data and transmit detailed status and application information as needed.
Smart drive systems increase manufacturing efficiency.
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ntelligent plant concepts are taking hold in all kinds of industrial operations. Comprehensive drive solutions provider NORD DRIVESYSTEMS offers “NORD 4.0 ready” components designed to facilitate and further this development.
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Modern process plants require automation technology with advanced functional intelligence. Components must be able to provide key data from the field via various different networks and make a wealth of information including data from connected sensors and actuators available. In addition, smart field devices are increasingly expected to actively monitor events in the field and react autonomously.
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Drive manufacturer NORD DRIVESYSTEMS addresses these demands with a modular range of geared motors, drive electronics, and software functions. The differentiated range of distributed drives facilitates the configuration of highly economical solutions tailored to a particular application’s characteristics. Featuring an on-board PLC, NORD inverters can implement logical sequence control. They offer full connectivity for communication with other nodes on the network, including flexible access from a device with a standard Ethernet interface by means of Ethernet tunneling. Know when to act The first and foremost prerequisite of intelligent process control–wherever the controller is installed and however it is connected (by cable or wireless, via Industrial Ethernet or Internet)–is accurate data from the field level. The components themselves must communicate their operating status in order to allow conclusions about what is happening in networked system segments. There must be appropriate interfaces for the vertical integration of sensors and actuators into control, management, and production planning systems, and high-quality data transmission must be ensured. NORD frequency inverters therefore monitor and transmit drive data and also collect information from
NEWS Up to 24 drives from NORD DRIVESYSTEMS per beverage filtration unit–distributed drive electronics reduce the necessary cabling and all but eliminate EMC issues.
externally connected digital and analog sensors and actuators. Moreover, they enable condition monitoring and predictive maintenance using software capabilities for efficient diagnostics. The inverters can, for example, calculate the state of the gear lubricant and indicate when an oil change is required. They can also autonomously monitor wear on the braking surface as well as the load situation for the entire drive train. Based on such data, operators can implement predictive maintenance, thus augmenting plant availability.
Application development made easy NORD also facilitates application development, providing the user-friendly, free-of-charge NORD CON programming and parameterization software that supports drive-related functions according to IEC 61131-3, as well as the PLCopen motion control library. Customer-specific routines can be freely programmed in the text-based programming languages “Structured Text” or “Instruction List”. All driverelated functions can be implemented directly in the inverter PLC. Users therefore do not need to spend time and money on the development, verification, and validation of an application-specific firmware. Moreover, NORD CON enables remote access via Ethernet tunneling – for instance, from a notebook with a standard Ethernet interface –, which gives users very flexible remote diagnostics and maintenance options. NORD frequency inverters can also manage safety applications, notably for implementing Safe Stop 1 (SS1) and Safe Torque Off (STO). A library with these safety-related functions is available for free from the NORD website. It enables an evaluation of machine applications according to DIN EN ISO 13849 with the safety integrity software tool SISTEMA.
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Autonomous removal of obstacles The frequency inverters can utilize their versatile sensor interfaces to do much more than just pass on data to a central controller. These drives also react to changing process conditions according to their parameterization. They can implement closed loops based on their integrated PI controller functionality. In metering applications, for example, NORD drives detect the fill level and control replenishment. In all kinds of process applications, networked drives ensure that glitches that occur will often not result in downtime with considerable costs. By monitoring the load situation, the on-board PLC of the inverter is able to detect blockages of pumps, screw conveyors, or agitators. If proper drive parameters are set for glitch scenarios, a NORD drive will, for instance, first attempt to remove a mechanical obstacle by reversing direction and by pulse operation. If this effectively resolves the blockage, the drive will then resume normal operation. If the problem
persists, the inverter can submit an error signal to the control level and can possibly initiate a fallback procedure, e.g. have other networked drive units unlock a bypass. The PLC capabilities of these inverters significantly contribute to higher plant availability and lower service costs.
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Highly intelligent drive family: NORD frequency inverters for control cabinet or motor mounting feature integrated PLC functionality.
All frequency inverters are 100% made in Germanyâ&#x20AC;&#x201C;manufactured and tested at NORD Electronic Drivesystems in Aurich.
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State-of-the-art decentralized automation Distributed drive solutions for simple, low-cost, and efficient machine and system designs are still the fastestgrowing product segment for NORD. Drive systems based on the SK 200E line of frequency inverters are most in demand. They offer the same extensive functional range (including positioning, on-board PLC, safety-related drive functions) as their SK 500E counterparts for control cabinet installation. The robust distributed units from NORD cover an exceptionally large performance range. This allows for versatile installations with decentralized process control of pumps, compressors, screw conveyors, etc., with motor outputs up to 22 kW. Moreover, NORD inverters feature highperformance microcontrollers and can control synchronous as well as induction motors. The company configures mechatronic drive systems based on three-phase induction motors and permanent magnet synchronous motors with efficiency ratings up to IE4 (Super Premium Efficiency), all of which are manufactured in-house. The IEC standard motors enable simple, easy-to-service, and economical drive concepts. In addition, drive systems from NORD combining a motor and an electronics unit achieve the highest level of system efficiencyâ&#x20AC;&#x201C;an IES2 rating according to the current EN 50598-2 European Ecodesign standard. www.nord.com
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HIGH-TEMPERATURE PYROMETERS FIT FOR HARSH ENVIRONS
Easy operation, superior precision, and longevity combined in one rugged infrared thermometer.
Fluke Process Instruments introduces the Endurance series of high-temperature infrared thermometers. Featuring a stainless steel IP65 housing and galvanically insulated I/Os, these units enable continuous process monitoring of the most demanding industrial applications, including primary and secondary metals manufacturing, carbon processing, and silicon production.
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roviding a measurement resolution of 0.1 °C, they also meet the requirements of the semiconductor industry. Two models cover wide measured temperature ranges of +550 °C to +1,800 °C and +1,000 °C to +3,200 °C, respectively. They can be operated in one- or two-color (ratio pyrometer) mode. An optical resolution of up to 150:1 allows measurements of smaller objects from a distance.
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The series is designed for comfortable configuration and operation. The sensors feature an intuitive rear-panel user interface and a built-in web server for data archiving, traceability, and process troubleshooting. The PC-based Endurance setup and monitoring software includes time-saving tools such as the new match function which automatically detects the correct emissivity of the measured surface. What is more, Fluke Process Instruments has further extended the range of sighting options and now offers a high-resolution on-board video camera for remote monitoring of the application and sensor alignment via Industrial Ethernet. In addition to laser sighting, which marks the position or size of the measurement spot, LED sighting
projecting the actual spot size on the target is also available now. Endurance series pyrometers provide a robust solution for manufacturers seeking to improve product quality and uniformity, reduce reject rates, maximize throughput, and minimize energy costs. Periodic lens cleaning checks are unnecessary, since a dirty lens alarm tells users when it is really time to clean. Accessories include an air-purge collar. The rugged sensors operate reliably at ambient temperatures up to +65 °C or up to +315 °C using cooling accessories. The manufacturer provides a best-in-class fouryear warranty. The sensors use either Power over Ethernet (PoE) or DC power (18 to 48 VDC, 500 mA). They are available with Industrial Ethernet, RS-485, or Profinet interfaces as required. Contact for sales in Asia: asia@flukeprocessinstruments.com www.flukeprocessinstruments.com
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