27 | APRIL 2020
INDUSTRY INDUSTRIAL MARKET MAGAZINE
USA
ADDITIVE MANUFACTURING: UNLOCKING THE DISRUPTIVE POTENTIAL
6 BAUMER HEAVYDUTY ENCODERS IN DEMANDING CONVEYANCE TASKS
24 INTERROLL’S MODULAR SOLUTIONS FOR AUTOMATED PALLET CONVEYANCE NOW AVAILABLE IN THE AMERICAS
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REAL-TIME QUALITY INSPECTION OF ADHESIVE BEADS WITH IDS IMAGING UEYE LE BOARD LEVEL CAMERAS
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IN THIS MAGAZINE...
6 Additive Manufacturing: Unlocking the Disruptive Potential 12 IDS NXT ocean makes it easy to get started with AI-based image processing
14 Cryogenic chemistry made easy 15 Radiall Completes The Acquisition Of Timbercon, Inc 16 Dunkermotoren joins MindSphere World e.V 17 Dunkermotoren becomes part of the Open Industry 4.0 Alliance 18 Interroll’s modular solutions for automated pallet conveyance now available in the Americas
20 Rohde & Schwarz validates first 5G RRM conformance tests with the R&S TS-RRM test system
22 Rohde & Schwarz together with Fraunhofer Institutes HHI and IAF join forces in researching 6G at THz frequencies
24 HeavyDuty encoders in demanding conveyance tasks 26 UMS PRO: A new unflatness measurement system for SBL lines 29 NORD Introduces New Energy-Efficient Motor with Power Range from 0.16 to 60 HP 30 Robotic Parking Systems Continues to Rely on NORD Gear as Exclusive Power Transmission Provider for Its Automated Parking Systems
32 New Software Version NCP 4.2 33 CMP Launches New Quad Cable Cleat Range
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Send your press releases to: editor@ipmediaonline.com To receive Industry USA magazine free of charge, please subscribe online at www.magazine-industry-usa.com Industry USA is the US-language magazine for engineers, published by INDUPORTALS MEDIA PUBLISHING. It contains the latest product and company news for industrial markets. Industry USA edits its articles with the greatest of care, however we cannot guarantee the accuracy of the information presented in them. Our teams disclaim all responsibility concerning the content of this media or how it might be used. www.ipmediaonline.com
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34 The Journey Towards Autonomous Manufacturing 36 OPC UA Embedded Toolkit from Softing Now Includes Discovery Announcements 37 Mobile Android complete solution for configuring and setting the parameters of HART field devices
38 Leuze and iTRACE Announce the Blockchain Integration of 2DMI with the DCR 200i Camera Based Code Reader
40 e-con Systems provides Camera Support for Rockchip 96Boards 41 Magnetic encoder system with Drive-Cliq interface from Balluff 42 LEMO now showcases its product line on EPLAN Data Portal 43 FAULHABER brings integrated encoder for flat motors to market 44 New GPT gearhead family with numerous gear ratios a new class level for torque and speed
46 Maturity self-assessment for Industry 4.0 48 Safely connected 51 New type of contour measurement 52 SOURIAU, a major player in connectivity for Smart Agriculture 54 IP66 cable entries for all shapes and sizes
ADVERTISERS: MEPAX 21
Kip HANSON
EDITO
Contributor
3D PRINTING CONTINUES TO MAKE HEADWAY THROUGHOUT THE MANUFACTURING INDUSTRY The original patent for what is now known as 3D printing was filed in France on July 16, 1984. It described stereolithography, the manufacturing of three-dimensional objects by depositing successive layers of photo-curable resin. Just three weeks later, American inventor Charles “Chuck” Hull filed his own patent in the U.S. for the same technology. He soon went on to become the co-founder and CTO of 3D Systems, a company that has since become a world leader. What happened? Why was the French patent abandoned, while the one filed in America became so successful? Two things have worked in 3D Systems’ favour. In the ’80s, no one on that side of the Atlantic was ashamed to talk about money or raising funds to start a company. Viva capitalism! In France, on the other hand, creating a company was a tremendous challenge, a task that was often both unproductive and time-consuming. Perhaps most importantly—"last, but not least,” as Chuck Hull would say—3D Systems encouraged customers to pay regular maintenance fees on their equipment, which helped to ensure the continued protection of Hull’s patent and advance corporate growth. Meanwhile, the French company employing the three inventors—Alain Le Méhauté, Olivier de Witte, and Jean Claude André—determined that the invention had “no commercial prospects” and allowed the patent to expire. Fast forward to today. Stereolithography has evolved into a mature, widely-used technology that goes far beyond the “prototype only” printing of the late ’80s. In fact, “additive manufacturing” now encompasses seven distinct 3D printing technologies, with improvements and new uses seemingly arriving each day. The slow, expensive, and not very accurate printers of even ten years ago have given way to increasingly capable, production-ready machines, able to cost-effectively compete (in many applications) with traditional manufacturing technologies.
The materials used with 3D printing have evolved as well. The handful of resins available when Hull first introduced the SLA-1 has exploded into hundreds of polymers and, more recently, metals, giving manufacturers seemingly unlimited options for how to manufacture products, and what materials with which to make them. Further, it seems that 3D printing will soon move into the business of making human components, with dozens of scientific publications (backed by some early success stories) discussing the 3D printing of animal and human skin, organs, and bones. Another significant trend: it is increasingly possible to build large objects. Construction companies are using monstrous 3D-printers to print a variety of concrete structures, while vehicle makers are printing entire chassis. It should be clear by now that 3D printing is here to stay, and is indeed the future of manufacturing. This is why industries of all kinds have taken an interest in 3D printing over recent years. These include mechanical engineering, of course, but also construction, transportation, energy, electronics, and even food. As a result, new design and manufacturing methods centered around 3D printing are being discovered everywhere, making it possible to create shapes and parts that were previously unthinkable, let alone manufacturable. Make no mistake: our workshops and factories will continue to use traditional manufacturing techniques such as drilling, milling, boring, and turning. In many cases, these processes will become even more necessary, as 3D printed parts often require secondary machining, especially those made of metal. It’s for this reason that subtractive manufacturing (that is, machining) and additive will remain complementary—not competitive— for many years to come. At the same time, the latter will continue to open up new avenues for the development and manufacture of parts and systems. Say what you like about patents and missed opportunities, but it’s a very cool time to be in manufacturing.
27 | Industry USA | April 2020
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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. 27 | Industry USA | 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) materials 27 | Industry USA | April 2020
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MARKET OVERVIEW
The new HSE 180•S HT from Essentium.
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 27 | Industry USA | 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.
MORE INFORMATION 27 | Industry USA | April 2020
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S M A R T FA C TO R Y
MONTH’S PRODUCT
IDS NXT OCEAN MAKES IT EASY TO GET STARTED WITH AI-BASED IMAGE PROCESSING
IDS NXT rio: Industrial cameras with integrated AI core.
Training neural networks without AI expertise and creating individual inference cameras.
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DS NXT ocean is an all-in-one solution that makes it particularly easy for users to get started with AI-based image processing. From camera hardware including a self-developed AI core to intuitive training software for creating individual artificial neural networks and support, everything comes from a single source. This is unique in the image processing market. Users only need their application expertise and sample images to create a neural network.
With the help of the IDS NXT lighthouse cloud software, even non-experts without prior knowledge of artificial intelligence or camera programming can train an AI classifier with their own image data. Since it is a web application, all functions and the necessary infrastructure for creating the neural network are immediately available. This means that users do not have to set up their own development environment first, but can start training their own neural network right away. This involves three basic steps: To upload sample images, to label the images and then to start the fully automatic training. The generated network can then be executed directly on the IDS NXT industrial cameras, turning them into powerful inference cameras.
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Inference cameras for industrial use An inference camera can apply the “knowledge” acquired through deep learning to new data. This makes it possible to automatically solve tasks that would either not be possible with rule-based image processing, or would require great effort. Since IDS NXT industrial cameras have a special AI core, neural networks are hardware-accelerated and run directly on the devices – enabling inference times of just a few milliseconds. With features such as C-mount, robust housing, GigE network connection with RJ45 or M12 27 | Industry USA | April 2020
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IDS NXT ocean Design-In Kit.
connectors, RS232 interface and REST web interface, they are also fully-fledged industrial cameras. The IDS NXT rio and rome models are now available as serial cameras with different sensors and protection classes. Get started with the Design-In Kit IDS also offers an IDS NXT ocean design-in kit which is particularly useful for anyone who wants to test the potential of AI for individual vision tasks. It provides all the components a user needs to create, train and run a neural network in his productive environment. In addition to an IDS NXT industrial camera with 1.6 MP Sony sensor, lens and cable, the package includes six months of access to the AI training software. The use of deep learning-based image processing for individual applications can thus be realized in a short time. https://en.ids-imaging.com/ids-nxt-ocean.html
MORE INFORMATION 27 | Industry USA | April 2020
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CHEMICAL
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.
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www.dedietrich.com
27 | Industry USA | April 2020
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CO R P O R AT E
RADIALL COMPLETES THE ACQUISITION OF TIMBERCON, INC
Radiall America, Inc. announced today that it has completed the acquisition of Timbercon, Inc., a fiber optic interconnect specialist based in Tualatin, Oregon.
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We are excited to welcome Timbercon to the Radiall Group. By combining our activities, our objective is to offer the most comprehensive range of end to end active and optical interconnect solutions for harsh environments, through innovation, simplification and service,” says Pierre Gattaz, President & CEO.
Timbercon, Inc. will continue to operate as a standalone company under its current leadership, while leveraging synergies with Radiall. www.radiall.com
“Joining the Radiall Group will allow Timbercon to continue to elevate its commitment to stellar customer service and providing zero defect solutions, on time, and on budget to demanding markets. We are very excited what the future brings as part of the Radiall Team,” says Eric Meslow, President of Timbercon.
MORE INFORMATION 27 | Industry USA | April 2020
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CO R P O R AT E
DUNKERMOTOREN JOINS MINDSPHERE WORLD E.V
CEO Dunkermotoren Uwe Lorenz.
Automation is facing new opportunities and challenges as a result of digitalization and new technologies such as the Internet of Things. In order to create effective added value in such an environment, a crossmanufacturer and cross-value chain approach is indispensable. Partner ecosystems thus play a decisive role in creating interoperable solutions across the board.
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unkermotoren has recognized the importance of ecosystems in the IoT environment as a world market leader for integrated servo motors. With MindSphere World, Dunkermotoren has found a suitable partner ecosystem for the common path into the Internet of Things. Through strong partners from the fields of automation technology, system integration, mechanical engineering and software, interoperable IoT solutions based on the IoT operating system MindSphere can be offered, which would not have been feasible by any company.
About Mindsphere World Together with 18 partner companies, Siemens AG founded the “MindSphere World e.V.� association in January 2018 as a user organization for the cloud-based, open IoT MindSphere operating system. In the meantime, the association has grown to a total of 74 members. The goal is to expand the ecosystem around MindSphere worldwide. In addition, the association should support the individual members in the development and optimization of IoT solutions on MindSphere as well as the development of new markets in the digital economy. This includes proposals on requirements for the MindSphere IoT operating system and recommendations on creating uniform rules for data usage. The association also promotes science, research and teaching around MindSphere. www.dunkermotoren.com
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CO R P O R AT E
DUNKERMOTOREN BECOMES PART OF THE OPEN INDUSTRY 4.0 ALLIANCE
Nils Herzberg, Uwe Lorenz - OpenIndustry Dunkermotoren.
The digitalization of factories and plants as well as the Internet of Things promise ever new possibilities for the automation industry. In this development, a wide variety of technologies from the field level to the cloud and also across different stages of the value chain must be combined across manufacturers to create tangible added value for our customers. The supreme discipline here is that within such an ecosystem, all participants speak the same language and no time-consuming integration is required.
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unkermotoren, the world market leader for integrated servo motors, has accepted this challenge. At the same time, the drive technology manufacturer has recognized that this cannot be solved by one company alone, but only in conjunction with a partner ecosystem that consists of component manufacturers, software companies, machine builders and integrators. Dunkermotoren has found this partner ecosystem in the “Open Industry 4.0 Alliance”. The goal of this alliance is to build an interoperable and manufacturer-independent ecosystem that delivers functioning industry 4.0 solutions based on existing standards.
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About the Open Industry 4.0 Alliance: The Open Industry 4.0 Alliance acts as a partnership of leading industrial companies that pragmatically participate in the implementation of cross-vendor industry 4.0 solutions and services for manufacturing facilities and automated warehouses. The alliance was launched in April 2019. Since then, the alliance has grown to more than 40 members with different industrial core competencies and has made further technical advances over the last few months. The founding members include Beckhoff, Endress+Hauser, Hilscher, ifm, KUKA, MULTIVAC, SAP and Voith. The constantly expanding membership includes Balluff, SICK, Pepperl+Fuchs, Gebhardt and Software AG. www.dunkermotoren.com
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I N T R A LO G I S T I C S
INTERROLL’S MODULAR SOLUTIONS FOR AUTOMATED PALLET CONVEYANCE NOW AVAILABLE IN THE AMERICAS
With the Modular Pallet Conveyor Platform (MPP), Interroll offers a flexible, scalable and easy-to-install pallet conveyance solution.
Based on its successful Modular Conveyor Platform (MCP), Interroll is now introducing a modular platform for driven pallet conveyance in the Americas region. The Modular Pallet Conveyor Platform (MPP) system makes use of a number of components, including technical products that have been tried and tested hundreds of thousands of times by users. The new conveyor platform is an ideal addition to the Interroll Pallet & Carton Flow flow storage system.
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eliable and efficient pallet handling is becoming increasingly important in modern goods flows. In many cases, this hinges primarily on keeping the transport times between goods receipt and goods dispatch, or between storage, production and commissioning facilities in a business to a minimum and ensuring that these transport processes are highly efficient by means of automation—and keeping planning processes streamlined, assembly requirements low and expansion options flexible.
Ideal for automated pallet transport Interroll’s new solution for system integrators and plant constructors offers all this and more. The MPP is an exceptionally versatile pallet conveyor system, distinguished by its highly flexible modular design. In conjunction with Interroll’s tried-and-tested Pallet & Carton Flow flow storage system, the new pallet conveying platform is an ideal foundation on which to build comprehensive pallet storage and conveying solutions of any type and for any application. Unlike the flow storage system, in which pallets are buffered in intermediate storage areas on inclined belts due to the force of gravity, the MPP is a driven conveying system for pallets. Depending on the application scenario, the drive is powered by gear or drum motors, which even enables the creation of zero-pressure-accumulation conveyors. Simple planning, flexible design The fully modular system can be planned and arranged extremely simply and conveniently using Interroll’s popular Layouter tool. The MPP consists of chain or roller
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NEWS
conveyors, as well as additional modules such as transfers and turntables. Unique modules for special functions are also available on request. The modules are optimally coordinated and fully preassembled on delivery in order to make installation as easy as possible. Additionally, the system can be modified or expanded incredibly easily and cost-effectively at a later date.
subjected to extreme endurance tests and load tests before being introduced onto the market. It complies with all applicable safety regulations and generates a noise level of just 68 dB(A) during operation. www.interroll.com
Depending on the conveyor design and the chosen modules, pallets weighing up to 1,200 kg can be transported at a top speed of 0.5 metres per second. The elements in the system are guaranteed to function perfectly within a temperature range of -28 to +40 ° C., meaning that the MPP can also be used in low-temperature applications. Depending on the control system used, the system can be designed differently—for different weights, with a variable speed or with an integrated positioning function, for instance.
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Pallet inspection stations can also be installed along the conveyor upon request. These enable the dimensions, weight, intactness or suitability of the pallets on the conveyor to be checked. Optionally, further inspections can be carried out: for example, in order to guarantee that only complete pallets with intact goods are transported on the conveyor. In all of this, however, Interroll has placed great importance on optimum workplace safety and a healthy work environment. The new MPP was extensively tested and 27 | Industry USA | 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 27 | Industry USA | 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
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MEASUREMENT
ROHDE & SCHWARZ TOGETHER WITH FRAUNHOFER INSTITUTES HHI AND IAF JOIN FORCES IN RESEARCHING 6G AT THZ FREQUENCIES
While the new 5G technology is at the first stages of rollout, Rohde & Schwarz, the Fraunhofer Institute for Telecommunications, Heinrich Hertz Institute, HHI and the Fraunhofer Institute for Applied Solid State Physics IAF are taking a step further with demonstrations in the terahertz (THz) frequency band, related to the 6th generation wireless mobile communication (6G). The collaboration has resulted in a wireless transmit and receive system operating between 270 and 320 GHz, with further frequency extensions for potential 6G bands already in preparation.
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G research is already underway in industry and academia. While 5G introduces mmWave frequencies with wider bandwidths for higher data rates and enables new applications such as in wireless factory automation (Industrial IoT) and for autonomous vehicles, the aim of 6G is to push the boundaries of transmission bandwidths even higher.
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Although it is not clear yet which technologies 6G will entail, it is already apparent that frequency bandwidths need to be further increased to enable terabit class data rates. Wide contiguous frequency blocks can only be found at sub-THz and THz bands, i.e. in the frequency range above 100 GHz. The utilization of THz frequencies for 6G is estimated to become commercial in the next 8 to 10 years. But Rohde & Schwarz has already presented a demonstrator setup for 300 GHz to customers. The system was also displayed at the 27 | Industry USA | April 2020
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EuMW2019 in Paris as part of a workshop on mmWave and THz Wireless Communication, where it consisted of 300 GHz transceiver frontends, the R&S SMW200A vector signal generator and R&S FSW43 signal and spectrum analyzer as well as of units for synchronization of transmitter and receiver. Involved in the current collaboration are the Fraunhofer HHI and the Fraunhofer IAF. The HHI works on signal processing, synchronization between transmitter and receiver, and system integration. The IAF contributes with high-performance millimeter-wave transmitter and receiver modules. The joint research targets frequencies above 100 GHz, where the primary focus is on the D-band (150 GHz) and the H-band (300 GHz). Carrier frequencies above 300 GHz are still subject of fundamental research. A first demonstrator resulting from the research collaboration
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is a system allowing signal generation and signal analysis at 300 GHz with 2 GHz bandwidth. The signal can be arbitrary modulated for conducting transmission experiments with Beyond 5G candidate waveforms, which are appropriate for THz communication or for performing channel propagation measurements Dr. Taro Eichler, Wireless Market Segment Manager at Rohde & Schwarz, said, “Rohde & Schwarz offers innovative, top-of-the-line tools for research during the early stages of 6G development. This allows us to engage in in-depth discussions with customers and to monitor the technical and market trends long before the commercialization of 6G. We are excited to partner with Fraunhofer HHI and IAF, benefiting from their leading expertise in development of mobile communication networks and systems, infrastructure and standards. We look forward to a fruitful partnership also in the future.”
Rohde & Schwarz at the very cutting edge of technology. IAF appreciates the mutually highly beneficial cooperation and is happy to continue exploring new innovations with Rohde & Schwarz.” Rohde & Schwarz builds its 6G research on a solid background of mobile communications test and measurement expertise, stretching from the early stages of 2G all the way up to and including 5G and beyond. Pioneering activities beyond 5G have already started about a year ago, when Rohde & Schwarz set up the world’s first ultra-wideband channel sounder for mobile communications exceeding 100 GHz: https://www.rohde-schwarz.com/_229356-596500.html
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Dr. Wilhelm Keusgen, Head of mm-Wave Group at Fraunhofer HHI, said, “As an institution committed to leveraging innovations for the digital society, Fraunhofer HHI is happy to partner with an innovative industry-leading T&M expert such as Rohde & Schwarz on the latest and upcoming communications technologies. Our cooperation has been rewarding and will pave the way for the development of 6G”. Dr. Michael Schlechtweg, Head of Business Unit High Frequency Electronics at Fraunhofer IAF, said, “As one of the first global providers of chipsets and electronic components capable of reaching already now the high frequencies required by 6G, we are collaborating with valued partner 27 | Industry USA | April 2020
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MECHANICS
HEAVYDUTY ENCODERS IN DEMANDING CONVEYANCE TASKS In open pit mines, HeavyDuty encoders by Baumer Hübner have been proving themselves over and over. Their robust design and double-sided bearing setup ensures maintenance-free operation and a long service life even under severe loads and in adverse environments.
The ingenious Baumer HeavyDuty sealing concept ensures IP 66 and IP 67 protection over a wide temperature range up to +95 °C. The sophisticated combination of labyrinth and shaft seals permanently protects the HeavyDuty encoders against all types of solids, moist and contamination by adherence.
Open pit excavators and spreaders are real giants among machinery. Every day they do the hardest work under extreme conditions - dust, dirt, rain, heat. A great strain also imposed on the rotary encoders, which are responsible for speed control of conveyor belts. Many manufacturers therefore rely on HeavyDuty encoders from Baumer Hübner. What does it take for encoders to deserve the hallmark “HeavyDuty”?
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inera El Abra is an open pit copper mine, located 75.6 kilometers northeast of the Chilean city of Calama. Mine output per day are more than 200,000 tons of copper ore for copper cathode production. Conveyor belts transporting the ore over many kilometres must deliver maximum performance. For doing so, they are driven by powerful electric motors. HeavyDuty incremental encoders HOG 10 by Baumer Hübner are ideal for motor speed feedback in a such a demanding outdoor application. They endure dust, dirt, vibration and other harmful impacts that are every-day occurencies in open pit mines. 10,000 kilometres away, at the port of Rotterdam, brother model POG 10 is on duty: In the largest port of Europe, more than 300 million tons of bulk cargo are handled every year, including more than 55 million tons of iron ore and coal. These intermediately stored goods are handled with bucket wheel excavators with a capacity of 5,000 tons per hour. HeavyDuty encoders by Baumer Hübner were chosen for this application because they withstand salty air, rain and frost without any problem. These are just two examples of
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how HeavyDuty encoders have proven themselves in tough and challenging tasks for many years. “HeavyDuty” – precision under heavy load The English term “HeavyDuty” means extremely resilient, so HeavyDuty encoders are said to be particularly robust. But that’s only part of the story and not simply refers to robustness. The term implicates the promise that such encoders will reliably and precisely perform over a long period of time without ever letting users down. For this, HeavyDuty encoders must meet several criteria: Precision is a focal point. Anyone believing these encoder heavyweights could afford compromising in this point is on the wrong track. On the contrary, HeavyDuty encoders must deliver the same precision signals as their little brothers. Plant control systems utilize these signals for speed monitoring at drives or position feedback at machine parts. To controllers, this is the only way to “get informed” of any excess speed or the drive falling below a defined speed limit so they can intervene accordingly. Even minor measuring
Incremental HeavyDuty encoders of the HOG10 / POG10 series ensure reliable 24/7 operation even under the toughest conditions. Their resilient, extremely resistant housing, outstanding corrosion protection and longterm stability in the sealing concept ensures fail-free operation in any environment.
errors can have drastic consequences that may result system damage, e.g. in bulk material conveyance. Robust technology for maximum sytem uptime Besides precision, reliability is likewise important – as shown in the examples of open pit mining and bulk material transport. For reliable performance in the harsh conditions present in open pit mines and port installations, the encoders must withstand hard shocks, vibration and other shaft impacts without losing their precision capabilities for many years. Product exchange is expensive, not because of encoder pricing but because of installation in places difficult to access and system downtime for the time of exchange. Robust, thick-walled housings and a shock and vibration resistant interior are basic requirements. In addition to that, Baumer Hübner encoders provide generously dimensioned bearings with large bearing spacing at both shaft ends. Not only mechanical robustness but also electrical resilience is a must. For example, if electromechanical fields generated by live, unshielded cables are present close to the encoder. Without appropriate shielding, the encoder electronics may be destroyed or at least be impaired at an extent resulting in measuring signals of bad quality. Shafts currents generated by voltage difference may burn the bearing lubration and lead to bearing damage or destruction. Electrical isolation is therefore indispensable for HeavyDuty encoders.
To ensure fail-free operation, electrical functionalities and signal quality undergo 100 percent inspections at Baumer Hübner. Comprehensive quality certificates certify customers absolute encoder reliability. No matter whether copper mining in Chile or bulk materials handling and transport in the port of Rotterdam, HeavyDuty encoders by Baumer Hübner ensure permanent operation reliability without downtime. Even under the toughest conditions.
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Tightness is another must. Whether moisture, dust or dirt HeavyDuty encoders must be well sealed. This is especially important at critical, neuralgic points: shaft and electrical connections. Sealing includes corrosion protection by appropriate materials and coatings, against ingressing salt water and chemicals that would impair encoder functionality.
Original HeavyDuty encoders “HeavyDuty” is neither a protected concept nor a standard but has become an established term on the encoder market. Inventor of this special encoder class is the world market leader Baumer Hübner with HeavyDuty encoder expertise dating back to the 1950s. This knowhow and experience have incorporated into the development of HOG 10 considered to be the “original” for more than 25 years and the blueprint for every HeavyDuty encoder. Baumer Hübner HeavyDuty encoders not only excel by precision, reliability and durability, but also by the wide selecton of product variants with varied mechanical, electrical and functional options. Incremental and absolute encoders are available in 58 mm housings and as large designs with 287 mm flange size and 150 mm hollow shaft. Baumer Hübner encoders support all relevant analog and digital interfaces. High power outputs ensure excellent and noise-immune signal quality even over long a distance - depending on the product variant up to 550 meters, in fiber optic transmission even up to 1.5 kilometers.
www.baumer.com
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MECHANICS
UMS PRO: A NEW UNFLATNESS MEASUREMENT SYSTEM FOR SBL LINES
Ungerer’s stretch-bend-levelling lines (SBLs) are in use all over the world.
Two measurements improve flatness by a factor of ten and reach almost no loss of material.
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ith UMS PRO, Ungerer introduces a system for unflatness measurement of strip steel that combines the commonly used high tension and low-tension measurement methods. In conjunction with a high-speed controller, users obtain considerably improved coil flatness (by a factor of ten) after the stretch-bendlevelling unit (SBL). The measuring system can be easily retrofitted on almost all existing stretch-bend-levelling lines, even those from other manufacturers.
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Low-tension or high-tension? Up till now, this has been the question that strip metal manufacturers have had to ask themselves when planning the purchase of a Stretch-BendLevelling (SBL) line (Figure 1). These machines produce a uniform flatness across the width of the coil. They equalize material and surface tensions and align the metal fibers with the levellers in such a way that key parameters such as yield strength and elongation can be optimally adjusted. The flat strips which are then wound into coils are must meet these quality requirements before they can be used in highly demanding applications.
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Prerequisite: Precise measurement, fast control The prerequisite for best levelling results is firstly the measurement of the real strip’s unflatness after levelling. Inventor of the actual levelling process, Ungerer is still an expert in SBL systems offering the market a worldwide presence. In the machines from Ungerer the unflatness measurements are firstly made immediately at the leveller’s output with a rubberized roll made of high stiffness material with integrated piezo pressure sensors (high-tension method, see Figure. 2), The second flatness measurement of the strip is made at very low tension by a pull-down measurement roller as it comes out of the machine (low-tension measurement; Figure 3). In order to achieve a real time closed loop control, the sensors send their measurement results wirelessly via a PCM transmitter both to the PLC and to the UMS Pro controller specially developed for this application, which calculate and immediately send back the setpoint values to the leveller.
NEWS With UMS PRO, the unflatness of strip steel is measured twice and corrected within a very short time. The picture shows the first high-tension measuring station integrated in a roll made of solid material shortly after the leveller.
he second (low-tension) measuring station is located in the low-tension output area.
Low Tension: Good measurement results, long dead zone The low-tension measurement takes place at the end of the process, after the coil has been unwound. Because the strip is then no longer under high tension, this measurement -called the pull-down measurement- delivers very precise results with a control accuracy of approx. 99%. However, the measuring point here is 20 to 25 meters (on the strip path) behind the levelling zone, so a long dead zone must be considered. If we include the distance required for adjustment, there are always about 50 meters which lack the desired or required flatness, because the first feedback and the flatness measurement only take place after approx. 25 meters and the feedback from the second controller only reaches the pull-down roller after a further 25 meters. It can therefore be assumed that the strip of each coil is flat over a length of approx. 50 meters but does not lie within the tolerance range of 99% accuracy. This value is only reliably achieved when the leveller has accurately adjusted to the unflatness of the incoming material.
Ungerer’s UMS PRO: an exclusive benefits from the advantages of both measurement systems Thus, both measuring positions and methods offers advantages and disadvantages. The target of the Ungerer’s developers has been then to enhance and keep the advantages of both methods: the minimal strip loss from the high-tension measurement, and the maximum accuracy from the low-tension measurement. This goal was achieved by the combination of both methods and has been recently set to the market under the name UMS Pro. The measurement systems of both rolls (which are configured as master and slave) send their data to the central controller, which enables the parameters sending to the leveller in closed loop mode at high computing speed and which ensure that the strip is accurately stretched accordingly. This brand new joint data evaluation allows the user to get the best of both methods without having to accept their respective disadvantages. In addition, if one of the two rollers is under maintenance, it is still possible to operate the machine.
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High-Tension: Fast action, inaccurate results On the other hand, high tension measurement takes place almost immediately at the leveller’s output. Adjustment takes place quickly accordingly, and so, the loss of strip is really minimal. Since the strip is under high-tension, the results of the measurement and consequently of the levelling are not as accurate as with the low-tension
measurement. It nevertheless achieves a control accuracy of approx. 95% immediately after the leveller unit.
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NEWS
The combination of high- and low-tension measurement in combination with sophisticated control technology improves flatness by a factor of ten and minimizes strip loss.
eliminated. Ungerer’s UMS Pro controller is the only one in the world that controls both systems, creating a flatness measurement system which is at the same time highly efficient and highly available.
manufacturers of stainless-steel thin strip. After the SBL process with UMS PRO, the 1550 mm wide strip achieves far greater flatness than in a rolling mill, which for physical reasons cannot be obtained with pure cold rolling (Figure 3).
Result: Flatness improvement by a factor of ten and measurement that is twice as fast The improvement that this double measurement brings can be expressed in numbers. By measuring after the leveller, a flatness of 95 to 96% is already achieved, after the pull-down, it is 99%. The result is coils that are exactly flat and can be machined precisely. For example, it meets the requirements of manufacturers of premium smartphones who manufacture from the coils mobile phone housings and their components, such as slots for SIM cards.
Simple retrofitting of existing equipment The UMS PRO system can of course be used in all new SBL systems from Ungerer and other suppliers. However, it’s noticeable that it is also highly suitable for retrofitting on existing systems. From the mechanical side, it’s clear that to replace only one roller in the stretching block with a sensing roller is enough to achieve the requested result.
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Cooperation between two experts The innovation of UMS PRO lies, on the one hand, in the idea of combining both measuring methods and, on the other hand, in jointly evaluating the data from both sensor systems. In this demanding task, Ungerer (a specialist in pull-down systems) worked together with BFI, the research institute of the Steel Institute VDEH and expert for pull-up measurements. Among other things, BFI has developed the controller that evaluates the results of both measurements, correlates them and determines the corresponding control parameters on this basis. Also new is that measurement results are displayed in Windows 10 with Labview. The measurement report is available among other options as a “waterfall diagram” which shows exactly the flatness over the width and length of the coil and displays the results of both measurements to the operator at the same time. The picture shows the measurement report at one of the world’s leading 27 | Industry USA | April 2020
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ROI dependent on material value The new double measurement technology of coils flatness has already been integrated by Ungerer in several SBL lines, both in existing, and in new lines in China, Korea, and Italy, among others. It has been proven in practice that it has then shown to result in the production of higher quality coils with lower material loss. The higher the price per kilogram of the material, the quicker the measuring process pays for itself. Ungerer has developed a calculator that allows to quickly and easily estimate the “Return on Investment” for UMS PRO. As a rule of thumb, you can say: with thin stainless steel, the investment in the measuring system pays for itself after around three years. For copper coils it is as low as one year, and for titanium the payback period is even shorter. Author: Klaus Lenz, CEO, Ungerer Technology GmbH, Pforzheim www.ungerer.com
MECHANICS
NORD INTRODUCES NEW ENERGY-EFFICIENT MOTOR WITH POWER RANGE FROM 0.16 TO 60 HP
New UNIVERSAL motor extends portfolio of asynchronous electric motors.
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ORD Gear Corporation, a leader in industrial gear reducers, motors, and variable frequency drives, has announced the addition of a new energy-efficient electric motor to its line of asynchronous motors. The threephase NORD UNIVERSAL motor is available in 20 models and provides a power range of 0.16 to 60 HP.
Options for the NORD UNIVERSAL motor include quick connectors, single or double protection canopies, space heater, spring applied brake, and forced ventilation. If required, the motor enclosures can also be provided in IP66 rating, which means they are dust tight and protected against heavy seas or powerful jets of water.
Available in 4-pole configuration, the robust motors suit IEC frame sizes from 63 to 225. They are available in B3 foot, B5 flange, or B14 face mounting and can be supplied as NEMA C-face through 30 HP and NEMA foot mount. The motor also can be directly mounted to NORD gearboxes to provide a compact and more efficient drive solution.
These motors are manufactured in Europe and carry CE, UL, CSA, CCC, ISI and EAC certifications to serve all major markets in the world. www.nord.com
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As a standard, the motor is protected to IP55, is Totally Enclosed Fan Cooled TEFC, and Class F Insulation rated. The motor is also certified to Bureau Veritas for marine and offshore applications. The 3-phase NORD UNIVERSAL motor can be used with four standard voltage supplies noted on the motor nameplate: 380V 50Hz, 400V 50Hz, 415V 50Hz, and 460V 60Hz as well as at 440V 60Hz and 480V 60Hz.
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MECHANICS
ROBOTIC PARKING SYSTEMS CONTINUES TO RELY ON NORD GEAR AS EXCLUSIVE POWER TRANSMISSION PROVIDER FOR ITS AUTOMATED PARKING SYSTEMS
Twenty-year relationship punctuated by two Guinness World Records for Robotic Parking’s next-generation parking facilities.
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ORD Gear Corporation, a world leader in industrial gear reducers, motors, and variable frequency drives, and Robotic Parking Systems, Inc., a manufacturer of high-speed automated parking structures, continue to take parking garages to the next level. Robotic Parking Systems has relied on NORD as its exclusive power transmission provider since 1999.
Traditional parking garages are not only an inefficient use of space and construction materials, but they also contribute to pollution, waste drivers’ time, and put them in potentially unsafe situations. Automated parking structures solve all those issues and more. Drivers simply leave their vehicle in an entrance stall and take a ticket from the nearby kiosk. As they do, the front of the garage stall opens and the floor slides forward, carrying the vehicle into the futuristic, human-free structure within. There it is transported through a series of shuttles, elevators, and turntables until it reaches its assigned parking spot, all automatically. When the driver returns, they slide the card into another kiosk and the process is reversed, delivering their car within three minutes or less to a secure stall, facing forward, ready to go.
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Based in Clearwater, Fla., Robotic Parking Systems uses NORD’s helical bevel gear units to move vehicles into position. For large parking structures, where upwards of 100 vehicles might be motion at once, that could mean hundreds of such NORD systems are employed to ensure the vehicles are parked and returned quickly and efficiently. The companies teamed up nearly 20 years ago on a seven27 | Industry USA | April 2020
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level, 314-space garage in Hoboken, New Jersey—it was the first of its kind in the United States. NORD Delivers Dependability Automated parking structures have become particularly attractive in densely populated areas because without the need for driving ramps, they are able to fit more vehicles in a much smaller garage. Since completing the first structure in New Jersey, Robotic Parking Systems has led numerous similar installations throughout the world, including two in the Middle East that achieved Guinness World Record status. In 2013, a parking garage in Dubai was recognized as the Largest Automated Parking Facility with a capacity of 1,191 vehicles. Five years later, the company broke its own record with a 2,314-space garage in Kuwait, which has a throughput of 425 vehicles per hour.
“Our operating environments are often extreme, and that’s why we have equally extreme and stringent selection criteria for our mechanical and electrical components,” said Royce Monteverdi, president and CEO at Robotic Parking Systems. “For example, we expect a gearbox to provide at least 40,000 hours of continuous operation. NORD has never
NORD’s2-stage helical bevel gear units provide superior performance in a compact, modular design while delivering up to 97 percent efficiency. Featuring oversized output bearings and strong UNICASE housing for extended service life even under high radial loads, the gear units are available in two housing options and provide a robust, versatile solution for a variety of applications, including material handling, intralogistics, and food and beverage. Options include foot, flange, or face mounting; hollow or solid shaft; and a choice of six sizes. The 92.1 series is designed to disperse heat and keep the gear unit cool in high temperature environments. Said Monteverdi: “We’ve been relying exclusively on NORD for our power transmission needs since 1999 and have never had a failure.”
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Operating in such a high-volume environment where dependability and efficiency are paramount requires that every component of the intricate system works perfectly every time. The hot desert climate and a largely unmanned facility push the stakes all that much higher.
failed us in that requirement, which is one reason we’ve been using their products since the company began. As a matter of fact, their helical gear drives are perhaps the champion among all our mechanical components in terms of longevity and reliability. We are quite happy with the NORD products we’ve implemented into our robotic parking facilities, and with the relationship overall. They’re just a great company to work with.”
https://www.nord.com/cms/us/product_catalogue/ geared_motors/helical_bevel_geared_motors/pdp_ helical_bevel_geared_motors_62720.jsp 27 | Industry USA | April 2020
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S M A R T FA C TO R Y
NEW SOFTWARE VERSION NCP 4.2
The highly approved Neugart Calculation Program (NCP) is now available in new software version NCP 4.2.
Update for the Neugart configuration tool.
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he direct route to the most cost-efficient and energyefficient gearbox/motor combination – with the highly approved Neugart Calculation Program (NCP). The user-friendly configuration tool is now available in the new software version NCP 4.2. Customers of the gearbox specialist can download the free version now at www. neugart.com.
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Complex load trends in the drivetrain can be calculated in the NCP, and the optimum application-specific motor/ gearbox combination determined on this basis. With the update, it is now also possible for propulsion drives in Automated Guided Vehicles (AGVs) and the new NGV gearbox range that is tailored to these vehicles. Existing projects from current or older NCP versions can now also be loaded for newly designed controlled systems and compared with them.
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As well as these new functions, Neugart has simplified the operation of the tool with version 4.2 and improved user friendliness: conversions are no longer required when importing read-out motor data, for example. Users of popular CAD programs can now also use the familiar full stop as a separator as well as the comma. Calculations can also be carried out in the input fields. And the gearbox documentation has also been optimized, meaning that the user detects whether the selected gearbox is actually suitable on the basis of utilization bars. And last but not least, NCP 4.2 has an example for every application, which makes it easy to learn how to use the tool. www.neugart.com
S M A R T FA C TO R Y
CMP LAUNCHES NEW QUAD CABLE CLEAT RANGE
Leading cable gland and cable cleat manufacturer, CMP Products, has launched its new quad cable cleat range “Saturn” (QSDSS), which allows cables to be safely installed in quad formation.
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esigned and developed by CMP’s in-house R&D team, the Saturn quad cleat has a market-leading high short circuit rating of 152kA and has undergone stringent third party testing and certification to produce one of the strongest cleats of its kind. The Saturn cleats safely restrain single cables in quad (also known as quadrafoil or quatrefoil) formation, whilst protecting the integrity of the cables and cable management system in the event of a short circuit fault condition.
CMP has also developed the “Venus” (QPSS) cable cleat, which is manufactured with an integrated C-clamp and bolt; providing installers with versatility of installation. The Venus has a high short circuit rating of 135kA and can be installed in a range of applications where quadruplex cable is fitted.
The new quad cable cleat range has a compact design for space constrained-projects and is manufactured in the UK using 316L stainless steel. This provides superior strength and excellent corrosion resistance, making the quad cleat suitable for some of the harshest environments.
We have listened to our customer’s needs, producing a cable cleat that provides both safety and reliability. The demand for cable cleats is constantly growing as their essential role in cable management systems becomes increasingly recognised.”
Designed to restrain cables across a range of industries including datacentres, rail, energy and more, the Saturn has been third party certified in accordance with IEC 61914:2015.
www.cmp-products.com
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All of CMP’s cable cleats are manufactured with safety as a priority for both end-user and project infrastructure.
Lee Frizzell, Technical Director at CMP said: “In a spacesensitive but safety-conscious industry, the Saturn series offers a compact solution, whilst maintaining an incredibly high level of restraint, demonstrated by robust third-party testing.
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MECHANICS
THE JOURNEY TOWARDS AUTONOMOUS MANUFACTURING
Within the industrial world, leaders are defining their journey to autonomous manufacturing. Manufacturers are focusing on digitization strategies that will help to drive efficiency across their plants. As data is increasingly aggregated across manufacturing lines, the reality of autonomous lines is likely to be reached in the next five years.
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his paper explores the journey towards autonomous manufacturing—what a typical journey looks like and best practices for how manufacturers can begin to achieve this. A review of production systems in Industry 4.0 When reflecting on the concepts of Industry 4.0, we need to consider where production systems have come from and the changes that have been made over time to improve throughput and efficiency.
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Production improvement starts with robotic process automation (RPA), where you take a repetitive process and apply some form of mechanization to improve the throughput rate. The interesting thing here is that it doesn’t improve the processes quality, but does make it less variable—simply because the process is more repeatable. For example, if your current process produces 1,000 defects, RPA will make 10 times as many defects, but also produce 10 times as many good parts. This is great for throughput but not very effective for improving quality.
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Once manufacturers started shifting paradigms to become more data-led in their production systems (by using historians, PLCs, etc.), it enabled them to draw on that data to inform the expert analysis of the process. This results in improved control limits and a reduction in the variance and in the number of quality defects. It does however make the operators’ job more difficult, as they need to manually maintain the process within these finite control bounds. The next level of improvement is to make these adaptive changes as quickly as possible, with an understanding of the system from start to finish, to improve production. This final step brings us closer to the goal of autonomous manufacturing. Production systems need to be flexible to tolerate the variance in upstream processes, without compromising on the quality of the final output. The future of industry 4.0 is definitely much more flexible. We’re at a point where artificial intelligence (AI) systems are able to correct at the highest rate possible, which is ahead of real-time, to produce the best quality at the lowest cost, without the need for a human expert.
achieve. Unless the system achieves an incredibly rigorous sampling and tracking of the component flow, people alone are not able to join the data from step A through to step Z. The solution to this complexity is an Expert Execution System (EES) that allows manufacturers to express the relationship between the start of a process and the end of the process, without having to enforce the rigorous traceability that would typically be required. This system requires looking at the process with a slightly different view. It’s important to understand the quality result from each step in the process to make a final quality improvement at the end of the process. Existing systems can be used The paradigm of autonomous manufacturing is specifically designed to work with existing processes. The only change is that the manufacturing system becomes more dataled, by using production data and quality data to make the prescribed process changes that result in improved quality. The journey to autonomous manufacturing is, in fact, predicated on having an existing production system although it can also work in greenfield spaces. Autonomous manufacturing only requires enough data to describe the process in order to make a substantial impact on the system.
The state of autonomous manufacturing today The journey to autonomous manufacturing is complicated. It’s not as trivial as simply turning on a solution. In the final step described previously, the AI solution needs to offer guidance, making corrective suggestions to the production team to improve quality. This helps to reduce the manufacturing risk because the quality result is assured despite a large variance in input material. Total system efficiency is improved because less scrap means greater production capacity, as well as the production of better quality parts. Most plants today draw data from their production systems and send it to their engineering or production teams. Operators are left to follow their own inquisitiveness as they look through the data to devise an optimization or system improvement. There isn’t a holistic view or use of data from the start to the end of a process to achieve an overall system improvement.
Best practices for autonomous manufacturing The two most important things manufacturers can do to prepare production systems to achieve the goal of autonomous manufacturing are: - Identify and save production data. As soon as a plant can start saving production data, it opens the opportunity to use that data to optimize the future. That’s the single most important thing manufacturers can do now if they haven’t yet started. - Improve the quality system. To improve quality, it’s important to ensure that the details of the defect are recorded (type, location, and description), and not just the fact that a defect has occurred. This will allow AI to automatically diagnose the root cause of the problem and to provide continuous directions - to the machine or to the operator—so as to improve quality.
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These data led investigations are also limited by the complexity of the manufacturing system. These systemsof-processes are often too complex to express in the terms of classical engineering descriptions of their processes. An engineering model that would be able to handle material from the start of the process through to the finished goods is too complex to express analytically or interrogate with traditional methods. In addition, the traceability of the component through a complex process is very difficult to
The shift from reactive to prescriptive AI In reactive manufacturing, a quality failure is discovered at the end of the line and the production team will make a set of reactive changes to the system to correct for the immediately observed error. This approach has two core features: the first is that the defect has already occurred and the second is that the factory keeps producing poor quality goods until the root cause has been solved. A prescriptive system is very different, as it involves making a small change now to avoid future quality failures. A small set of corrective actions are made in anticipation of a quality cost that is never realized. These prescriptions can help to reduce the cost of non-quality. In the reactive case, by contrast, one waits for the quality failure and all the associated costs to occur before correcting the failures in the system.
https://dataprophet.com
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OPC UA EMBEDDED TOOLKIT FROM SOFTING NOW INCLUDES DISCOVERY ANNOUNCEMENTS
Softings uaToolkit Embedded adds metadata and discovery announcements.
Version 1.31 uaToolkit Embedded adds metadata and discovery annoucements to OPC UA field devices which eliminates the need for preset information in the subscriber.
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ofting’s uaToolkit Embedded for implementing embedded OPC UA Servers with client/server and publisher/subscriber communication just enhanced the OPC UA publisher and subscriber with metadata and discovery announcements. The publisher now sends the metadata for the published data set. The subscriber can use this data for the decoding of the published data set which reduces the need of preset information in the subscriber. V1.31 also supports the latest Long-Term Support version (LTS) V1.1.1 of OpenSSL. (LTS for OpenSSL V1.0.2 ended on December 31, 2019 but is still supported).
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“As industry 4.0 and IIoT continue to develop, we have seen a very significant and sustained increase in OPC UA adoption. The uaToolkit Embedded is our offering for customers who want to use OPC UA in sensors, small devices and low-end controllers,” says Thomas Rummel, Senior Vice President Engineering & Product Management at Softing Industrial. “Meanwhile there is an increasing amount of OPC UA Companion specifications for devices. The VDMA (Germany’s Mechanical Engineering Industry Association) alone coordinates the activities of over 26 working groups that define a common, cross-sectoral language between 27 | Industry USA | April 2020
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machines and plants. And the new OPC UA FLC (Field Level Communication) initiative will further increase the demand for embedded OPC UA.” Softing’s uaToolkit Embedded has been certified in the Compliance Lab of the OPC Foundation for the Nano Embedded Device Server profile, the Micro Embedded Device Server profile and the Embedded UA Server profile. The toolkit has a low memory footprint and requires little computing power. This makes it particularly suitable for firmware development of field devices, and also for use in control or remote I/O systems with limited resources. It also supports OPC UA Companion specifications with a tool for importing OPC UA nodesets. The toolkit is available on the Softing Website as full and trial version: https://industrial.softing.com/en/products/ protocol-software-and-sdks/opc-ua-embedded-toolkit. html
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MOBILE ANDROID COMPLETE SOLUTION FOR CONFIGURING AND SETTING THE PARAMETERS OF HART FIELD DEVICES Softing Industrial, together with the German company i.safe MOBILE GmbH and the USbased company ProComSol, now offers a complete solution for setting the parameters and configuring HART field devices in Android applications.
Mobile Android bundle for configuration and parameter setting.
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he combination of Softing’s mobiLink interface, i.safe MOBILE’s Android tablets and smartphones and ProComSol’s DevComDroid App for mobile field devices has been successfully tested as a solution for simple and safe configuration and parameter setting of HART field devices also for hazardous areas. The bundle is available from i.safe MOBILE. i.safe MOBILE GmbH, based in Lauda-Koenigshofen, Germany, has more than 10 years of experience in the development of equipment for use in explosion hazardous areas and is one of the most innovative and well-established specialists in the market. All i.safe MOBILE products are certified for safe use in hazardous areas (ATEX, IECEx, CSA, EAC, etc.) and are suitable for robust use in industry and outdoors. ProComSol Ltd, based in Lakewood OH, USA, is a leader in the development and manufacture of HART communication products for the process industry.
Thomas Rummel, Senior Vice President Engineering & Product Management at Softing Industrial: “Our companies have complementary skills. A partnership will bring many benefits to the HART market. Our mobiLink simplifies mobile access to field devices for plant operators, system integrators, device developers and other users in the process industry. Together with the certified tablets and smartphones from i.safe MOBILE for use in hazardous areas and the DevComDroid app from ProComSol, we now have a cost-effective and easy-to-use complete solution for Android applications.” Martin Haaf, CEO i.safe MOBILE: “The mobiLink interface in combination with our IS930.1 tablet and IS530.1 smartphone and ProComSol’s DD-based apps is a powerful offering for our customers. We are pleased about this expansion of our portfolio of first-class communication solutions for process automation.”
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Further information: • mobiLink product info: https://industrial.softing.com/en/products/usb-andbluetooth-modems/mobilink-multiprotocol-interface.html • About i.safe MOBILE: https://www.isafe-mobile.com/en/about-us.html • About ProComSol: https://procomsol.com 27 | Industry USA | April 2020
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LEUZE AND ITRACE ANNOUNCE THE BLOCKCHAIN INTEGRATION OF 2DMI WITH THE DCR 200I CAMERA BASED CODE READER
iTRACE Technologies, Inc., a leading provider of supply chain security applications for anti grey market and anti counterfeit, and Leuze, a global leader in automation sensors, announced today the integration of iTRACE 2DMI with the Leuze DCR 200i Camera Based Code Reader for Blockchain registration and authentication.
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TRACE helps brands fight the issues of counterfeit, grey market, diversion and production overrun of their products with its blockchain connected 2DMI® supply chain security. With the integration of 2DMI® with the Leuze DCR 200i range of camera-based code readers, customers are now able to capture transaction and authentication information automatically anywhere in the supply chain.
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“The integration of the Leuze DCR 200i camera-based code reader is using our standard mobile application infrastructure which allows these industrial sensors to automatically capture the same information as the iPhone and Android devices anywhere in the supply chain.” said iTRACE Founder and CEO Mark Manning. “This means that any system can now automatically participate in track, trace and authentication of any item or component and push that data to a blockchain or tracking database via the iTRACE Blockchain Gateway.”
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Using iTRACE 2DMI® and the DCR 200i allows the part being scanned to be securely identified and the transaction recorded on digital ledger technologies like blockchain, enabling a secure connection between the physical product and the digital ledger which is necessary to complete any blockchain tracking or authentication application. The key to the security of the application is the ability to create the digital twin of the physical product to ensure that is the original item that is scanned at each location. Leuze has recognized that “iTRACE 2DMI® provides a much higher level of security and damage resistance than QRCode, Data Matrix and 1D Barcodes are able to do” said Joerg Woerner, Business Development Manager at Leuze. “This makes the combination of the DCR 200i and 2DMI® ideal for difficult and harsh environment applications in aerospace, automotive and medical device”. https://itracetech.com www.leuze.com/en/usa/
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E-CON SYSTEMS PROVIDES CAMERA SUPPORT FOR ROCKCHIP 96BOARDS
As a pioneer in OEM camera modules, e-con Systems is introducing camera support for Rockchip RK3399 based 96Boards compliant Rock960 developer kit.
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-con Systems Inc., a leading embedded camera solution company, today announced the launch of e-CAM50_CU96, A lowlight 5MP camera board for 96Boards compliant Rock960 developer kit featuring Rockchip RK3399 processor. e-CAM50_CU96 is based on OnSemi’s 1/2.5” AR0521, a 2.2 µm pixel CMOS image sensor with integrated Image Signal Processor (ISP).
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e-CAM50_CU96 is capable of streaming HD (1280 x 720) at 70 fps, FHD (1920 x 1080) at 60 fps and 5 MP (2592 x 1944) at 25 fps in uncompressed (UYVY). The higher Signal to Noise Ratio (SNR) supported by this camera helps to produce clear images without noise and better dynamic range helps in retaining more details in shadows and highlights. Along with these features, the powerful in-built ISP helps to brings out the best-in-class video in uncompressed UYVY format. The camera is also provided with the S-mount (M12) lens holder that enables customers to choose lens from a wide range of options as per their requirement.
The Rock960 platform kit is based on the RK3399 SoC which is a Dual Cortex-A72 + Quad Cortex-A53 CPU, with upto 2 GHZ frequency. This board comes with 4GB RAM, 32GB eMMC, USB3.1 type C, HDMI 2.0, 4 lane CSI-MIPI, etc on the 96Boards Consumer Edition Standard form factor. With Capability to stream 5MP at 25 fps, Rockchip based Rock960 is perfect partner for e-CAM50_CU96 to run application requiring high resolution images. High quality video from e-CAM50_CU96 integrated with Rockchip’s powerful multi-core processor enables running of robust vision and image processing applications (Realtime camera vision application eg: Face detection, object identification). Availability e-CAM50_CU96 is currently available as Engineering samples for evaluation. Customers interested in evaluating e-CAM50_CU96 can request samples from e-con Systems’ online store. Video: https://www.youtube.com/watch?v=LnrZPWTnyxw www.e-consystems.com
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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.
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 ± 12 µm and a resolution of 1 µm the measuring system meets these requirements. The system is also simple to retrofit.
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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.
www.balluff.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. Search for the products: https://eplandata.de/portal/en_en/catalog/LEMO
S M A R T FA C TO R Y
FAULHABER BRINGS INTEGRATED ENCODER FOR FLAT MOTORS TO MARKET
Integrated encoder for flat motors.
Less than seven millimetres for precisely fitting encoder.
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he BXT motor family, comprising brushless DCmotors with especially short design, was expanded with the diameter-complaint IEF3-4096 magnetic encoder. With just 6.2 mm of additional length, the motor/ encoder units also remain extremely short. In addition, the encoder is fully integrated in the robust motor housing. In this flat design, the IEF3-4096 offers three channels with index function and a high resolution of up to 4096 lines per revolution. Furthermore, a variant with line driver is available with the IEF3-4096 L. The encoder can be combined with the 2214… BXT H, 3216…BXT H and 4221…BXT H housed BXT motors.
The combination of the BXT motors with the IEF3-4096 encoder is the ideal solution if it is necessary to precisely position in a constrained space and high torques are also required. Typical applications are found in robotics, medical technology, laboratory automation and industrial automation. The encoder is connected with a ribbon cable; suitable connectors are available. The advantages at a glance: • Short design, since fully integrated • Index function and high resolution • Line Driver available • For precise positioning with high torque in constrained spaces www.faulhaber.com MORE INFORMATION 27 | Industry USA | April 2020
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NEW GPT GEARHEAD FAMILY WITH NUMEROUS GEAR RATIOS A NEW CLASS LEVEL FOR TORQUE AND SPEED
New GPT gearhead family with numerous gear ratios© FAULHABER - GPT Gearhead family.
The new metal GPT planetary gearhead family characterized by its compact dimensions, high torque and very fine graduations of the numerous gear ratios. It is extremely robust and tolerates both frequent as well as sudden load changes. The gearheads operate with high efficiency can be combined with many different motors and enable various shaft configurations.
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he pure metal GPT gearheads achieve performance values comparable to more expensive technologies on the market like ceramic components. The gearheads are available with diameters of 22, 32 and 42 millimetres. The gearheads achieve top values for torque as well as for speed. Compared to the predecessor models, the continuous input speed was more than doubled above 10,000 rpm, and can support input speeds up to 20,000 rpm in intermittent mode. The 42GPT Series can sustain an intermittent torque up to 25 Nm while its length is squeezed down to 71 millimetres. The GPT gearheads are designed to be extremely robust and tolerate both continuous as well as very abrupt and sudden load changes. At the same time, they are significantly shorter than other models in the same diameter.
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The gearheads can be equipped with up to four reductions stages each stage is individually optimised to achieve the highest power in terms of torque and speed an important feature of the product family is the high number of available gear ratios and their very uniform distribution. As a result, the motor power can be utilized optimally: a higher torque can be achieved with the same input speed; a higher speed can be achieved with the same torque. In addition, power consumption is significantly reduced through a much higher efficiency compared to previous product generation the new GPT family also is particularly suited for accurate positioning applications granted by a very low backlash characteristic. With high performance values and the great robustness, the gear heads of this new product family are suitable for various demanding applications. Their compact design fits particularly well with the new BXT brushless flat motor family when size is a key constraint integrating actuators inside applications. A large selection of DC motors is also
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GPT Gearhead open.
available in combination with the new GPT gearhead family. They are ideal for different types of robots – inspection, assembly, rehabilitation or exoskeletons – as well as for production and laboratory automation, for packaging machines, measurement and testing equipment or for semiconductors handling. www.faulhaber.com
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MATURITY SELF-ASSESSMENT FOR INDUSTRY 4.0
One of the biggest questions posed by manufacturers looking to transform their operations with artificial intelligence is: How do we know if we’ve got the data for this? It is a really good question. Machine learning is largely dependent on the ingestion of data - and not just any data. This article looks at the complexity that surrounds large industrial operations and the type of data manufacturing plants are probably already collecting. We also take a look at supporting the systems and infrastructure required. It starts with quality In modern production environments, there are many places to measure the pulse of your operation: from takt time on your production line, to the size of your goods-receiving warehouse, and then to scrap and rework rates, and even the cost of non-quality. All of these have a direct impact on your business’s efficiency, and it is important to understand the dynamic interplay between these variables.
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At some point in your production process, a qualitydeviation occurs and this quality event is a function of all the processes upstream of the event. This has an impact on all the processes downstream of the event. If uncaught, this quality deviation propagates all the way to your customer and that becomes an even more difficult conversation to have. So the most critical data, and minimum requirement, is to have some measurement of quality and where in your process the quality measurement is made.
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Some organisations use the simple differentiator of “internal quality” (where the quality inspection team has identified a defect and quarantined it) and “external quality” (where the incoming inspection at the customer has identified the defect). In processes where there are different defect types, it is also very valuable to have the defect type, but this is not a minimum requirement. Following the process: identification and traceability To gain useful insights into your entire process the quality result needs to be connected to the conditions that either enabled a good quality result or led to a poor quality result. To achieve this process mapping, there are two key requirements: - An identifier (usually a part ID or batch number); and - A record of where in the process the component is.
The International Organization for Standardization (ISO) maintains a suite of standards related to quality management, known as the ISOÂ 9000 family. ISO-9001 details the requirements for quality management systems (QMS) and this standard has several minimum requirements for the identification and traceability of business. These requirements are far in excess of what is required to track the quality result through a process, but are a great yardstick to guide future quality system implementations. However you achieve it, the next minimum requirement is the traceability of an article or batch through your process.
The difficult part of this problem is the determination of the complex interplay between parameters: the extent to which a small change in one impacts adjacent parameters and how the change cascades down through subsequent processes. The complex question is: how is the control target
A holistic representation: combining quality, traceability and control This is the hardest part of realising value from Industry 4.0 installations. Combining these three different data sources is crucial to creating a representation upon which an AI system can learn how process parameters influence quality and process yield. This is largely based on mapping out the process but is also heavily dependent upon capturing a description of the variability and randomness of each variable. It is unlikely that manufacturers have a view of their data that meets these requirements so this is one of the key pieces of work that we do at DataProphet. Running with AI DataProphet uses machine learning to understand how a plants process variables interact and combine. Machine learning is amazingly well suited to this problem and the output is a control plan that can enable production teams to fine tune processes to reduce defects and eliminate scrap.
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Process control: set-points and targets Controlling your manufacturing process is undoubtedly happening now because your process isn’t just running on random. It is highly likely that if the parameter has an impact on the quality result, it is already measured and controlled. There are many parameter control paradigms: from simple closed loop PID control, through to more advanced black-box Model Predictive Control (MPC). All of these compensatory control regimes have an impact on the shape of distributions of the control variable - as do the parameters of the transfer function describing the underlying process.
set and what method (if any) is being used to compensate for the inherent variation in all the other process variables?
https://dataprophet.com
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SAFELY CONNECTED
Real-time quality inspection of adhesive beads with uEye LE board level cameras.
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onding has become a key technology in the modern automotive industry. According to the Industrieverband Klebstoffe e.V. (adhesives industry association), a car today contains around 15 - 18Â kg of adhesive and runs through dozens of gluing systems during production. Bonding is becoming more and more a new alternative to welding, screwing or riveting. The reasons are simple: safety and economy. But to be able to guarantee this, a high-precision adhesive and sealant application is necessary. The French company AKEOPLUS has developed the AkeoBI sensor that checks adhesive beads in real time directly on the production line and thus ensures 100% quality in material deposition.
In crash tests, vehicles with a high adhesive content usually perform best. This is because the parts to be bonded are not negatively affected during bonding. Welding generates heat, which can influence the materials used and their properties. Screws cause holes. Glue, on the other hand, bonds without material changes - a real safety factor. Adhesive systems are now used in both engine and body construction. They securely connect sheet metal to each other or fix car windows in the corresponding frames, thus ensuring high rigidity of the body. The latter also guarantees a high potential for energy savings. A prerequisite for strong connections and also for sealing, however, is the exact application of the adhesive beads in all bonding processes, especially with safety-relevant parts. They must be dispensed at all locations in the same quality - even in corners and curves. Error minimization and traceability AkeoBI, is an intelligent production tool, developed by AKEOPLUS, that helps to guarantee 100% quality of material deposition. The sensor inspects all types of beads in real time directly on the assembly line - whether glue, mastic, silicone or foam. Mounted on adhesive guns on fixed bolts on the assembly line or directly on the robot arm of the bonding
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Real-time inspection: Reports are available immediately (OK or NOK).
In use, e.g. in the automotive industry.
AkeoBi - Sensor for quality inspection of adhesive systems - Lightweight and compact, AkeoBi can be integrated into almost any production plant.
system, special algorithms check bead width, continuity and position and detect any surplus or lack of material with an accuracy of +/- 0.5 mm. This all happens at a speed of 450 mm per second. Due to its compact dimensions of only 170 mm x 50 mm and its low weight of 1.5 kg, AkeoBI can be integrated into almost any production plant. The system can be individually configured to meet the requirements of various applications. A central unit can, for example, carry out the inspection with two sensors simultaneously or only trigger random checks. AKEOPLUS enables the detection of defective material applications on the basis of previously stored criteria by means of a specially programmed powerful software - clearly visualised for the user on the associated user interface. A report on each part checked is available immediately after each inspection. The operator can immediately locate faults and quickly correct them without interrupting production. This prevents unnecessary downtime, ensures traceability and increases production reliability.
This allows either several characteristics to be checked simultaneously or the AOIs to be captured in an exposure series with different parameters. The camera model is therefore particularly suitable for space-critical inspection tasks in quality assurance. The speed of these compact industrial cameras was also ideally suited to the requirements of AKEOPLUS. The price-performance ratio as well as the IDS software suite - with the IDS typical plug & play capabilities - were also decisive criteria. “The efficient programming interface of the IDS Software Suite enabled us to configure the camera accurately and easily. Indeed we were able to test and define precisely pixel format, image size, frequency and all necessary features in advance. The images are then processed by the camera software. Start, stop and frequency of acquisition are precisely controlled thanks to the high performance of the IDS camera manager,” explains Thibaud Cheippe, developer at AKEOPLUS.
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3 high-resolution cameras with 360° panoramic view Three high-resolution industrial cameras provide the images on which the inspection is based and also provide AkeoBI with a 360° panoramic view of the components to be inspected. High-performance LEDs directly in the sensor provide the necessary illumination. The GigE uEye LE cameras from IDS Imaging Development Systems used here
are each equipped with a 1.3 megapixel CMOS sensor from e2v. Besides their outstanding light sensitivity, these GigE board level cameras also have a range of other distinctive features: The sensor of the UI-5241LE offers, for example, two global and rolling shutter variants that can be switched during operation, thus enabling maximum flexibility for changing requirements and environmental conditions. In addition, a maximum of four areas of Interest are available.
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Outlook More than 100 AkeoBI sensors are already in use worldwide, e.g. at the French automobile manufacturer Groupe PSA, who owns the brands Citroën, Opel and Peugeot. However, the combination of high-resolution cameras, high-performance LEDs and matching algorithms offers companies from a wide range of industries the opportunity to increase the quality of their adhesive bonds and thus their products and at the same time generate real competitive advantages. In addition to the automotive industry, its suppliers at various stages of the value chain and the aerospace industry benefit from the efficiency and high level of traceability offered by the sensor. Since safety-relevant parts in particular require a 100% inspection, real-time execution on the production line also ensures a high degree of cost-effectiveness. The camerasupported solution from AKEOPLUS ensures contactless, safe connections that deliver what they promise.
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Client With many years of experience in different industries - in France and internationally - AKEOPLUS combines its competences in the fields of automation, data and operational efficiency to develop adaptive and scalable assistants for industry 4.0. Aiming to make digital technology a strong growth driver for its customers, individually tailored technological solutions for the future are created. www.akeoplus.com 27 | Industry USA | April 2020
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Camera GigE uEye LE board-level industrial camera: Compact CMOS single board camera with excellent image quality and additional features Safely connected Interface: GigE Model: UI-5241LE Sensor type: CMOS Manufacturer: e2v Frame rate: 50.0 fps Resolution: 1280 x 1024 / 1.31 MPix Shutter: Global Shutter, Global Start Shutter, Rolling Shutter Optical class: 1/1.8” Dimensions: 45.0 mm x 45.0 mm x 26.5 mm Weight: 24 g Interface connector GigE RJ45 Applications: 3D scanning, security technology, gaze and gesture tracking, traffic monitoring and license plate recognition, industrial image processing, quality assurance, medical technology, astronomy www.ids-imaging.com
S M A R T FA C TO R Y
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.
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.
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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.
www.leuze.com
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SOURIAU, A MAJOR PLAYER IN CONNECTIVITY FOR SMART AGRICULTURE
The growth in world population is placing increased demands on agricultural production. This is one of the major challenges of modern agriculture, now in the midst of major transformation. Now that “intelligent” and connected equipment is becoming available on the market, answers to these needs are now within reach, while at the same time addressing environmental concerns.
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eal-time analysis of land and crops, the use of drones and geolocation systems, the implementation of software in agricultural equipment and greenhouse cultivation lead to new operational methods and the development and introduction of new devices and hence a need for connectivity. SOURIAU has been active in the agricultural sector for more than 20 years by providing its customers around the world with complete interconnection systems for harsh environments, continuously adapted to market evolutions.
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Alexandre Lagrange, Industrial Product Manager at SOURIAU explains: “the agricultural equipment market is currently undergoing a major transformation. Agriculture is more and more globalized but despite its intensive development, it is learning to be more judicious (as with integrated farming) and aware of ecological concerns. It is in this transformation that smart agriculture is relevant because it allows the analysis of needs, the optimization of crops and the improvement of yields, for example in the area of lighting for greenhouse crops (indoor cultivation) which is now an exploding market”. It has been this need to continuously increase production and productivity which has led to the development of lamps which are increasingly intelligent and sophisticated. With new technologies such as horticultural LED bulbs that can provide variable spectra depending on the plant’s growth stage and consume less energy, agricultural lighting has seen an increase in activity and encouraging results in terms of sustainable cultivation.
Another example of resource adjustment are intelligent irrigation systems, capable of carefully calibrating the amount of water required. Intelligent sensors are distributed and precisely geolocated in the fields to detect and report soil quality. The connector requirements for these indoor or outdoor applications nevertheless have common characteristics. SOURIAU industrial connectors such as the UTS and UTL ranges (designed and qualified to the UL1977 and IEC61984 standards) are ideal for these environments. These products are resistant to extreme temperature variations, from -40 °C to +105 °C, bad weather (IP68 and IP69K) and UV (no mechanical alteration confirmed after 5 years of exposure).
Souriau offers the micro38999 series of connectors, specially designed to be integrated in drones. Their compact size and low mass make them ideal for applications with space and weight constraints, while the coupling mechanism derived from the MIL-DTL-38999 military standard is capable of withstanding high levels of shock and vibration without any impact on performance. www.souriau.com MORE INFORMATION
Thanks to their suitably-chosen materials, these ranges of plastic connectors for harsh environments are not affected by regular spraying with fertilizer and pesticides. And with their easy-action, robust locking systems among other things, they offer ease of use combined with a service life of 250 cycles. These series also feature built-in ease of use thanks to a product design suited to either overmoulded applications or standard installations.
be vehicles with advanced assistance systems for weed detection, that require a high-speed data connection to transfer HD video to the control centre. For these types of application, it will be essential to be able to count not just on high speed data transfer, but also signal protection. The metal connectors of the JBX series or Souriau’s UT0 series provide excellent signal shielding and guarantee 360° continuity. Souriau also offers overmoulded cables for all its connectors to afford even better protection of the system in terms of waterproofing and robustness.
Drones and intelligent agricultural machinery As intelligent machines for agriculture develop, technical requirements may also evolve. For example, these could
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S M A R T FA C TO R Y
IP66 CABLE ENTRIES FOR ALL SHAPES AND SIZES
Connection technology expert CONTA-CLIP supplies versatile components for simple and time-saving cable management.
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he tool-less KDS and KES cable entry systems enable easy routing and flexible rearrangement of cables and conduits in enclosures and control cabinets, with reliable strain relief and IP66 ingress protection. To install any number of differently sized and shaped cables, enclosures no longer need to be fitted with variously sized openings, reducing the machining effort to a minimum. This enables manufacturers to supply fully sealed, preconfigured machine enclosures and control cabinets without knowing the exact final wiring requirements.
One-piece KES plates with push-through membranes enable high-density routing of up to 32 unassembled cables, wires, or conduits. The multi-part KDS system features a frame that can always stay in place once it is installed – removable sealing elements in different sizes can be inserted to change the assembly as needed. As a result, stock-keeping costs are also significantly reduced, since there is no need for various same-size enclosures with a range of different prepared openings. The KDSClick system consists of only three basic components: frames, inlays, and sealing elements. The sealing elements are available in over 100 variants for diameters ranging from 2 mm to 35 mm, with 1, 2, and 4 slots, for industrial flat ribbon cables, and as blind plugs. The frames are available for 4, 6, 8, or 10 sealing elements. Featuring an injected foam gasket, they preserve the IP66 protection rating even on painted or rough surfaces. To accommodate the selected sealing elements, various inlays (available in I, T, +, and ++ shapes) can be simply inserted in the frame. KDS-FP flange plates hold two or three KDSClick modules and provide space for a total of up to 30 sealing element
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NEWS
The KDS and KES product families enable easy, variable cable management for all diameters and shapes.
positions, making them ideal for control cabinets that require a lot of wiring. CONTA-CLIP furthermore offers the KDS-R series for quick, tool-less assembly in metric M20 to M63 round enclosure openings. This system consists of a frame with an integrated gasket, a thread and locking adapter, a locknut, and sealing elements with optional inlays. The KDS program also includes KDS-FB frames for industrial flat ribbon cables. These are available in four frame widths and different partitions for flat as well as round cables. http://contaclipinc.com
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