24 | APRIL 2020
EMEA
industry THE INDUSTRY MAGAZINE FOR EUROPE • MIDDLE EAST • AFRICA
ADDITIVE MANUFACTURING: UNLOCKING THE DISRUPTIVE POTENTIAL
6 CMS 700I 3D NEW TYPE OF CONTOUR MEASUREMENT
38 NICOLÁS CORREA MOVES INTO TOP GEAR WITH REDEX TECHNOLOGY
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KOLLMORGEN’S NEW 2G MOTION SYSTEM
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IN THIS MAGAZINE…
6 Additive Manufacturing: Unlocking the Disruptive Potential 12 Service via APP for mobile use 13 Streamlining storage space for world-known automaker 14 World’s first installation of R32 rooftop units 16 A seventh Verlinde overhead crane of 40 tonnes was recently installed in Greg Transports’ warehouse facilities in Belgium
18 Seeq Announces Availability of R22 and Beta Release of Seeq Data Lab at ARC Industry Forum
20 Seeq Corporation Expands Series B Funding with $24 Million to Fuel Advanced Analytics Growth Strategy
22 IM-7500 Image Dimension Measurement System takes complex component readings quickly, easily and accurately
24 Instant High-Precision Measurement System Cuts Inspection Time for Presspahn 26 Rohde & Schwarz validates first 5G RRM conformance tests with the R&S TS-RRM test system
27 Sierra Wireless selects innovative R&S ATS1800C test chamber with gold reflector for 5G NR FR2 testing
EMEA
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INDUPORTALS
MEDIA PUBLISHING
28 ULTRA 80: a new bar feeder from LNS Group 30 Nicolás Correa moves into top gear with REDEX technology 32 Manufacturing Efficiency is On-time Deliveries and Satisfied Customers 37 New reflective signs bring safety to dark places 38 New type of contour measurement 39 Cryogenic chemistry made easy 40 impact and bend-resistant high-performance ceramics 42 More than 1500 autoclave cycles possible 43 Kollmorgen’s New 2G Motion System 44 #aworldwithoutiwis campaign 46 Magnetic encoder system with Drive-Cliq interface from Balluff 47 Innodisk Delivers the Future of Automation with CANopen Support 48 LogiDrive intralogistics solutions combine energy efficiency and the reduction of variants
50 LEMO now showcases its product line on EPLAN Data Portal 51 Red Lion Presents Layer 3 Gigabit Ethernet Switch 52 Emerson’s New Pulse Valve Delivers Higher Peak Pressure for Longer Bag, Filter Lifespan and Reduced Maintenance In Reverse-Jet Dust Collector Systems
54 Souriau announces a range of REACH-compliant composite connectors for aeronautics
Steed WEBZELL
EDITORIAL
3D PRINTING IS MAKING HEADWAY IN INDUSTRY The first patent for the manufacture of 3D objects by adding successive layers was filed as early as July 16, 1984. It was a French patent. The second patent was filed on August 8, 1984. By the inventor who would soon become one of the co-founders of 3D Systems. This American company has now become the world leader. So, what happened? How come that history will tell that the French patent got forgotten? Two things have worked in the American company’s favour. In the ’80s, on the other side of Atlantic, no-one was ashamed to talk about money or raising funds to start a company (aka capitalism!). (For those who remember, creating a company in France was a real challenge at the time, a task that was both unproductive and very time-consuming). And then most importantly (“last but not least”, as Charles Hull the originator of 3D Systems’ patent would say), to ensure the continued protection of his patent, he made sure the maintenance fees were paid regularly. In France, someone probably found way to save a bit of money by quietly removing patent protection out of the list of “minor expenses”. Fast forward… Very soon after, new patents arrived, consolidating the initial work done by 3D Systems. Fast forward again… The first 3D printers were released in the late 1980s. The company was launched. Skip to the next chapter… The 3D revolution has taken off. By adding successive layers, the technique of “additive” manufacturing was able to develop further. 10 years ago, only a few, very expensive 3D printers were capable of sufficient precision to produce industrial quality parts. At that time, they were mostly for making prototypes. Sometimes small quantities of parts were produced, but only in very small series. As well as dimensional accuracy, the 3D printers also lacked speed. Today, mastery of the technology enables very thin layers (a few tenths of a millimetre) to be produced, and the reduction in production times makes it possible to achieve industrial-level speeds.
It must be said too, that about ten years ago, the mixtures of “glues” and powders used to amalgamate the successive layers were only just beginning to diversify; now the catalogues of machine manufacturers are filled with different types of polymers and various metal powders. It should be noted in passing that we are seeing a growing number of scientific publications about 3D printing of animal and human skin to accelerate the healing of wounds. And another very important trend: it is becoming possible to build large objects (a vehicle capable of carrying a load of 250 kg, for example). Over the past several years, all branches of industry have taken an interest in 3D printing. Mechanical engineering industries, of course, but others as well. As a result, new design and manufacturing methods using 3D printing are being discovered everywhere, in design, architecture, construction, automotive, aeronautics, railways and the whole transport sector for passengers and goods (both with driver or driverless, for long distance haulage or last mile delivery), the energy sector, electronics, the food industry, etc. This technology makes it possible to create shapes and parts that were previously impossible to make. Make no mistake: at the heart of our workshops and factories, manufacturing techniques using subtractive machining (drilling, milling, boring, turning) and additive techniques (3D printing) are and will remain complementary. But it is clear that the latter open up new avenues for the development and manufacture of parts and systems. And of course, if all industries can be able to benefit from this technology in future, it is also because machine prices have fallen considerably, and manufacturers are striving to develop their machine capabilities at a rapid pace. - Read more on pages 6-11 in this issue.
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THE INDUSTRY MAGAZINE FOR EUROPE • MIDDLE EAST • AFRICA
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ROHDE & SCHWARZ
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INDUPORTALS
MEDIA PUBLISHING
MARKET OVERVIEW
ADDITIVE MANUFACTURING: UNLOCKING THE DISRUPTIVE POTENTIAL Author: Steed WEBZELL
The growing popularity of 3D Printing or Additive Manufacturing bodes well for the sustainable future of Planet Earth.
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D printing or additive manufacturing has been described as one of the most disruptive technologies of the present age – the key to the future of manufacturing. Invented in the early 1980s, it has risen in popularity hugely in recent years thanks to the rapid evolution and convergence of several technologies in the digital era, making it easily accessible to professionals and hobbyists alike. Additive Manufacturing (AM) or 3D Printing, once the exclusive preserve of rapid prototyping, is now seen as the answer to produce products or parts anywhere, anytime. Unlike conventional or subtractive manufacturing, which makes use of processes like milling, cutting or grinding to remove material, AM involves adding of material, layer by layer, to form an object or a part, using a CAD software or 3D object scanner. There are many different processes, technologies and materials used in AM, the materials range from thermoplastics to metals, and ceramics to biochemicals, the latter often used in medical implants. One of the main advantages of additive manufacturing is that it facilitates production of customised parts on demand at relatively affordable costs – the parts range from a lost wheel of a toy car to the tracked wheels of the Mars Rover. More importantly, the process also enables use of intricate designs with complex geometries that reduce weight while adding strength to difficult and/or expensive to manufacture
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The fuel nozzle manufactured by GE for the LEAP jet engine.
MARKET OVERVIEW
The BigRep LOCI Concept.
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The seat bracket manufactured by General Motors.
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MARKET OVERVIEW GE Additive’s Arcam EBM Spectra L.
parts made by traditional methods. The example of the fuel nozzle designed and 3D printed by GE for the LEAP jet engine is well known. Previously assembled from 20 components, this walnut-sized complex nozzle is now a onepiece marvel of engineering, thanks to 3D printing. It also weighs 25 percent less than its traditionally manufactured counterpart, is five times more durable and 30 percent more cost-efficient. As Janne Kyttanen, a 3D visionary and inventor of 3DTI – the first ever manufacturing technology which integrates 3D printing for mass customisation – maintains, the only limitation in applications of AM is creativity, or the lack of it.
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While the advantages are many, the AM process is not without its share of disadvantages, the foremost being the high cost both in terms of initial investments as well as operational expenses. The latter is thanks to the high cost of materials, which in most cases are supplied by the hardware manufacturers, and tied up with OEM agreements. This also rules out mass manufacturing, especially of large parts, as the economics here is clearly in favour of conventional manufacturing processes. However, for special requirements, AM works to great advantage regardless of size and volumes. The example of a seat bracket – a standard auto part that secures seat-belt fasteners to seats and seats to floors – manufactured at General Motors using Autodesk’s generative design software, illustrates this vividly. What was a boxy part consisting of eight pieces welded together, is now a sleek looking anchor, 3D printed in stainless steel. The substitute is not only 40 percent lighter, but also 20 percent stronger, and cheaper to produce as it reduces the number of vendors and the welding job. Little surprise then that every automobile manufacturer today has invested in AM facilities in quest of optimising vehicle design to save on costs. An average car has about 30,000 parts. While all these cannot be manufactured by 3D printing, there are several which can be thus identified, like the seat bracket in the example mentioned above, benefitting from the technology as it evolves.
3D printed plugs by EOS FDR technology. 24 | Industry EMEA | April 2020
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Innovations at Formnext At Formnext 2019 (Frankfurt, November 2019), Europe’s largest trade fair for Additive Manufacturing and the next generation of intelligent manufacturing solutions, leading companies such as 3D Systems, Addup, BigRep, DMG Mori, EOS, Formlabs, GE Additive, HP, Markforged, Renishaw, Siemens, Stratasys, Voxeljet and many others presented several new and more efficient manufacturing technologies and advanced solutions for industrial use – software, hardware, materials and services – besides making a plethora of announcements of tech tie-ups and alliances. GE Additive, part of GE and world leader and pioneer in additive technology, unveiled a slew of products including the Arcam EBM Spectra L, a metal 3D printer that meets increased demand, especially from the aerospace industry. This new model offers larger build volume and faster speed, coupled with an integrated system architecture, machine health analytics and automation features. The Spectra L has been developed to increase productivity and reduce cost per part by 10%, thanks to almost double the build volume of the Arcam EBM Spectra H. The 4.5 kW beam power increases build speed by 20%, compared to the Arcam EBM Q20plus. The company also launched the Concept Laser M2 Series 5 metal printer, which meets the high expectations for part quality and consistency from customers, especially in the highly regulated aerospace and medical industries, which, together with automotive, are among the three leading users of AM technologies.
MARKET OVERVIEW
The hybrid aerospace bracket developed by 3D Systems.
BigRep, the company which develops the world’s largest serial production 3D printers, unveiled a fully 3D printed, autonomous electric podcar concept, the LOCI. The LOCI prototype is specifically designed as a “last mile transportation solution” in urban environment, for use at airports and train stations, daily work commutes, and as campus transport or for local deliveries. Developed using parametric modelling, LOCI utilises the full potential of AM and its limitless flexibility. The podcar’s design can be easily customised for a given location or application; adjusting handling purpose, materials, structural properties, special tyres for different terrains, custom branding, and integrated solar power. At Formnext, the company showcased three different LOCI iterations: The Berlin LOCI model presented as a single-person campus commuter; the San Francisco LOCI with narrow body for urban commuting; and the Dubai LOCI for airport transportation with a high-end luxury feel, solar panels, space for luggage, and rugged tyres for desert weather.
EOS, the world’s leading technology supplier in the field of industrial 3D printing of metals and polymers, showcased its Fine Detail Resolution (FDR) technology for processing polymers for the first time. EOS is the first manufacturer to develop a solution for powder-based industrial 3D printing using a CO laser. This makes it possible to produce extremely delicate yet robust parts with fine detail resolution surfaces and minimum wall thicknesses of only 0.22 mm. It will open up new applications for series production and will offer an even broader variety to the industry when it comes to choosing the right 3D printing technology from EOS for processing polymers. The FDR technology combines the best of two worlds – the detailed resolution of stereo lithography (SLA) with the durability and quality of selective laser sintering (SLS). Presented for the first time at Formnext, it opens up options for completely new applications in the field of polymer-based additive manufacturing, such as for filter units and fluid channels, plugs, and other electronic components as well as consumer goods such as eyeglasses.
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Another BigRep launch at Formnext was the NEXT AGV, an autonomous guided vehicle developed jointly with Bosch Rexroth for use on the shop floor of the smart factory. Integral to agile, smart production, the 3D printed NEXT AGV is powered by an inductive energy unit feeding off the grid, and can serve as an automated logistics carrier with a load capacity of up to 250 kg. Tools and additional devices such as robots can be mounted onto the platform. Special 3D printed wheels with two different materials allow the platform to perform sideways movements.
3D Systems, the company co-founded in 1983 by Chuck Hull, the inventor of 3D printing, demonstrated at Formnext 2019 four production solutions designed specifically for the Healthcare, Aerospace, and Automotive industries. The company is in a unique position to offer solutions specific to customer needs through hardware, software, materials and professional services, integrating additive into traditional production environments. Through a strategic partnership with GF Machining Solutions, 3D Systems combines its innovation and expertise in additive manufacturing with GF Machining Solutions’ leadership in precision machining. This enables manufacturers to seamlessly combine additive and subtractive technologies to more efficiently produce complex metal parts within tight tolerances, and reduce total cost of operation. One of the solutions demonstrated at the joint booth was the production process to create an aerospace bracket in seven steps that integrate additive technologies, traditional metal technologies and innovative software solutions to achieve high-quality, repeatable parts at an optimised cost per part.
Essentium, Inc., announced the expansion of its AM platform with the introduction of high-temperature (HT) 24 | Industry EMEA | April 2020
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MARKET OVERVIEW
The new HSE 180•S HT from Essentium.
materials and new models of its award winning Essentium High Speed Extrusion (HSE™) Printing Platform. The nozzle temperature of the new HSE 180•S HT reaches 550°C and uses a wide variety of materials to produce parts that can withstand temperatures of 180°C. In bringing high-temperature AM capabilities to market without compromising speed, strength, scale or economics, Essentium has accelerated the potential of industrialscale AM, and delivered on its commitment to create a global, open ecosystem that puts customers in control of their innovation. The company also introduced four new materials including PEEK, High-Temperature Nylon (HTN), HTN-CF25 and HTN-Z (ESD safe) designed to deliver high heat, chemical and fatigue resistance and high strength for industrial applications. In addition to introducing the high-temperature HSE 3D printing platform, Essentium announced it will seamlessly integrate Materialise 3D printing Magics Essentials software with the Essentium HSE 3D printer. The integration between software and printer delivers an open and complete FFF suite comprising an endto-end workflow with all features needed for industrial scale 3D manufacturing to transform factory floors.
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Another major player, Renishaw, launched InfiniAM™ Sonic acoustic process monitoring software to complement its InfiniAM suite of AM monitoring tools. InfiniAM Sonic enables engineers to detect acoustic events within the AM build chamber and turn this data into useful information about build quality. The software is the first of its kind in the AM industry. The InfiniAM Sonic package is installed into the RenAM 500Q system as a factory fit option and includes four acoustic energy sensors to detect vibration in the build. The RenAM 500Q system is fitted with four high power 500W lasers to achieve build rates of up to four times faster than conventional single laser systems. Maximum efficiency is achieved on the RenAM 500Q because the lasers can work across the entire build plate, allowing the laser interaction to be managed effectively to ensure quality is unaffected by multi-laser interaction when processing. Renishaw is also collaborating with Sandvik Additive Manufacturing to qualify new AM materials for production applications. This 24 | Industry EMEA | April 2020
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The Renishaw Team at Formnext 2019.
encompasses a broad range of metal powders, including new alloy compositions that are optimised for the laser powder bed fusion (LPBF) process and which provide superior material properties. If 3D printing can replicate an object by just scanning and printing, it also opens a security threat. A key can be easily photographed or scanned and a duplicate printed anywhere. The event on technology that holds the key to the future of manufacturing came to an end with an award for a key – not an ordinary key, but the 3D printed “Stealth Key”, designed and manufactured by UrbanAlps AG, a Swiss manufacturer - the winner of the first prize of the purmundus challenge at Formnext 2019. Using stealth technology, UrbanAlps has created a physical key and cylinder system in which the code is neatly hidden under robust, narrow projections. As the purely mechanical key cannot be scanned, it offers maximum security and works independently of digital systems – neutralising the threat, effectively using the same technology. These are just a handful of examples from among the 852 exhibitors (632 in 2018) participating at Formnext 2019, representing the entire additive value chain. The event attracted over 34,000 visitors from 99 nations. The AM community is growing globally. The way forward Rising concerns over environmental degradation and climate change has finally caught the attention of governments and policy makers, as well as industries worldwide. Sustainability is the new mantra, carbon neutrality the new goal as more than 60 countries are aiming to reduce carbon emissions to net-zero by 2050, according to the United Nations. In mid2019, Bosch – the global supplier of technology and services – declared that the company would become carbon neutral in 2020. Many corporates are in the process of implementing their own schedules to achieve the same. As the world moves towards sustainability, 3D printing will have an important role to play, especially in all spheres of
MARKET OVERVIEW
The Stealth Key was awarded the first prize of the purmundus challenge.
mobility. Lightweighting – reducing the weight of all forms of transport on land, air and sea – is the top priority for OEMs. Generative design software is the enabling technology that makes this possible. When General Motors redesigned the seat bracket using Autodesk’s generative design technology in Fusion 360, the software came up with more than 150 alternative designs from which the most optimal design was chosen. Autodesk and BMW are working on using generative design technologies and additive manufacturing methods for creating a new kind of vehicle that can be lighter, faster, cheaper, reliable and easier to produce. The combination of generative design and additive manufacturing has wide applications beyond mobility. The technology has great potential in many other fields where materials are used – architecture and construction, buildings and plants, industrial machinery and consumer goods – with productivity gains and energy savings, helping reduce the carbon footprint. Speaking of materials, 3D printing has also made rapid inroads into the food domain, especially the confectionery segment, enabling intricate and attractive designs in cakes and chocolates. With rapid evolution and rising affordability as the hardware and consumables become cheaper, 3D printing or additive manufacturing will grow in popularity in years to come. From the humble footwear to the mighty spacecraft, the technology is rapidly revolutionising the way these are designed and manufactured, offering the key to a sustainable future.
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I N T R A LO G I S T I C S
MONTH’S PRODUCT
SERVICE VIA APP FOR MOBILE USE
The NORDCON APP and NORDAC ACCESS BT offer a mobile commissioning and service solution for all NORD drives.
NORD DRIVESYSTEMS goes mobile: With the NORDCON APP and the NORDAC ACCESS BT Bluetooth stick the drive specialist has created a mobile commissioning and service solution for all NORD drives.
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he NORDCON APP and the NORDAC ACCESS BT Bluetooth stick for all NORD electronic components are used for drive monitoring via a dashboard, drive analysis via a convenient oscilloscope function and drive parameterisation of NORD drive systems. The dashboardbased visualisation can be used for drive monitoring and fault diagnosis. With a help function and rapid access to parameters, parameterisation of drive units is simple and easy. In stand-alone operation, the NORDAC ACCESS BT can also be used for backup and recovery of drive parameters. The NORDCON APP and NORDAC ACCESS BT are available for all NORD drive electronics and can be used with decentralised frequency inverters as well as control cabinet inverters like the new NORDAC PRO SKÂ 500P.
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Added value for day-to-day work The NORDAC ACCESS BT is used as a link between the mobile terminal device and the app. The Bluetooth stick is used directly on the frequency inverter. Users therefore have practical access to the drive data and remain in full control. The NORDAC ACCESS BT can also be used without the app, for example to save parameter data. If the frequency inverter is damaged or if the drive has to be replaced, the original parameters can be easily uploaded from the stick. Parameter transfer between a drive and a PC is also possible. The app is available for iOS and Android operating systems in the App Store or in Google Play. www.nord.com
AU TO M OT I V E
STREAMLINING STORAGE SPACE FOR WORLD-KNOWN AUTOMAKER
To help clients optimize their storage space, Weland Solutions is always open to adapt vertical storage lifts after specific needs. The world-renowned car manufacturer, Koenigsegg, is one of many that’s excelled in their production with a customized storage solution.
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he automaker Koenigsegg is known all over the world for its iconic and exclusive cars. The company is always growing and with that a need for extra storage space. They decided to start a collaboration with Weland Solutions, and as a result, two custom-made vertical storage lifts of the model Compact Twin 2440 were installed. Two machines, one solution When Koenigsegg decided to work with Weland Solutions, it was mainly because they knew the company’s ability to customize machines after specific needs. A solution was created were two vertical storage lifts were connected to work together. Also, the interior and software were adapted and connected.
An environmental choice Weland Solutions always offers products with long sustainability. They also take complete responsibility for their machines, new as well as restored. That includes relocation, installation, start-up, and education for involved employees. From a customer’s perspective, restored products are also a cost-efficient choice. These reasons made it simple for Koenigsegg to hire the company. They invested in two restored Compact Twin 2440 and with the custom-made adjustments, their efficiency has excelled. www.welandsolutions.com MORE INFORMATION
“The world’s fastest car is designed and manufactured in Sweden, and so is the world’s fastest vertical storage lift. Our goal is to keep growing with Koenigsegg and with that, continue to adapt our machines after their specific needs,” explains Björn Karlsson, CEO at Weland Solutions.
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H VA C
WORLD’S FIRST INSTALLATION OF R32 ROOFTOP UNITS
As Lennox, air-handling specialist, is just launching the first R32 rooftop on the market, a Lidl supermarket is becoming the world’s first user of the e-Baltic units for energy-efficient delivery of hot and cold air.
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he advanced e-Baltic units, commissioned in January 2020, are fully compliant to the forthcoming 2021 Ecodesign regulation, and the French response to the EPBD regulations, RT2012. This world-first installation is seen as a key milestone in the industry and, moving forward, the Lennox strategy is to adopt R32 as a replacement for R410A due to its low Global Warming Potential (677 versus 1924) and its affordability.
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Originating in Germany in the 1930s, the Lidl group has grown to become one of the world’s largest supermarket chains with over 11,000 stores in 30 countries. In France, the company has around 1,500 supermarkets, 25 logistics platforms and 35,000 employees. Supporting such an impressive backdrop of growth, Lidl is committed to innovation and, in particular, to sustainable development.
Energy-efficient rooftop units One of Lidl’s ambition is to be able to produce more energy through their stores than they actually consume. To achieve this ambition, one of the aspects to consider is to reduce energy consumption. One of the reasons why Lidl selected the Lennox e-Baltic rooftop was to meet the building’s “bio” requirements. Bio (bioclimatic indicator), one of the three requirements of RT2012, is an index of good bioclimatic building design. This important measure takes into account heating, cooling and lighting needs, but is completely independent of the selected heating or cooling solution. Designed as a high-efficiency product, the e-Baltic emphasizes highly innovative components: lowconsumption electronically commutated motor fans; freewheel fan technology; newly designed piping; CO2 sensors; as well as a new generation of heat exchangers. The e-Baltic’s features enable the unit to adjust its power and airflow according to real climatic conditions; and thus, generate significant energy savings.
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R32 has many notable advantages that makes it the ideal replacement to R410A. It is a pure and economical substance, that is not patented and therefore, available from many suppliers. R32 is also already being used in the residential market. Another factor in R32’s favor is its low GWP. GWP stands for Global Warming Potential and represents the amount of energy absorbed by a refrigerant - and therefore the heat it releases into the atmosphere - relative to the same mass of CO2. Each refrigerant’s GWP is defined by the Intergovernmental Panel on Climate Change (IPCC), and its value can sometimes be updated. Speculative costs must also be considered in the refrigerant selection decision. To explain further, the challenge here is to not only be prepared for new regulations, but to absorb the inflated prices of refrigerants with high GWP. The risk of shortage means that prices are rising, a trend that is set to continue. Users will not have to face this problem with R32. In this context, Lennox has worked on designing new products that would provide cleaner air while using R32 as a new refrigerant; and is therefore the manufacturer offering the very first rooftop on the market using an alternative to R410A. Importantly, the design of the e-Baltic allows to reduce the refrigerant charge by up to 30%, which enables a decrease of the Carbon Dioxide equivalent; which also generates a tax reduction of 75%. In fact, the e-Baltic choice has enabled Lidl to halve its impact on the ozone layer while reflecting its commitment to a responsible ecological investment.
Environmental scrutiny There is increasing scrutiny across Europe on the impact of industry upon the environment. For this reason, the European Ecodesign regulation aims to support the design of products that combine energy efficiency and the rational use of resources. The aim is to promote eco-design in all devices that consume energy, including heating and cooling systems. By way of example, the 2021 Ecodesign directive looks to ensure the energy performance of the device in line with seasonal efficiency requirements.
Through the Lennox Cloud, connectivity allows permanent monitoring of the e-Baltic; which offers the potential to implement preventative maintenance routines. This means that at any time of the day or night, Lidl can access all the performance metrics of the e-Baltic units to ensure optimal use. The product utilize many sensors and advanced software based on the company’s experience and know-how, ultimately helping users such as Lidl predict any risk of downtime and plan maintenance operations accordingly. The ability to predict and forecast those operations can save companies such as Lidl considerable time, resources and money. In addition, the selection of The Lennox Cloud connectivity option offers an extended warranty that extends for up to 10 years; and thus ensure optimal use of the rooftop on the long run.
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Another European directive is F-Gas, which came into force in January 2015. F-Gas aims to limit the use of HFCs (hydrofluorocarbons) in the fight against global warming. Refrigerants with a GWP (Global Warming Potential) greater than 2,500 are banned from January 2020, while other HFCs such as R410A (GWP 1924) and R134a (GWP 1300) will have their availability limited by the drastic decrease in production quotas. In other words, these refrigerants will become more difficult – and thus more expensive – to source. Keen to support its environmental ambition; while meeting regulatory requirements and ensuring the comfort of its customers and staff; Lidl looked for suitable rooftop units for its brand new store. After a comprehensive review of the available solutions, the company opted for the e-Baltic rooftop from Lennox. R32, the obvious replacement to R410A.
Perfect choice Ideal for food and non-food retail outlets, as well as restaurants and larger shopping centers, the e-Baltic is part of the comprehensive Lennox range of air-cooled rooftop packaged units. These autonomous air-handling machines offer plug and play capability for the delivery of hot and cold air, in any season. The e-Baltic is the perfect option when looking for a product that combines high efficiency and a new refrigerant, while making a responsible investment. As a matter of fact, the e-Baltic offers connectivity to ensure optimal performances and optimal use of resources.
www.lennoxemea.com
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I N T R A LO G I S T I C S
A SEVENTH VERLINDE OVERHEAD CRANE OF 40 TONNES WAS RECENTLY INSTALLED IN GREG TRANSPORTS’ WAREHOUSE FACILITIES IN BELGIUM
One of Belgium’s leading hauliers has fitted out its warehouse with Verlinde overhead cranes and other high capacity equipment designed for an ongoing and intensive steel coil logistics business.
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reg Transports is one of the largest hauliers in Belgium in the steel business, specializing in steel coils for the car making industry in particular. 2015 marked the year the haulier acquired a warehouse offering it the opportunity of running its business more smoothly by storing steel coils delivered directly from various Arcelor Mittal Belgium factories by rail or road. It then transports them to end customers anywhere in Europe 7 days a week. The haulier, by virtue of this, offloads and loads 60 to 100 wagons together with 300 trailers on average every day.
The haulier had initially chosen overhead cranes whose operational capacities did not meet the load requirements. The company very soon encountered numerous operational difficulties and failures that were not resolved quickly enough by the firm that had installed the equipment. The successive failures became impossible to handle and were incompatible with the developing business activity. Greg Transports therefore decided to call upon the services of Electrolevage to carry out these special operations more rapidly, generally under 24 hr. This independent Belgian manufacturer specializes in the study, manufacture, assembly and maintenance of industrial lifting machinery, gantry cranes, monorail trolleys and jib cranes made from VERLINDE components. It very soon became quite clear that it was indispensable to replace the existing lifting machinery by equipment aligned to needs, that was dependable and robust. “At the start of our collaboration we assured our customer a systematically fast breakdown service both during the week and at the weekend which led, very soon afterwards, to our being consulted for the replacement of the existing cranes,” explains M. Dedrij, Managing Director of Electrolevage. We
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have worked for 15 years with Verlinde whose equipment is acknowledged as being reliable and of quality. We first proposed a 35-tonne crane based on Verlinde components in 2017. This was met by the satisfaction of users for its rapidity and reliability. Then orders for 5 other overhead cranes (2 with spans of 40.5 meters) were placed in order to keep abreast of the increase in volumes of coils handled by GregTransports that vary from 250,000 to 300,000 tonnes per month. Storage capacity at the facility is 130,000 tonnes of steel and 25,000 pallets.” “The overhead cranes in place at Greg Transports before our arrival were then transferred to a less intensive activity. The equipment was of good quality but not designed for the intensive handling of steel coils”, adds Mr Van de Wiele, Verlinde’s technical sales agency manager for Belgium, Luxembourg and Switzerland. We proposed equipment able to cope with the high handling throughput rate of coils. The Jib crane and end-carriage parts are designed for an M6 working cycle, which means intensive operations at full load and at top speed.”
These Verlinde cranes have capacities four times greater than those they replace and Electrolevage provides 4 years full warranty. A technician has been specially trained and is dedicated to the maintenance and servicing of these cranes. This order was very significant for Electrolevage. The maker was already experienced in this field, i.e. the handling of steel coils but never before to that extent. “The assembly and commissioning of the 22-meter cranes took a little more than a week and almost three weeks for the 40-metre cranes. The abnormal load transportation at night of girders required 2 semi-articulated trucks of a total length of 53 m and 12 persons for signalling duties,” adds Vincent Dedrij. Since the first crane was set up three years ago, Greg Transports has continued to place orders, the latest being a crane that will be delivered in early 2020. He unreservedly declares his full satisfaction as to their, quality, robustness and dependability.
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High capacity overhead cranes The Greg Transports warehouse facilities are currently equipped in all with 4 x 35-tonne cranes with a span of 22 meters and 2 x 35-tonne cranes with a span of 40 meters, perfectly aligned with the intensive operations required. They all provide high speeds of 63m/min for crossing, 40m/min for travelling and 16m/min for hoisting. They are
fitted with variable speed for all movements, radio remote control and LED lighting systems. A swing correction system is also installed as loads are heavy but require significant precautionary measures during manipulation. An impact on a coil could lead to serious consequences.
www.verlinde.com
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SEEQ ANNOUNCES AVAILABILITY OF R22 AND BETA RELEASE OF SEEQ DATA LAB AT ARC INDUSTRY FORUM
New R22 features fueling continued growth for Seeq in enterprise deployments and expanded machine learning support will be demonstrated at the Forum.
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eeq Corporation, a leader in manufacturing and Industrial Internet of Things (IIoT) advanced analytics software, announces availability of their latest release, R22, and beta availability of Seeq Data Lab, at the ARC Industry Forum 2020. Seeq applications include Workbench for easy to use advanced analytics, Organizer for publishing insights in reports and dashboards, and now Seeq Data Lab for accessing Python libraries.
Additional R22 features requested by Seeq users include: - Improved Scatterplot in Workbench: conditional filtering and more display options help users find relationships among signals more quickly.
These applications empower engineers and scientists in process manufacturing organizations to rapidly analyze, predict, collaborate, and share insights to improve operations and business outcomes.
- Multi-user Awareness: now easy to know when other users are viewing, editing, or presenting the same Worksheet or Topic.
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New R22 features support enterprise data governance initiatives and priorities to support Seeq expansion in large organizations. For example, Seeq Integrated Security honors OSIsoft PI security restrictions for PI data access and enables administrators to set signal-level permissions on data in historians and other time series data stores. Each user therefore only has access to the data they need, facilitating data access compliance. 24 | Industry EMEA | April 2020
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- NOAA Weather Service Connector: data from the National Weather Service API can be easily integrated into Seeq analytics.
Seeq Data Lab, now in beta, was driven by Mark Derbecker, Seeq’s Vice President of Engineering, in response to requests by Seeq users to gain access to Python machine learning algorithms, and data scientist requests to leverage Seeq functionality. “Our objective is to remove any barriers for process engineers who want to expand their Seeq analytics efforts to the rich ecosystem of Python libraries,” says Derbecker. “At
the same time, Seeq Data Lab will enable data scientists to participate directly in process data analytics.” Seeq Data Lab is built on Jupyter Notebooks and a Seeq Python library, called Spy, to access Seeq functionality, and it is managed by the same administration features as other Seeq applications. The result is a comprehensive set of experiences for process engineers analyzing time series data including viewing and reporting of data in Seeq Organizer, advanced analytics with Seeq Workbench, and expanding analytics capabilities with Python libraries in Seeq Data Lab. Seeq Data Lab also enables data scientists to find insights using machine learning algorithms and libraries, system integrators to create custom analytics for their clients, and asset vendors to enrich their remote monitoring and predictive analytics services for customers.
- Advanced models: Python libraries for inclusion of Neural Network, Random Forest, K-means, and other algorithms.
- Non time-series data: Python libraries enable analytics which include population statistics, data look-ups, and multi-dimensional data. ARC’s Forum, their 24th, attracts leading vendors, customers, and partners from across the automation industry. The ARC Industry Forum has been an important event for Seeq in recent years, and for the 5th year in a row Seeq customers will present on their use of Seeq to improve production outcomes. In addition to Seeq R22 availability, Seeq announced in December it had achieved Amazon Web Services (AWS) Industrial Software Competency status and that its advanced analytics solution was available in the AWS Marketplace. Seeq is also available as a software-as-aservice (SaaS) application on Microsoft Azure and in the Azure Marketplace. In addition to AWS and Microsoft Azure support, Seeq partners with many process automation vendors to support on premise deployments by connecting to systems sold by OSIsoft, Siemens, GE, ABB, Honeywell, Inductive Automation, AVEVA, AspenTech, Schneider Electric, and others.
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All of the browser-based Seeq applications – Organizer, Workbench, and Data Lab – connect to a shared Seeq server to enable collaboration, access connected data sources, and enable administrative control. For example, graphics created in Data Lab may be viewed in Organizer Topics, data modeled in Workbench may be accessed by Data Lab users, and Data Lab algorithm results are available for use in the other Seeq applications. Example use cases for process engineers and data scientists using Seeq Data Lab include;
- Custom visualizations: Python libraries for the display of specific data types and calculations can be incorporated in Data Lab analytics.
www.seeq.com/whats-new-r22 24 | Industry EMEA | April 2020
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SEEQ CORPORATION EXPANDS SERIES B FUNDING WITH $24 MILLION TO FUEL ADVANCED ANALYTICS GROWTH STRATEGY
Saudi Aramco Energy Ventures joins Altira Group, Chevron Technology Ventures, and existing investors to expand Seeq’s international and cloud-based businesses.
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eeq Corporation announced today that is has secured a $24 million expansion of its Series B funding. This expansion round is led by Saudi Aramco Energy Ventures (SAEV), the corporate venture subsidiary of the world’s leading integrated energy and chemicals company, Saudi Aramco. It includes renewed participation by Altira Group, Chevron Technology Ventures, Second Avenue Partners, and other existing investors.
Seeq enables engineers and scientists in process manufacturing organizations to rapidly analyze, predict, collaborate, and share insights to improve production outcomes. Customers include companies in the oil and gas, pharmaceutical, chemical, energy, mining, food and beverage, and other process industries. The funding will accelerate Seeq’s expansion of development, sales, and marketing resources, and will also increase its presence in international markets.
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“Seeq is providing an important improvement in software for customers in process industries to accelerate insights, action, and impact on their production and business outcomes,” comments James Sledzik, Venture Executive at SAEV. “We are pleased to be leading the effort enabling Seeq’s continued growth.” Upon final closing, Seeq expects the Series B expansion to reach approximately $30 million, which is in addition to Series B funding led by Altira Group. “With the backing of SAEV and our existing investors, Seeq is positioned to continue its rapid growth by addressing 24 | Industry EMEA | April 2020
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market demand for advanced analytics innovation,” says Steve Sliwa, CEO and co-founder of Seeq Corporation. “Through our direct sales personnel and more than 50 channel partners, our customer base has expanded to more than 40 countries with deployments as large at 5,000 users within one company.” This announcement follows a momentous 2019 for Seeq. Last month, the company announced it had achieved Amazon Web Services (AWS) Industrial Software Competencystatus and that its advanced analytics solution was available in the AWS Marketplace. These achievements will enable Seeq customers to rapidly investigate and share insights from process manufacturing data stored either on premise or in the AWS cloud.
Automation Solutions, Inductive Automation, AVEVA, AspenTech, Schneider Electric, and others. Highlighting the company’s momentum, in August 2019 Seeq ranked #369 on the Inc. 5000 list of fastest-growing private companies, and in November 2019 ranked #43 on the Entrepreneur 360 list. Seeq’s new release, R22, introduces features enabling support for the integration of structured data from SQL Server, MySQL, and CSV files; easier distribution of Seeq Workbench analyses to coworkers; and an expansion of Seeq machine learning integration and features. www.seeq.com
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Seeq had previously made its advanced analytics software available as a software-as-a-service (SaaS) application on Microsoft Azure and in the Azure Marketplace. Cloud-based Seeq deployments enable engineers at companies like Royal Dutch Shell PLC to access faster insights and reporting on real-time data. Other companies using Seeq include pharmaceutical industry leaders such as Merck and Roche, as well as chemical industry leaders like Lonza and Covestro. In addition to cloud support, Seeq partners with an extensive set of process automation vendors for on premise deployments by connecting to and working with systems sold by OSIsoft, Siemens, GE, Honeywell, Emerson 24 | Industry EMEA | April 2020
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MEASUREMENT
IM-7500 IMAGE DIMENSION MEASUREMENT SYSTEM TAKES COMPLEX COMPONENT READINGS QUICKLY, EASILY AND ACCURATELY
Aerotron Avotec is a maintenance and repair organisation in the aviation industry that specialises in the repair and overhaul of a variety of rotary and fixed wing aircraft components for civil and military customers. The company is based in Scotland. Aerotron Avotec is renowned for its technical excellence and meticulous approach to repairs as well as offering one of the lowest warranty rates in the aerospace industry.
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ecause of the demanding nature of its work, Aerotron Avotec has to work with a wide range of complex parts that can include tiny bearings as well as shafts, gears, brake components, wheels and large outer casings for aircraft undercarriages. Engineers at the company are tasked with inspecting parts to extremely tight tolerances and this can often mean taking key measurements from difficult to access areas. At the same time, readings taken can be of a nature that prevents them from being measured with traditional measurement equipment.
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Checking these parts to meet the stringent demands of customers would ordinarily require Aerotron Avotec to acquire expensive, specialist “one-off” measurement tools. For example, a small gear shaft not only needs measurements taken of its external splines but also its internal spline and fixed central shaft. Pin measurements need to be taken to measure gear wear while the bearing lands on the shaft also have to be checked for wear. Normally, carrying out these 24 | Industry EMEA | April 2020
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checks requires three different traditional measurement tools – an external micrometer, a specialist micrometer with calliper jaws to access the central shaft (which is partially enclosed by the internal gear) and a specialist bore gauge with an open centre to allow the internal gear surface (which is obstructed by the internal shaft) to be measured. After scanning the market for the most suitable solutions to its problems, Aerotron Avotec invested in the IM-7500 optical imaging measurement system from Keyence which has enabled measurements such as those mentioned to be acquired using just the one instrument and in a fraction of the time that it used to take. At the same time, using the Keyence system has increased significantly the accuracy of measurements taken by Aerotron Avotec, mainly through being able to reduce the amount of human interface involved when measuring the part and with the associated tooling. Once the information
gathered is programmed into the memory of the machine, parts of the same specification can be measured quickly and simply with one or two button clicks. This greatly reduces the number of man-hours that would traditionally be spent on such a task. The IM-7500 Image Dimension Measurement System is designed to be easy to use (with no measurement expertise required) and to measure up to 99 dimensions in just a few seconds, with a measurement volume of up to 300mm x 200mm. Featuring automatic recognition of component position and orientation, the system eliminates positioning errors as well as focus errors and skill level errors.
One of the main benefits that the Keyence system has brought to Aerotron Avotec, then, is to simplify the company’s highly complex measurement requirements. The IM-7500 has not only minimised the potential for human error when taking measurements but has also reduced the number of tools that are required for the task.
A spokesperson for Aerotron Avotec says: “The Keyence solution was recommended to us by the manufacturer of one of the items of equipment that we overhaul and repair because they also use it. This was a new departure for us because we hadn’t owned or used any Keyence equipment before. However, we looked at other solutions that were available before opting for the IM-7500 because the Keyence optical image measurement system is the solution we believe most closely matches our requirements.” Claire Lillywhite, Applications Engineer, Metrology & Microscopy Divisions at Keyence, concludes: “Aerotron Avotec is typical of the kind of customer we are working with when it comes to supplying our advanced and automated measuring systems. Aerotron Avotec demands efficiency, accuracy, consistency and a sound return on investment (ROI) and that’s precisely what we were able to offer.”
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Also, every type of measurement can be carried out on many different parts – whether machined, turned, injection moulded or stamped – without having to switch programs. As well as offering consistency in all its readings regardless of the operator, the IM-7500 automatically records all captured data and produces a range of comprehensive inspection reports which can be read on a PC or hand-held device running standard software.
In some instances, the Keyence equipment has enabled series of measurements that would have needed a few days to acquire to be completed in a couple of hours or even less. The IM-7500 has also allowed measurements to be taken that otherwise would have required the purchase of bespoke tooling.
www.keyence.co.uk
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MEASUREMENT
INSTANT HIGH-PRECISION MEASUREMENT SYSTEM CUTS INSPECTION TIME FOR PRESSPAHN
Specialist engineering solutions provider Presspahn built a reputation for supplying a range of industries with materials and components for electrical insulation, thermal insulation and mica-based insulation. The company has remained ahead of the market by adopting modern manufacturing techniques driven by innovation, precision and consistency backed by low costs and minimal lead times.
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nspection is a key part of Presspahn’s stringent quality control systems for its manufactured products but the company found that using conventional manual technology meant allocating a significant amount of time to inspecting a wide range of its complex parts.
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As demand from customers increased for Presspahn’s products, it became clear that it was no longer feasible to rely on traditional methods of measurement such as digital callipers and manual shadowgraphs. For example, checking some dimensions could mean having to plot points on a CAD system to determine features that it was not possible to measure directly. This presented a particular challenge for parts with repeating features that needed to be plotted each time, not least because Presspahn found itself having to invest huge amounts of time on inspection while simultaneously reducing the level of detail that was being checked at intermediate inspections.
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Furthermore, it wasn’t unusual for a first article inspection (FAI) to take over an hour to complete. The company also found that increasing numbers of customers were looking to have products checked via such inspection methods as initial sample inspection reporting (ISIR), AS9102 FAI (sometimes called production process verification) and the production part approval process (PPAP) which is favoured by supply chains to the automotive industry. Customers were also demanding detailed inspection reports as well as statistical analysis of parts. The solution Presspahn had often considered taking advantage of the advanced inspection technology developed by Keyence, a company with a global reputation for the highest standards of part measurement. Presspahn had used some Keyence measurement devices in the past and had been impressed by the compact design of the products as well as their ease of use and the high-quality statistical reports that could be generated.
Keyence is recognised as an innovative leader in the development and manufacture of industrial automation and inspection equipment, including code readers, laser markers, machine vision systems, measuring systems, microscopes, sensors and static eliminators. Presspahn chose Keyence’s latest addition to its Instant Measurement System series and found that the biggest benefit was the ability to save time, with inspections that would previously take over an hour capable of being done in under 10 seconds – and that included printing the report.
Features of this new measurement system include an automatic measurement function that enables all settings to be completed with one click, the ability to record all measurement results and create reports automatically, and an intuitive interface that involves simply placing the part on
Other features not available elsewhere include large diameter telecentric lenses, a programmable ring illumination unit, a light probe unit for measuring at specific heights and a large, high-speed/high-precision stage that measures volumes up to 300mm x 200mm (and the field of view at three times the speed of conventional systems). Matthew Pinder, Managing Director at Presspahn, says: “The Keyence IM-7020 has made a huge difference to the way that we can now meet the requirements of our customers. A combination of speed, accuracy, ease of use and immediate access to inspection data means that we can shorten timescales spent checking parts and not have to involve the customer in the inspection process.” MORE INFORMATION
Thanks to the Keyence IM-Series Image Dimension Measurement System, it became possible to carry out the full inspection of every component in less time than it would have previously taken to inspect just one. Also, thanks to the statistical reports provided by the Keyence device, Presspahn inspectors were able quickly to raise any concerns and discuss them with customers. This could lead to concessions being requested or drawing changes made but for the first time the process was able to take place without having to ship parts to customers to carry out their own inspection.
the measurement stage and pressing the “Measure” button. Significantly, no measurement expertise is needed to operate the device, with measurement points automatically identified, consistent values delivered through automatic focal adjustment, and different parts identified and measured without having to change profiles.
Matthew adds: “As well as supplying us with its advanced and sophisticated inspection equipment, Keyence has provided us with an excellent level of technical support which ensured we were able to train our staff quickly in order to make the best use of this unique piece of kit.” www.keyence.co.uk/PRESSPAHN 24 | Industry EMEA | April 2020
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MEASUREMENT
ROHDE & SCHWARZ VALIDATES FIRST 5G RRM CONFORMANCE TESTS WITH THE R&S TS-RRM TEST SYSTEM
The Global Certification Forum GCF and PTCRB certification organization have accepted first test case validations in various FR1 and LTE band combinations using the new Rohde & Schwarz R&S TS RRM 5G radio resource management (RRM) conformance test system. The solution is the latest addition to a successful family of RRM conformance test systems.
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obile communication technology requires conformance tests since mobile network operators worldwide rely on the certification schemes of GCF and PTCRB for mobile devices in their networks. The updated version of the R&S TS RRM has gone through this certification process, ensuring that the solution is suitable for the 5G RRM requirements defined in the 3GPP specifications and is now certified by GCF as platform 296. RRM testing, as required by GCF and PTCRB, is a combination of several protocol and RF test methods. It is used to determine the reaction time of a cellphone to a changing RF signal and the time it takes for the device to switch to different signal sources.
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Rohde & Schwarz is well known as a one-stop solutions supplier for conformance and operator acceptance testing from 2G through LTE. The updated version of the R&S TS RRM now features also 5G NR signaling functionality, thanks to the inclusion of the new R&S CMX500 radio communication tester. As a result, the solution now offers coverage for LTE, WCDMA, and 5G technologies. The integrated test system, operated by the sequencer software R&S CONTEST, offers 24 | Industry EMEA | April 2020
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highly efficient and precise, reproducible measurement results. A unique feature of the R&S TS RRM is that it offers a smooth upgrade path to 5G for users with a previous version of the well-established R&S TS RRM. The upgrade to 5G RRM testing can be achieved simply by adding the new R&S CMX500 as an extension box. The 5G RRM test cases are also supported by R&S TS8980, the unique RF conformance test system in the market supporting mobile technologies all the way from 2G to 5G on one platform. www.rohde-schwarz.com/wireless
MEASUREMENT
SIERRA WIRELESS SELECTS INNOVATIVE R&S ATS1800C TEST CHAMBER WITH GOLD REFLECTOR FOR 5G NR FR2 TESTING Leading IoT solutions provider Sierra Wireless has selected the compact antenna test range (CATR) based R&S ATS1800C for mmWave frequencies (FR2) testing thanks to its class-leading characteristics. The transportable solution from Rohde & Schwarz features a state-of-the-art golden CATR reflector with rolled edges and a very smooth surface to minimize scattering and to provide precise measurement results as required for operation at high frequencies.
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est and measurement is moving from conducted testing to over-the-air (OTA) testing, especially in 5G NR due to the increased frequency range. One challenge of OTA testing is to maintain a compact test chamber size while providing a large quiet zone (QZ), or useable measurement area, in a wide frequency range. Rohde & Schwarz developed the R&S ATS1800C to combine all this, meeting current and upcoming requirements for 5G NR OTA testing. The R&S ATS1800C is a turnkey, high-end chamber with a small footprint of only 1.3 m2. Thanks to its movable design, it is highly flexible and transportable, allowing the chamber to be easily moved from one lab to another. The solution provides a large quiet zone of 30 cm, fulfilling 3GPP 5G NR conformance test requirements. With its high shielding efficiency, the R&S ATS1800C is designed to provide a trouble-free environment for uninterrupted measurements of 5G antennas, modules and devices.
Bill Seefeldt, Senior Vice President of Engineering at Sierra Wireless, commented: “As a wireless solutions leader, we wanted to find a CATR based solution to ensure the best measurement quality and accuracy. We were impressed with the OTA solutions Rohde & Schwarz offers, and we selected the R&S ATS1800C. Sierra Wireless is a longstanding customer of Rohde & Schwarz.” Alexander Pabst, Vice President of Systems and Projects at Rohde & Schwarz, added that “Rohde & Schwarz is committed to providing top-of-the-line T&M solutions to our customers in the mobile communications industry. We are pleased to provide Sierra Wireless with the unique, gold reflector version of the R&S ATS1800C. We look forward to further cooperation with Sierra Wireless on cutting-edge wireless communications technologies.”
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A unique characteristic of the R&S ATS1800C is its stateof-the-art gold CATR reflector, transforming the incoming spherical wave front to a plane wave. Manufacturing the reflector requires processes that are accurate in the micrometer range. To achieve such high precision, Rohde & Schwarz has developed an innovative manufacturing method, delivering high quality reflectors reproducibly.
The R&S ATS1800C supports the testing of devices weighing up to 8 kg, which makes it well suited for testing a variety of active or passive DUTs, from small chip modules to tablets and laptop or even small cells. Hardware triggering allows measurements during continuous movement of the highprecision 3D positioner, which can reduce measurement time by a factor of 5 to 10.
www.rohde-schwarz.com/ats1800C
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MECHANICS
ULTRA 80: A NEW BAR FEEDER FROM LNS GROUP
The upcoming market launch from the Swiss specialist is more than just an evolution of its Sprint range. The ULTRA 80 is much more akin to a real revolution in the field of bar feeder systems.
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An oversized base frame LNS innovates in the bar feeder market, as the first company to offer an extremely rigid 700 kg mineral cast iron support beam. Its mass helps “seat” the machine in position. It guarantees machining quality by damping to a maximum the vibrations generated by the rotating bar. To make this support beam, LNS Group uses a specific patented manufacturing process. The inserts and metal plates are pre-positioned and integrated into the mass and thus are immediately positioned correctly when demoulding. This core component of the machine is geometrically finished, the precision of manufacturing is such that no reworking is required. The complete machine weighs up to 2 tonnes and remains perfectly stable even while long bars with a diameter of 80 mm and weighing over 160 kg are rotating.
Front rest In response to requests from its customers, LNS Group designed a highly flexible front rest system to reduce number of cases where users need to change the guiding elements. The front rest is an essential support element for the bar before it enters the lathe spindle, keeping the bar perfectly centred, while accepting a wide range of bar diameters. It adjusts automatically to bars of different diameters, so the operator does not have to change the guiding elements. This innovative and patented front rest is complementary to the Hydrobar principle and does not replace it, moreover the ULTRA 80 follows the same principle to offer ideal guidance characteristics. This technology, which the company has built its reputation on, is therefore still very much a feature of the ULTRA 80. High oil flow contributes to optimal hydrodynamic centring of the bars to be machined. Numerous other innovations in the ULTRA 80 The Human Machine Interface (HMI) supplied with the ULTRA 80 has a large colour touch screen and numerous context-sensitive menus, guiding the operator through the
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NEWS
actions. Extremely graphical, this HMI offers a layout that allows users to directly access the information needed for increased productivity, safety and provides messages and alerts with text and images. ULTRAÂ 80 is available in two versions, with internal ramp or external lift to offer customers the configuration best suited to their requirements. The oversized insertion and extraction system is also equipped with a booster for all chucks available on the market. With all the innovations provided by this new bar feeder, LNS Group guarantees manufacturers even greater safety and productivity. https://lns-europe.com
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MECHANICS
NICOLÁS CORREA MOVES INTO TOP GEAR WITH REDEX TECHNOLOGY
Two recently introduced milling machines from Nicolás Correa are leveraging the benefits of the latestgeneration of the Rack & Pinion drives technology from REDEX. Chosing the advanced REDEX drive train is the way to enable superior dynamic performance for users of the new FOX-M Gantry-type CNC milling machine, and the FENIX travelling column CNC milling machine.
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he FOX M represents a new and innovative concept of Gantry-type machine which combines traditional roughing capacity with the speed and precision of high-performance machining. It features a unique system which controls the temperature generated in the vertical axis of the machine. While high dynamic capacity of 2530 m/min in the X and Y are supported by V-shaped linear guideways, the Z axis features a box type guideway cooled with water, allowing up to 30 m/min of speed and ensuring an optimum damping capacity even when the ram is fully extended.
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A FOX M was present on Nicolás Correa’s stand at the last AMB exhibition in Stuttgart, where it was arguably the biggest machine at the show. Seven models are available, spanning X-axis traverse distances of 5.000 to 14.000 mm. The 6.000 rpm spindle is available with two different spindle motors: 37 kW /1298 Nm or 52 kW / 1375 Nm. Both options are offered with either ISO-50 Big Plus or HSK-100 taper.
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Moreover, UDX milling head is also available in this model, featuring 10,000 rpm with 30 kW / 620 Nm, mechanically transmitted through bevel gears; unique in the world. One of the main differentiators with Correa FOX M milling machines is the head technology. For instance, the company’s UAD universal and OAD orthogonal indexing milling heads are unique in the market, with patented technology allowing rotation every 0.02°. And the Correa two-axis ’twist-type’ contouring head can be alternately supplied to those seeking five-axis machining solutions. This type of head features high performance electro-spindle or spindle geared transmission. Typical applications for the FOX M include construction machinery components, railway parts, machine tool components and wind energy frames, etc. The FENIX is another recent addition to Nicolás Correa portfolio, introducing a new concept of travelling column machine with lateral RAM. Highly robust, the FENIX is
based on a system of L-guided RAM technology, with high precision enabled through a mechanical system of RAM droop correction. A flexible machine ideal for both roughing and finishing operations, FENIX is available in X-axis travels of 4.000 to 25.000 mm. The 6.000 rpm UAD milling head features 33 kW / 990 Nm. Both UAD and two-axis contouring heads are available for applications that include artillery guns, wind energy hubs, heat exchangers and large rotors, to list just a few. A common denominator between the FOX M and FENIX machines is that they both leverage the benefits of the latest REDEX planetary drive-train technology in the rack & pinion X axis drive, especially featuring the latest developments that reduce vibration and noise, while improving precision and service life.
accuracy performance of the X axis of the FOX M and FENIX. A solution which provides users of these machines with superior output torsional stiffness, ultra-high output radial stiffness and tilting moment, higher input speeds, optimal preload, and superior acceleration and torque density. Moving forward, REDEX gearbox solutions will be at heart of many future machine-tool developments from Nicolás Correa. Nicolàs Correa latest expriences once again clearly shown that REDEX constant aim is to meet all the needs of machinetool builders seeking the latest advances in rack and pinion drives, planetary servo-reducers, spindle drive gearboxes. The company skills also includes differential drives, rightangle bevel gearboxes, multi-speed gearboxes and a host of associated products. All over the world, REDEX works with its customers on a close partnership basis, not only in terms of product quality and reliability, but with an enhanced added value through its strongly reknown before- and after-sales service standing on its local service centers.
Among many others, that’s one of the reasons why Javier Hernando, Technical Director at Nicolás Correa, has confirmed that using REDEX high-tech rack & pinion drives for linear axis has clearly improved the vibration and
www.redex-group.com
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This exciting development is an example of how REDEX continues to focus its efforts in the most challenging areas, for instance by still focusing efforts to evolved the planetary gear train to always reduce vibration, noise and transmission errors.
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MECHANICS
MANUFACTURING EFFICIENCY IS ON-TIME DELIVERIES AND SATISFIED CUSTOMERS
A machining workshop seeks to produce a certain number of parts, at a required level of quality, in the most efficient way, delivered on time. Traditionally, manufacturing businesses defined efficiency by return on investment. Success was measured in terms of continuous runs of thousands or hundreds of thousands of pieces and maintaining steady output from one or many machines was the goal. From that point of view, a machine that was running and making parts was considered efficient.
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oday, manufacturers more frequently carry out lowvolume/high-mix production scenarios tailored to varying customer needs. Lot sizes may range from hundreds of pieces to single digits. However, even when all the machines in a shop are running nonstop, customers nevertheless could still be waiting for parts they ordered. High-volume output strategies conflict with the flexibility and complex planning requirements of low-volume production scenarios.
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In the current manufacturing environment, true manufacturing efficiency involves striking a flexible balance between maximum output and timely fulfillment of a wide variety of individual customer orders. The focus is on the end result: on-time product delivery and satisfied customers. Quality Control While balancing output and demand, manufacturers must be careful to maintain product quality. Dealing with parts of unacceptable quality will force unplanned changes in production schedules, consume time and money and delay deliveries. Haphazard planning will cause production stoppages and leave machines sitting idle while shop floor labor costs multiply to handle the unforeseen problems the stoppages create.
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Workpiece quality in manufacturing generally is described in terms of meeting part dimension and surface finish requirements. An additional measurement of quality, namely on-time delivery performance, can be called process quality. The manufacturer must control processes to the degree that the planned production time is sufficient to complete the work and deliver it to the customer at the promised time. Pleasing Customers Versus Posting Profits A shop’s machines can run 100 percent of the time, but if poor delivery performance disappoints customers and they stop buying the shop’s products, the shop will fail. Keeping customers happy is a primary goal but concentrating on customer satisfaction alone can threaten profitability. Focus on the customer is critical, but a manufacturer must maximize utilization of its equipment while also meeting customer part volumes, quality requirements and delivery requirements.
The Heart Of Efficiency To describe manufacturing efficiency in basic biological terms, the heart of any production operation is the machining process. Although the body’s heart is indispensable, it does not work on its own. It is part of a system that includes the rest of the body and the brain. In manufacturing, if the heart is machining technology, the body is the overall manufacturing organization including engineering, business planning and administration. The brain of the organization is the group of personnel who coordinate all elements of the system. However, the brain cannot simply decide that the heart should pump faster, just as a person cannot control his or her heartbeat just by thinking it will be so. In the same way, a machining process is not always controllable from a rational perspective.
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Promises and planning Successful manufacturing involves coordinated interaction of multiple groups within the manufacturing organization. One group promises customers certain outcomes regarding the cost, quality and time of delivery for the parts they order. The other groups in the organization, including engineering, purchasing, workshop personnel and administrators, make sure that those promises are kept.
The various groups define efficiency differently. Machining staff want to optimize individual machining processes for maximum output. Groups outside the technical machining process concentrate on improving the performance of the system overall. Their analysis covers issues such as overall equipment effectiveness (OEE) and labor productivity.
In today’s world of digital technology and the Industrial Internet of Things (IIoT), people, especially young people, want answers and clear rules for controlling the machining process. Unfortunately, in many cases there are no rational 24 | Industry EMEA | April 2020
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rules, and it is necessary to accept, react to and solve the unexpected problems of machining. Unexpected Problems And Unskilled Workers In a perfect world, shop personnel have the knowledge, skills and experience needed to handle unexpected problems in the machining process. However, many shop owners complain that it is difficult to maintain a sufficiently capable workforce. While training would appear to be a way to overcome the shortage of skilled workers, surprisingly, though, some shop owners say their training efforts often are wasted because employees lack a positive mindset towards learning new skills. Owners report that in many cases where they offer technical training, employees believe that they already know enough to do their assigned work and require no additional training. (see sidebar)
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Total Manufacturing Time Analyzing a shop’s efficiency and eliminating waste can provide additional time for machining and thereby greater flexibility and responsiveness to customer needs. The total time required to manufacture a part is the sum of many separate activities. They include actual machining time, tool handling, workpiece manipulation, quality checking, unplanned problems, waiting, administration tasks and others. Some of the activities are essential and cannot be eliminated, such as tool changes and workpiece manipulation. Beyond 24 | Industry EMEA | April 2020
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required activities, shops also spend time handling unforeseen circumstances such changes in planning, quality problems and waiting for missing tooling or workpiece materials. In one case, a shop reviewed a number of different activities involved in machining a part to find the amount of time each consumed (Figure 3). Actual machining time was 15 percent of the overall production total, while setup and waiting consumed a quarter of the time and unplanned problems, such as missing or delayed tooling or stoppages to clear excessively long chips, represented another 25 percent. By reducing the time taken for unplanned problems, setup time, tool handling, waiting and administration, actual machining time grew to 50 percent of the total (Figure 4). The expanded time gave the shop greater flexibility to match machining operations to specific customer job requirements. Unforeseen Effects Of Time-Saving Efforts As a result of a time-saving investigation like the one noted above, another shop was able to triple the hours that spindles were actively cutting parts. However, the shop found that part output did not triple in return. Further study revealed a number of issues that contributed to the phenomenon. A major issue was that the original process time included off-machine deburring. The time saving initiatives indicated that deburring could be performed more efficiently on the machine itself. However,
NEWS
when the off-machine deburring was moved to the machine tool, overall spindle time increased to account for the deburring operation. The situation shows that time savings in one area can result in increased consumption of time, or apparent decrease in efficiency, in another area. The lesson is that operational changes must be considered in relation to the manufacturing process overall. It is a difficult balance, and there are no general rules except to look for ways to use the available time as effectively as possible. Changing Plans Achieving efficiency and flexibility require continual adaptation to changing production demands. Changes often originate externally when a customer modifies a product design or changes the number of parts required. The manufacturing shop must alter its plans in response, but that can disrupt the shop’s plan overall and lead to a disorganized response that causes further disruption.
In some situations, instead of purchasing a backup machine a shop will work with its own equipment until overload occurs then enlist a subcontractor. But if that subcontractor is struggling with the same problems of too much work and insufficient staff, the responsibility simply shifts to a different party. It is extremely difficult to convince shops to build spare capacity with the possibility it will be used rarely at best.
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When planning is disorganized, some shops push workpieces through the workshop in random ways, putting the work on any machine available and causing more problems. The situation can become a vicious circle. When planning issues begin, they can multiply like a virus. A small disruption soon can become large. And like a human virus, the disruption can be very difficult to overcome.
The Spare Capacity Option One way to effectively raise shop efficiency and flexibility is to add spare machining capacity. The concept of spare capacity is foreign to the majority of shops, and a shop’s finance department may endorse investing in new machining capacity but demand that the new equipment does not sit idle. They see a machine as a one or two million Euro (or dollar) investment, and can’t understand that when it is purchased as spare capacity it may stand unused and not regularly do anything. But in reality, it does do something significant: it ensures happy customers. It is a useful backup that supports flexibility and facilitates handling of unforeseen problems.
Long Delivery Times Versus On-Time Delivery The pressure to deliver on time may extend the actual production time. If manufacturing a job under normal conditions takes a week, but the customer wants an absolute guarantee that delivery will be on time, a shop may state a lead time of two weeks to provide a time 24 | Industry EMEA | April 2020
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MECHANICS
cushion/buffer. In another instance, if a customer needs one completed workpiece by a certain date, a shop may start two workpieces to have a backup in process in case something unforeseen happens to the first part. These makeshift practices needlessly consume production time and expense and actually extend delivery times beyond what they would normally be. Multi-Tasking Choices Another way to increase shop efficiency and flexibility, although expensive, can be to employ automation in the form of a multi-tasking machine and a pallet pool. A shop can quickly change an automated cell from one job to another and use the pallets to build and store future setups. Such a system can be built around a multi-tasking machine surrounded by workpiece pallets and accompanied by a tool magazine with multiple tools, all serviced by a robot. In this arrangement, day shift personnel can set up the machine and pallets to process a variety of parts, and the night shift can produce the parts. This solution, however, is relatively expensive and is not the level of investment that every company can afford. Impediments to Multi-Tasking An organizational impediment to the multi-tasking approach is the typical factory practice of arranging machines based on function alone, as in maintaining a separate milling department, turning department, etc. In many cases, it is better to have machines organized into cells where each group of machines has certain process capabilities suited to specific groups or families of workpieces. Grouping of machines simply by function also encourages shop personnel to describe themselves in a limited way, such as lathe operator or milling machine operator. Training operators to be multifunctional and able to operate different types of machines gives a shop the flexibility to balance its own internal capacity issues. Conclusion Present-day efficiency in manufacturing includes a strong emphasis on customer satisfaction in addition to finding the best ways to machine parts. Manufacturers must balance efforts to consistently provide on time delivery with the need to be profitable. In addition to optimizing the machining operations, careful attention to issues including part and process quality, planning organized from the perspective of the manufacturing organization as a whole and continuing analysis of the elements of machining time consumption can significantly expand the time available to machine parts and result in increased flexibility and efficiency. By: Patrick de Vos, Business Development Manager & Technical Education Manager Seco Consultancy
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www.secotools.com
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Supporting an Efficient Manufacturing Mindset Evolution of manufacturing strategies presents machinists with a range of new challenges. Highly automated machine tools, intuitive software and advanced cutting tools have reduced a machinist’s hands-on responsibilities. Unfortunately, one side effect of this sophisticated manufacturing technology is a tendency of some manufacturing personnel to settle into a “good enough” frame of mind regarding their job skills. Many shop owners have found that when some employees are offered job training, they are unenthusiastic and feel that they have sufficient skills to handle what they are required to do. Those employees do not have the mindset necessary to grow and advance in the new manufacturing environment. In Flanders, this frame of mind is described with the saying: “It is useless to give a candle and reading glasses to an owl, if he is not able to or not willing to read.” The U.S. phrase equivalent is “You can lead a horse to water, but you can’t make him drink.” Basically, no matter where in the world, people may be given all of the means they need to accomplish a goal, but if they don’t want to participate, the effort is in vain. In most machine shops today, the hardware, tooling and machining programs are present and powerful. Accordingly, people have become the crucial element of manufacturing efficiency. Along with a forward-thinking mindset, the special skill required today is an ability to read the machining process – not by working with a computer but by standing at the machine and listening and observing the process. Generally, the process will indicate its status, in the same way that one can listen to his or her own heart and feel if it is going well or not. That awareness is not calculated with a formula. It is essential to know what to watch for and what the favorable factors are in the process environment. Seco provides many forms of technical training, machining knowledge and support. When shop employees have the right mindset, Seco is there to help them learn and apply what they need to be successful.
PLANT SAFETY
NEW REFLECTIVE SIGNS BRING SAFETY TO DARK PLACES
Brady Corporation’s new, highly reflective ISO 7010 safety signs greatly increase safety in dark places. The signs reflect twice as much light when lit with a torch or vehicle headlights and can be used both in- and outdoors. Highly visible Brady’s reflective signs are highly visible because they reflect light back without blinding thanks to their retroreflective prismatic sheeting. In general, they are twice as reflective as signs with standard glassbead retroreflective sheeting. This will enable workers to better see the signs in dark and harsh weather environments when lit with a torch or vehicle headlights.
Customise All reflective ISO 7010 safety signs can be customised in Brady factories. They can be delivered with or without legend, in any language. Custom sizes are available up to 0.9 x 4 metres. www.brady.eu
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Great for outdoor use Reflective signs are available on aluminium boards for outdoor use. The boards feature double bended sides and do not have any sharp edges. They are available in round, triangular and rectangular shapes to fit any ISO 7010 safety sign shape. Every board is also available with round or square poles in different lengths, with brackets or base plates for optimal outdoor installation. All signs have a great outdoor lifespan thanks to Brady’s B-7639 UV blocking laminate that protects them.
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NEW TYPE OF CONTOUR MEASUREMENT
With the new CMS 700i 3D contour measurement system, Leuze electronic is presenting a world’s first for volume measurements: a complete solution for the fault-free storage of goods that can be autonomously commissioned and maintained by the customers via WebConfig.
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ith the CMS 700i, Leuze electronic is brining a new 3D contour measurement system to market. It is based on the CML 730i measuring light curtains and can be adapted to specific customer requirements. The complete system includes all components, the switch cabinet, fastening elements and connection technology all under one part number.
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The CMS 700i measures the contour and position of passing objects regardless of their shape and surface structure. Even flat objects such as polybags can be precisely and economically detected without complicated camera installation. The minimum dimensions for height, width and length are 5 x 50 x 50 mm3. The object information can, for example, be used to optimize the load on a pallet or to optimize the incoming goods.
At the same time, deformations or protrusions of the object that might cause problems or downtime when warehousing automatically are reliably detected. The CMS 700i thereby increases the availability and cost effectiveness of the system. With the intuitive WebConfig, commissioning and remote maintenance can be performed easily by the customer. Should a component need to be replaced, this can be accomplished efficiently with Plug & Play, without any specialist knowledge from supplier experts. This saves time and money. The Ethernet TCP/IP or PROFINET interface ensures speedy integration of the 3D contour measurement system. The system can collect peripheral data, e.g., from scales or bar code scanners, via an open Ethernet interface and pass it on with a time stamp. The CMS 700i can thereby be freely combined with additional functions and is suitable for both new and existing systems in the area of intralogistics. www.leuze.com
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CRYOGENIC CHEMISTRY MADE EASY
CryoFlowSkid by De Dietrich Process Systems GmbH with flow reactors from InnoSyn B.V. on board.
The newly developed CryoFlowSkid enables 3 step syntheses for the continuous production of chemical intermediates or active pharmaceutical ingredients in kg quantities per hour.
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n particular, syntheses with highly exothermic reaction steps and proceeding through unstable intermediates can be carried out in the CryoFlowSkid with significantly higher efficiency than with a batch process. Thus the technology for e.g. organometallic chemistry can often be considerably intensified.
The CryoFlowSkid was developed by De Dietrich Process Systems GmbH (D, Mainz) together with InnoSyn B.V. (NL, Geleen). InnoSyn contributes the chemical process know-how and the flow reactors. These core components developed by InnoSyn are manufactured from different metals in a 3D printing process.
The compact, mobile system can be operated in typical chemical pilot plant environment and it is fully automated. The system is highly modular so that e.g. the reactors can be easily exchanged.
De Dietrich Process Systems, as the manufacturer of the entire system, is responsible for the engineering, production and worldwide sales and service of the complete CryoFlowSkid. For this joint co-operation the two companies signed a collaboration contract. www.dedietrich.com/de
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IMPACT AND BEND-RESISTANT HIGH-PERFORMANCE CERAMICS
The Dortmund-based Moeschter Group GmbH specialises in high-performance materials. The group has four independent companies under its umbrella: Dotherm, Isocos, Doceram and Doceram Medical Ceramics, each of which develops and markets professional solutions for industrial applications in their specific fields.
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otherm and Isocos manufacture electrical and thermal insulation using engineering plastics, fibreplastic composites and state-of-the-art high-tech materials. Doceram focuses its developments on industrial ceramic material with outstanding properties used as an alternative to metal. Doceram Medical Ceramics focuses on dental semi-finished products, develops and produces dental milling blanks under the Nacera brand, from which all-ceramic dental prostheses are manufactured.
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Doceram: individual industry solutions with the standards of tomorrow Doceram makes the fascinating potential capabilities of high-performance ceramic usable as a new type of material for industrial applications. With its solutions for welding technology in automotive engineering, the company has become the world market leader. General mechanical engineering, sheet metal working, forming technology, the food industry and electrical engineering companies also rely on ceramic products from Doceram. Due to its typical characteristics, the material is used in a very wide range of 24 | Industry EMEA | April 2020
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industrial applications and is growing increasingly popular. One of the reasons is that low-wear components, which have a significantly longer service life than conventional metallic materials, increase process reliability and minimize the risks to production. In many cases, ceramics can do more than steel Doceram high-performance ceramics are non-metallic materials based on ceramic powders produced by sintering and optimized for technical applications. By using various raw materials such as zirconia, silicon nitride and aluminium oxide as well as different manufacturing processes, the properties of the finished product can be adapted precisely to the customer’s requirements. For example, material A-132, which is based on aluminium oxide, has a maximum operating temperature of 1,700 °C and an extremely high degree of hardness (2,000 HV 0.5). In contrast, the maximum operating temperature of Cerazur, a zirconia-based material, is 1,000°C, but it achieves an enormous flexural strength of 1,300 MPa and, unlike most
ceramic materials, an enormously high fracture toughness of 12 MPa√m. Among the most important properties of industrial ceramics are its exceptionally high wear resistance and temperature stability. It enables more than 20 times longer service life compared to conventional materials. Furthermore, it is electrically insulating and magnetically neutral, making it ideal for use in the production of electronic components. Another important advantage over metallic materials: DOCERAM industrial ceramics are chemically inert. Wide range of applications in mechanical and plant engineering Today high-performance ceramics are used to manufacture, among other things, forming tools, standard components such as cylindrical, centring or welding pins, general wear elements, holders for inductive processes, bushings, thrust pieces, sliding shoes, hydrocyclones, melting crucibles, spacers, gauges, balls, supports, underlays, protective plates and bearing bushings.
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Precision and technical cleanliness through cylindrical pins For cylindrical pins, Doceram mainly uses the zirconiabased material Z-101. This material is characterised by high hardness, bend resistance, fracture toughness and dimensional stability. Their extreme resistance to abrasion ensures long service lives and guarantees technical cleanliness. In addition, the material has such high impact strength that it is the first choice for a wide range of
applications. At the same time they are electrically insulating and non-magnetizable, this is a considerable advantage in resistance welding for example, and also makes it the ideal product for applications in the assembly and testing of electronic components. For applications in automation technology, Doceram recommends Z-1000 as the material for cylindrical pins, which are used for positive positioning of gripper jaws or quick-coupling elements for example, and as maintenance-free bearing axles for swivel levers, rollers or gear wheels. Doceram’s cylindrical pins are also used in roller bearings as rollers for slowly rotating, maintenancefree needle bearings in the high temperature range. In the electronics industry and in testing technology, cylindrical pins are used as abrasion-resistant stops when positioning printed circuit boards in automatic placement machines or test equipment. Together with customers from the automotive, mechanical and plant engineering industries, the Doceram team develops individual, custom-fit solutions from small to large series. In the field of welding technology, Doceram offers a wide range of standard parts: welding centring pins, positioning pins and cylindrical pins. https://doceram.com/en/
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MORE THAN 1500 AUTOCLAVE CYCLES POSSIBLE
New drive from FAULHABER for medical applications. Brushless DC-motors of the 2057…BA series FAULHABER.
FAULHABER developed the new sterilisable 2057…BA family of motors especially for medical applications. In the sensor-free variant, the drives can withstand more than 1500 autoclave cycles. They are optimized for high speeds of up to 65,000 rpm, as are required in, e.g., the handpieces of dental equipment.
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he motors of the 2057…BA series are fitted in a moisture-resistant, stainless steel housing. During the development process, they were thoroughly tested for resistance to the loads experienced during autoclaving. Based on these tests, it is ensured that the standard motor can withstand undamaged at typically 1000 cycles in the autoclave. For the sensor-free variant, this value is 1500 cycles.
Autoclavable motors are frequently used in the handpieces of dental or surgical hand-held instruments. Very high speeds are generally required there. The 2057…BA series achieves a speed of up to 65,000 rpm. Further applications for this motor type are found in other areas of medical care, such as in ventilators. Like all motors from FAULHABER, the models of this series are characterised by high power values in relation to their volume. They are therefore very well suited for tight installation situations. Their low weight makes them predestined for use in the handpieces with which doctors and dentists perform delicate tasks, often over several hours.
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www.faulhaber.com
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KOLLMORGEN’S NEW 2G MOTION SYSTEM
Kollmorgens next generation of AKD2G servo drives and AKM2G servo motors are optimal matched to deliver maximum performance without compromise.
Demonstrates Value of Single-Source Solutions and System-Based Design.
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ollmorgen announces the 2G Motion System, a servo solution based on the latest thinking about single-source, systems-based design. The 2G Motion System was designed specifically to harness the performance capabilities of Kollmorgen’s AKD2G servo drive and AKM2G servo motor. Motor and drive are precisely matched in every element (e.g. drive switching frequency, commutation algorithms, motor magnetics), avoiding micro-incompatibilities that can occur when engineers select components from various manufacturers. The result is a system that delivers maximum performance, efficiency, and effectiveness in even the most demanding applications, including: industrial printing, laser cutting, packaging, robotics, inspection and measurement, machine tools, winding machines, and food processing.
• Increased dynamic performance: The AKM2G can reduce indexing and move and settle times by delivering increased torque and power in the same size or smaller package. • Faster development and commissioning: The 2G Motion System optimizes performance in every system configuration, saving machine engineers the time and effort of evaluating various vendors and component combinations. • Machine cost savings: Single-cable design, dual-axis drives, and co-engineered options reduce material and machine assembly costs. Improved motor and drive efficiencies reduce energy consumption, lowering operational costs. MORE INFORMATION
Key benefits of the 2G Motion System include: • Reduced design envelope: For new machine designs, the AKM2G allows designers to decrease the size, complexity, and footprint of the machine, while still getting the power and performance their application needs. The AKM2G can also be dropped into existing machines to increase performance, compared to competing motors, without increasing the size of the motor. The AKD2G includes
SafeMotion options, expandable I/O, and dual-axis models, all without increasing drive size.
• Special features: Kollmorgen Servo on a ChipTM, SafeMotion monitor, WorkBench GUI, extended I/O variant, extensive feedback options, single- and dual-cable options, shaft, mounting, and connector options, holding brake option, and much more. www.kollmorgen.com 24 | Industry EMEA | April 2020
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#AWORLDWITHOUTIWIS CAMPAIGN
Less chocolate, pasta and refreshments – That’s what a world without iwis would look like.
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orld in which there’s not enough chocolate for everyone? For many, that is a virtually unimaginable scenario. But the process of turning cocoa beans into chocolate confectioneries, sprinkles or chocolate coatings day after day demands such things as high-quality conveyor chains for the chocolate moulds. And these often come from iwis.
With its #aworldwithoutiwis campaign, the Munich-based chain manufacturer iwis antriebssysteme is highlighting a number of its applications. Since last September, Twitter and LinkedIn users have been able to gain an impression of the diversity of the company. And one thing they learn is that it simply wouldn’t be possible to produce many different things in a world without iwis. And it really is the case that there would not be enough chocolate products without the maintenance-free MEGAlife chains with their special attachments and precise length tolerances.
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Spaghetti, penne, farfalle – corrosion-resistant, maintenance-free chains for pasta production No matter whether we are talking about spaghetti, penne or farfalle, the world of pasta production would also be a very different place without iwis. To ensure that people can continue to enjoy such popular pasta products, iwis is constantly producing high-performance conveyor chains for production lines. The production of pasta is a precise operation, and it is particularly important that the chains used are corrosion-resistant and maintenance-free and that they run precisely in parallel operation and are wearoptimized. Only then can they guarantee an extended 24 | Industry EMEA | April 2020
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iwis MEGAlife: High performance chains with innovative, maintenance-free and wear-resistant joints PINS with friction-optimized surface coating ROLLER with corrosion resistant surface SINTERED BUSH hardened and treated for optimum tribological performance
service life and hence trouble-free production of the pasta we all love.
www.iwis.com
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High quality for transporting coffee pods and capsules For many people, a world without iwis would bring noticeable changes first thing in the morning. After all, the chain manufacturer ensures that they can start each day with just the right amount of coffee. iwis chains that have been manufactured with extreme precision and sorted into sets are used in the production of coffee pods and capsules. Only then are they able to meet the coffee industry’s demands in respect of parallel operation in production machines. The chains are protected against corrosion, optimally lubricated and maintenance-free. For the coffee industry, this means maximum efficiency thanks to minimum downtime and little loss of material thanks to high precision. The aim is to ensure high quality and quantity when transporting the coffee pods and capsules. In the food industry, it is important that chains are dry, clean and efficient. The high fatigue strength and wear resistance of iwis chains result in an impressive overall performance that allows them to meet the strict requirements in food production.
quickly conveys beverages to the designated crates. No matter whether steel, plastic or stainless steel is required, iwis also offers a high quality choice of materials. The drinks industry is thus putting its faith in reliable and wear-resistant materials and good technical support. Not only that: Innovative iwis systems for condition monitoring and relubrication extend the service life of the chain drive, allowing customers to concentrate on their core business instead of dealing with the hassle of unforeseen maintenance work.
Quiet and fast: iwis chains ensure that drinks bottles are conveyed safely And solutions from iwis are equally indispensable in the beverage industry. iwis FLEXON flat-top chains ensure stability and safety when conveying Euro, Vichy or longneck bottles. The flat-top range from iwis quietly and 24 | Industry EMEA | April 2020
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MAGNETIC ENCODER SYSTEM WITH DRIVE-CLIQ INTERFACE FROM BALLUFF
The BML absolute magnetic encoder in the SGA series stands out in any application where high absolute accuracy of position and end-of-travel is required. Comprehensive diagnostics functions ensure reliable operation and more efficient maintenance. With its Drive-Cliq interface the Balluff measuring system can also be perfectly integrated into Siemens controller environments. Siemens has certified the system accordingly.
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lug and play installation makes incorporating into the drive system easy. The controller automatically detects the sensor and its basic settings. The sensor also offers great flexibility, since leaving and reengaging with the tape is permissible. This opens up simple and economical solutions for demanding applications in the field of automation as well as machine tool building, especially specialty machines.
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Since the system works magnetically, it is also extremely insensitive to temperature change, dirt (such as from dust and oil), or wear. Thanks to its compact form factor the measuring system is also easy to integrate into existing applications, even in tight mounting conditions. The generous read distance of 1.3 mm makes installation easier.
In practical operation continuous plausibility checking ensures high reliability, since the system consistently check the measurement quality. Automatic condition monitoring checks the signal quality and, using the controller, is a convenient way to evaluate the function reserve. Status LEDs and diagnostic functions ensure reliable operation and more efficient maintenance. The linear measuring system is suitable for both long measuring lengths up to 48 meters as well as for applications which require high precision. With an accuracy of up to ± 12µm and a resolution of 1µm the measuring system meets these requirements. The system is also simple to retrofit. www.balluff.com
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INNODISK DELIVERS THE FUTURE OF AUTOMATION WITH CANOPEN SUPPORT Innodisk’s CAN bus expansion cards now support CANopen, opening the door for even more sophisticated applications in automation.
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nhanced automation is key to unlocking the fourth industrial revolution and a sure way to improve profitability for corporations around the world. With Innodisk’s introduction of CANopen support in its CAN bus embedded peripherals, Innodisk delivers a powerful solution that helps bring enhanced automation to global technology leaders—further strengthening Innodisk’s position as a key contributor to the future of automation. Making Innodisk’s Embedded CAN Bus Modules Even More Versatile With support for the CANopen higher-layer protocol, Innodisk’s embedded CAN bus modules are now more versatile, enabling even more sophisticated solutions in robotics, motion control, medical applications, and the automotive industry. The introduction of CANopen support underlines Innodisk’s ambition to have the strongest lineup of embedded peripherals, as well as emphasizes the company’s dedication to bringing innovative solutions to the forefront of AIoT and Industrial IoT (IIoT).
www.innodisk.com
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An Open Protocol for Innovative Solutions CANopen is a communication protocol for embedded systems developed by CAN in Automation, a non-profit consortium of CAN-users and manufacturers. Like other CAN higher-layer protocols, such as SAE J1939 and DeviceNet, CANopen helps devices in embedded systems communicate with each other. It is the preferred CAN bus higher-layer protocol in automation, motion control systems, and other high-tech industries and powers some of the world’s most innovative industrial solutions.
Combining the Best Hardware with Industry-leading Software Support Innodisk’s introduction of CANopen demonstrates the company’s unwavering dedication to best-in-class software support for its products. With increasingly sophisticated solutions and ever-smarter devices, seamless hardwaresoftware integration has never been more important to Innodisk’s customers, and the introduction of CANopen is one of many ways the company is addressing this need. With powerful SDKs, flexible APIs, and versatile embedded peripherals such as the CANopen-enabled EMUC-B202, Innodisk delivers capable and easy-to-use solutions ready for deployment across the most innovative industries in the world.
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LOGIDRIVE INTRALOGISTICS SOLUTIONS COMBINE ENERGY EFFICIENCY AND THE REDUCTION OF VARIANTS
The LogiDrive intralogistics solution from NORD is designed for intralogistics projects at airports, parcel centres, high-bay warehouses or other warehouse logistics facilities.
Large intralogistics projects for airports, parcel centres, high-bay warehouses or other warehouse logistics facilities must reconcile several competing requirements. With the LogiDrive concept for drive technology, NORD DRIVESYSTEMS takes a comprehensive TCO approach that combines energy efficiency and the reduction of variants with optimal system solutions for intralogistics.
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onveyor belts in intralogistics installations for airports, warehouses and parcel centres are often designed for the expected maximum load and with corresponding safety factors. This often results in drives that are oversized for the application. However, in real operation, such systems achieve the maximum load only with a small proportion of the conveyed items. As a result of such design, the drives only operate in the inefficient partial load range for most of the time. With the LogiDrive concept, NORD counteracts this trend with a specific reduction of variants using modern synchronous motors. In comparison with conventional asynchronous technology, these have an improved energy consumption performance in the partial load and partial speed ranges. Therefore, they are more energy efficient in these operating points and also keep efficiencies at a high
level, even in case of overdimensioning through a reduction of variants. This results in a low total cost of ownership (TCO). Four of five drive variants not required NORD frequency inverters can control the output speed via a frequency range of 25 to 100 Hz. Thanks to their high overload capacity modern synchronous motors have a single motor type that can be used instead of different motor sizes. Dependent on the performance requirement, it is operated by its inverter with different frequencies. As an example, in a NORD project for baggage transport at an airport with 700 drive units, the number of variants could be reduced by about 80%. Eight variants of the 11 used drive configurations related to a standard system solution, the NORD LogiDrive. Proven standard solutions are tested and can be safely used. Cost reduction thanks to standardisation The LogiDrive systems from NORD are highly efficient, extremely easy to maintain and install thanks to plug-andplay technology, and result in a considerable reduction
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of spare part stocks during operation. The whole concept is designed for easy planning and commissioning. The standardised geared motor variants are specially designed for intralogistics, parcel logistics and airport technology, and are particularly suitable for reducing the number of variants. The compact design saves space and the lightweight aluminium housing enables weight savings of up to 25%. LogiDrive drive units comprise an IE4 synchronous motor with rated powers of up to 5.5 kW, a 2-stage helical bevel gear unit and a NORDAC LINK frequency inverter to be installed close to the motor. With class IE4 motor efficiency and system efficiency to class IES2, the drive units achieve excellent overall efficiencies - especially in the partial load and speed range. www.nord.com
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LEMO NOW SHOWCASES ITS PRODUCT LINE ON EPLAN DATA PORTAL
EPLAN Data Portal is a web-based platform that gives engineers instant access to electrical schematics from numerous component manufacturers, including, from now on, LEMO connectors.
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he EPLAN Data Portal is an integral part of the EPLAN drawing platform, which enables users to significantly reduce effort & engineering time, and also to easily generate the detailed and accurate documentation that is required by today’s end users of automation systems.
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EPLAN Data Portal contains a wide library of CAD components: over 900’000 data sets from more than 290 manufacturers. The data sets are classified in 4 categories, namely, electrical engineering, fluid power, mechanics and process engineering. Specifically, LEMO’s product line can be found under Electrical Engineering> Plugs. Advance search criteria include pin count, electrical current and more…. Moreover, the EPLAN Data Portal includes ordering information, logical symbols, product pictures and macros.
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“We first met the EPLAN team during the Electronica show in Munich 2018. It’s been a long-haul project, but thanks to my colleagues and the help of EPLAN in Germany, today we are happy to generate more than 20’000 datasets available online for LEMO products. In the future, we plan to enhance this library working on the 2D and 3D macros and adding items to complete the M and F series product line”, says Serge Buechli, Business Development Manager at LEMO SA. http://eplandata.de/portal/en_en/catalog/LEMO
S M A R T FA C TO R Y
RED LION PRESENTS LAYER 3 GIGABIT ETHERNET SWITCH
Enhancing Interoperability and Management of Vital Industrial Network Infrastructure.
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ed Lion Controls, global experts in communication, monitoring and control for industrial automation and networking, announced the release of their innovative new NT328G Layer 3 Ethernet switch today. Offering 28 high-speed ports (24-Gigabit, 4-10 Gigabit) and reliable wire-speed switching performance, the NT328G offers exceptional performance and reliability to meet the current and future needs of the Oil & Gas, Water & Wastewater, Energy, Transportation, and video and security sectors, as well as other bandwidth-intensive industrial applications.
“Industrial customers are demanding reliable wire-speed Layer 3 switching performance that is scalable to 10Gigabit speed to meet current and future bandwidth-requirements. Customers now have access to a future-proof and durable switch solution that addresses industrial requirements from the network edge to the core.” said Diane Davis, director of product management at Red Lion Controls. www.redlion.net/NT328G MORE INFORMATION
Red Lion’s NT328G Layer 3 industrial Ethernet models feature a flexible mix of copper and fiber ports, allowing for a vast variety of connection options, with Layer 3 routing that provides the ability to route across VLANs or subnets—versatility that ensures scalability. The industrial-grade NT328G’s robust feature set includes network redundancy, advanced, integrated security, policybased traffic control and easy-to-use configuration and management—reducing operating costs while providing continuous monitoring of network activity. Its sleek but rugged IP30 rackmount metal housing is constructed for long-life use in harsh industrial environments, including wide operating temperature conditions and hazardous
locations—durability that ensures reduced downtime. Ideal for large-scale and/or any industrial network, the NT328G has the flexibility to meet both present and long-term speed and media requirements—delivering investment protection for years to come.
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S M A R T FA C TO R Y
EMERSON’S NEW PULSE VALVE DELIVERS HIGHER PEAK PRESSURE FOR LONGER BAG, FILTER LIFESPAN AND REDUCED MAINTENANCE IN REVERSE-JET DUST COLLECTOR SYSTEMS
New ASCO™ Series 353 valve improves cleaning while cutting compressed air use and installation time.
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merson is introducing its newly redesigned ASCO Series 353 Pulse Valve, designed to help original equipment manufacturers (OEMs) and end-users achieve a more effective, efficient and convenient bag cleaning every time. With a higher peak pressure, wider temperature range, patented quick mount clamp connection and overall part simplification, the new series provides longer bag and filter life and lower maintenance.
The new valve can be used in a wide range of applications, including concrete processing, grain, agriculture and feed, metalworking (abrasive blasting), food processing, foundries, pharmaceutical, mining, rubber mixing/ processing, metal processing, lime industry, cement factories, power plants and steel mills. Without optimum peak pressure, dust collector cleaning becomes inefficient and the consumption of compressed air rises. Because it hits peak pressure quickly, the Series 353 creates a more effective cleaning process. The new design also leads to improved airflow through the filter bags or cartridges for optimized dust collector performance while reducing costly compressed air consumption.
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“Through a rigorous engineering design and testing process, Emerson has optimized the ASCO Series 353 Pulse Valve to open, hit peak pressure and close faster than the competition. This gives our customers optimized filter cleaning and significant compressed air savings across all reverse-jet dust collector system applications,” said vice president of global marketing for Emerson’s industrial automation business, Erik VanLaningham. 24 | Industry EMEA | April 2020
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In addition, the valve is designed with fewer moving parts for increased reliability and simplified maintenance. A longer valve lifespan—over one million cycles on average—results in more time between valve maintenance cycles. The Series 353 also offers a patented quick mount clamp connection, providing faster, easier installation, as well as connection options, like the classic dresser connection and threaded version. Emerson’s redesigned Series 353 provides a broader operating temperature range of -40°C to 140°C (-40°F to 284°F), making it suitable for moderate-to-harsh industrial and hazardous environments. www.emerson.com
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S M A R T FA C TO R Y
SOURIAU ANNOUNCES A RANGE OF REACH-COMPLIANT COMPOSITE CONNECTORS FOR AERONAUTICS
The goal of European REACH regulation is to improve health and environmental protection by banning the use of SVHC (Substance of Very High Concern) chemicals and at the same time promoting the competitiveness of the European Union’s chemical industries.
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ouriau, like most manufacturers, uses hexavalent chromium, one of the substances listed as hazardous, in the surface treatment processes for many of its connectors. Although the European Chemicals Agency has granted derogations of up to 12 years depending on the application, Souriau wished to anticipate this deadline. Souriau’s R&D has been working for several years on the implementation and validation of this change to its composite connectors, which affected both the products and the production lines. The first REACH connectors in the D38999 composite range were launched during 2019 and by next December, the entire range will be manufactured without the use of hexavalent chromium.
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An increasingly important part of Souriau’s D38999 range incorporates composite materials either with a nickel-plated finish or with no finish and is mainly intended for civil and military aeronautics applications. The advantage of the PEEK composite used, is that it offers high performance in severe environments, is corrosion resistant and weighs less than aluminium. The challenge for Souriau was to find a REACH-compatible chemical solution for hexavalent chromium-free treatment of the connectors. Thomas Pichot, R&D manager at Souriau explains: “We no longer use hexavalent chromium, which was previously needed to improve the adhesion of coatings on the composite substrate of our housings. We have developed and from now on are using a new preparation treatment, which allows us to ensure the adhesion of successive metal layers equally well without needing this substance. This builds on the approach we used for aluminium connectors, where we have also qualified hexavalent chromium-free passivation in our zinc-nickel treatment process. All substitute products developed and deployed are now certified non-hazardous and fully compliant with all the various environmental regulations,
including REACH. While the challenges are obviously of a technological nature, the benefits are largely ecological, since this changeover has already enabled us to halve the volume of hexavalent chromium used in our production site.”
safety. This new REACH range will have an impact on our orders for all these reasons, but also because it responds to the global demand from both customers and Europe”. www.souriau.com
A PEEK plating solution unique in the world Souriau’s perticular achievement has been to develop a chemistry that works with PEEK material. Plating on to composite material is nothing new, but not on this type of plastic which is especially used in the aeronautics industry. This solution, unique in the world, is qualified QPL, according to the American standard MIL- DTL-38999 and the European standard EN3645. In addition to its qualification by accredited bodies, the process change has been validated by major aeronautics customers.
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As soon as the European REACH regulation was published, SOURIAU’s management and all the various teams realised there was a need for a vast program of innovation in surface treatment techniques in order to preserve connector manufacturing in France. The determination shown in the push to innovate and find alternatives to hexavalent chromium has added to Souriau’s achievements and demonstrated its know-how. As Nicolas Paumier, Product Manager D38999 composite explains: “Souriau’s proactivity in response to the REACH regulation shows its commitment to its customers, who also face the same issues, whether in terms of innovation, the environment or people’s health and 24 | Industry EMEA | April 2020
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