Industry Asia Pacific | 28 - January 2019

28 | J A N UA R Y 2 0 1 9

Industry

Asia Pacific THE INDUSTRY MAGAZINE FOR ASIA

RED LION ADDS DA10D AND DA30D PROTOCOL CONVERSION AND DATA ACQUISITION DEVICES

5 FLUKE PROCESS INSTRUMENTS TWO KNOW MORE THAN ONE

16 NEW NORDBLOC.1 BEVEL GEAR UNITS WITH 50 NM

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KENNAMETAL MAKES DEEP BORING EASY

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THE INDUSTRY MAGAZINE FOR ASIA

INTERROLL

RED LION

SIC MARKING

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SECO TOOLS

SECO TOOLS

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FLUKE PROCESS INSTRUMENTS

FLUKE PROCESS INSTRUMENTS

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MITSUBISHI ELECTRIC

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INTERROLL

NORD

NORD

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KENNAMETAL

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ADVERTISERS: MEPAX 6 • NORD 23

www.industry-asia-pacific.com

Contributing Editors: • Emmanuel AHOSSI • Nessren BAZERBACHI • Romain CLASS • Maria DE PABLOS • Anna HARDALOUPAS • Sofiane JEDIDI • Laura MUTTO • Marie RESPINGUE • Christophe VERGUET

Send your press releases to: editor@industry-asia-pacific.com To receive Industry Asia Pacific magazine free of charge, please subscribe online at www.industry-asia-pacific.com Industry Asia Pacific is the English-language magazine for engineers, published by INDUPORTALS MEDIA PUBLISHING. It contains the latest product and company news for industrial markets.

Industry Asia Pacific 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.

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THE ALFA ROMEO SAUBER F1 TEAM EXTENDS THE PARTNERSHIP WITH PROMOTIONAL PARTNER INTERROLL

Jens Karolyi, Senior Vice President Marketing & Corporate Culture (left) and Axel Kruse, Operations Director of Sauber Motorsport AG confirmed the renewal of the partnership at Sauber Motorsport in Hinwil, Switzerland.

The Alfa Romeo Sauber Formula 1 (F1) Team today announced the extension of its promotional partnership with Interroll.

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he successful collaboration between the two companies began in 2012 with the goal of optimizing the team’s logistical processes, a critical factor in operating successfully at the pinnacle of motorsport.

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“We are happy to be extending our longstanding partnership with Interroll,” said Frédéric Vasseur, Team Principal Alfa Romeo Sauber F1 Team and CEO Sauber Motorsport AG. “Building on our collaboration that has been successfully in place since 2012, we will continue optimizing our logistical processes which are an important key to success in Formula 1. We look forward to making further progress together.”

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“Interroll is pleased to continue the successful partnership with the Alfa Romeo Sauber F1 Team. We value the focus on quality, efficiency and innovation at Sauber. The exchange as well as joint events inspire us and our customers over and over again,” added Jens Karolyi, Interroll’s Senior Vice President of Corporate Marketing and Culture.

“Beyond sports, Sauber once again sets new standards in engineering.” www.interroll.com

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RED LION ADDS DA10D AND DA30D PROTOCOL CONVERSION AND DATA ACQUISITION DEVICES

Powerful Connectivity Tools Unlock Valuable Data from Orphaned and Legacy Equipment.

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ed Lion Controls, the global experts in communication, monitoring and control for industrial automation and networking, announced the release of the DA10D and DA30D Protocol Conversion and Data Acquisition devices today. Unlike other gateways or protocol converters that rely on complicated scripting or additional server hardware to connect to enterprise systems, the DA10D and DA30D offer powerful connectivity options in a simple-to-use configuration environment, enabling companies to quickly unlock valuable data in orphaned or legacy equipment and cost-effectively connect, monitor and manage their systems with ease.

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For factory automation customers who need to collect critical data from multi-generational or multi-vendor deployed systems, the DA10D and DA30D Data Acquisition protocol converters are new devices that offer standard Ethernet and serial ports to gather and share data from disparate systems. This new offering leverages Crimson 3.1 software, providing native support to over 300 industrial drivers, out-of-box OPC UA server capabilities and simple point-and-click configuration of MQTT cloud connectors for some of the industry’s most popular IIoT platforms from Amazon, Microsoft and Inductive Automation.

From the plant floor to the front office, the DA10D and DA30D Protocol Converter and Data Acquisition platforms were designed to act as a key part of any plant’s industrial data collection, visualization and management system, allowing for operational decisions that have meaningful business impact. Providing real-time data from virtually any equipment, anywhere, additional options include a data, event and security logger with cryptographic signature support and SQL queries which can be executed periodically or on demand, ideal for both simplifying recipe and batch management while ensuring the highest quality standards.

Further, the platform also offers an optional web server featuring mobile responsive design, a full-screen display ideal for tablet or mobile display, HTTPS operation with the provision of certificates, HTTP redirect, CSS and JavaScript support.

For more information about the end-to-end connectivity benefits of Red Lion’s DA10D and DA30D Protocol Converter and Data Acquisition platforms, visit www.redlion.net/DA

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With a proven process set for more than 120 active customers, we can adapt to all specific client needs with the highest reliability.

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SIC MARKING AT THE CUTTING EDGE OF INNOVATION

An important event was organized in Lyon on the 20th of November by CARA (the European Cluster for Mobility solutions): the 4th edition of Automotive Techdays.

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IC Marking has been selected as one of the most innovative players in the Automotive sector. They presented an All-in-one compact laser marking solution with a micro safety enclosure. This flexible solution is compliant with automotive standards. Options include an embedded 3D measuring system answering to the new Industry 4.0 trend.

This innovative system has been developed by the R&D team thanks to the Operational Excellence program and offers many advantages for their customers :

SIC Marking is an international company developing innovative permanent marking solutions and automated identification for the complete traceability of industrial components. For over 30 years, SIC Marking has engineered a full range of technically superior marking machines in dot peen, scribing and laser technologies. www.sic-marking.co.uk

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• Enhance productivity thanks to quicktool changeover, shorter marking time, • less production waste • Cost savings: compact footprint, low maintenance, fewer consumables, • 100% real-time quality control and increased reliability • Permanent marking on lightweight materials: steel/ composite/aluminum/additive manufacturing/plastics

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GROUP TECHNOLOGY: OPERATIONAL EXCELLENCE IN THE INDUSTRY 4.0 ERA

From before the Industrial Revolution until the present day, manufacturers have shared common goals: producing a certain number of parts, in a certain amount of time, at a certain cost. Manufacturing processes evolved from craft-made single-item methods to mass production lines and output of increasingly greater numbers of identical parts: a high-volume/low product mix (HVLM) scenario. Most recently, digital technology in programming, machine tool controls and workpiece handling systems are facilitating a manufacturing environment known as Industry 4.0 that enables cost-efficient manufacture of highly diverse parts in small batches: high-mix/low-volume (HMLV) production.

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n the era of Industry 4.0 it is fashionable to highlight the newest production techniques and digitalization technologies. However, maximum productivity and costefficiency still are based on a foundation of operational excellence. In the present economic environment, manufacturers generally consider speed to be a key indicator of operational excellence. A drawing comes into a facility and eventually a completed workpiece leaves the plant; manufacturers want the time between the two events to be as short as possible. Efforts to boost speed typically focus on strategies such as e.g. lean manufacturing or Six Sigma.

However, those strategies generally relate to HVLM production and are not always effective when applied in HMLV scenarios. An important contributor to streamlined

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HMLV output is the Group Technology approach, in which classifying and coding parts into machinable families enable a shop to achieve the highest level of operational excellence.

Group Technology Group Technology is a manufacturing organizational strategy in which parts with certain similarities such as geometry, material, manufacturing process or quality standards are classified into groups or families and manufactured under a common production method. Operations are planned for the part family rather than individual workpieces.

Very often when production is organized to handle part families, the arrangement is described as cellular manufacturing. Cellular manufacturing came to prominence in the 1980s, roughly when the era of HMLV production

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began. Manufacturers recognized that batch sizes were shrinking while the variety of workpieces and new workpiece materials were growing. Shops were confronted with a high diversity of different workpieces, produced in comparatively small batches. Time spent preparing for production rose exponentially, and manufacturers sought to control it.

The creation of part families in Group Technology is based on part codification and classification. Each part is assigned a code consisting of letters or figures or combinations thereof, and each individual letter or figure represents a certain feature of the workpiece or a production technique that is required to produce the workpiece. In Figure 1 the 6th digit in the part code represents workpiece dimensions, the 7th digit the raw material, the 8th digit the original shape of the workpiece material, and the 9th digit the level of quality required. Digits 3 through 5 describe the operations required to machine the part.

Production planners and estimators work with a drawing of a workpiece and develop a price quote by matching features on the workpiece with those on the complex workpiece and also determine other production elements such as the machine tool required, whether coolant will be needed, etc.

In addition, executing the Group Technology technique with the help of a sophisticated CAM system further reduces pre-machining engineering time requirements. Additional benefits include improved communication between departments in a facility as they all work from the same complex workpiece model.

The Group Technology approach initially was based on experience as personnel developing it interviewed process engineers, programmers and planners to gather information regarding the cost of various production operations.

Although the development occurred in the 1980s, compiling individual experiences and data and organizing them into a system was a process that resembles today’s initiatives in artificial intelligence.

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The part codes are used to plan production and make price quotes by referring to an imaginary or non-existent part called a complex workpiece, as shown on the second line of Figure 2. Complex in this case does not mean difficult; it describes a generic workpiece that illustrates all the features that a company is able to create, such as highand low-accuracy holes, deep and shallow pockets, side milled features, etc. The parts on the first line of the figure represent workpieces that can be produced with operations

selected from those described on the complex workpiece in the second line. Summing up the costs of producing the required features produces a representative total cost and simplifies estimation of pricing. It is not necessary to analyze the costs on an individual part-by-part basis.

In some cases, Group Technology prompts reorganization of the shop floor. The left side of Figure 3 shows the 28 | Industry Asia Pacific | January 2019

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circuitous path parts take through a shop that is organized in a traditional layout based on machine functions including turning, milling and grinding. However, when workpieces are grouped and processed as families in a cellular layout, shown at the right in the figure, machine tools can be arranged to streamline manufacturing flow and minimise part movement within the shop. Each different workpiece family is machined in the most efficient way without unnecessary transport within the shop. Significant reduction of the time required to produce the parts is the result.

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As always, the adoption of new concepts offers both benefits and challenges. The Group Technology approach offers benefits in engineering, process planning and manufacturing time savings, but possible challenges exist as well. First, to some extent the Group Technology approach reduces flexibility. The traditional shop setup is more flexible if there is a significant increase in demand for a certain workpiece configuration that creates a production bottleneck. In the traditional layout other machines in the department can be used to produce the parts. Secondly, managing machine downtime can also be a challenge. If one part family experiences a temporary decline in demand, the machines in the cellular layout will be idled.

Another possible difficulty arising from implementation of Group Technology concepts is a tendency to spend an excessive amount of time comparing one coding system to others. More important than the specific coding system 28 | Industry Asia Pacific | January 2019

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itself, however, is that a company should thoroughly know its equipment and resources and the results desired. In that case, a custom coding system created in-house can be a simple and efficient approach. Possibly rearranging the shop floor to machine part families more efficiently is another facility-specific decision. It may be easier for larger companies to realign their machinery while smaller companies may face economic constraints and other factors.

Faster, More Accurate Quotes The Group Technology approach to creating part quotations can increase both revenue and profitability. An example comes from an aerospace subcontractor in an HMLV production environment, with batch sizes from one to five workpieces, that receives about 4,000 price requests per year. Insufficient time to analyse and quote each part separately slowed the pricing process and the shop could make serious quotes for only 1,500 of the 4,000 possible jobs. About 2,600 orders were received. Then, using analysis supported by Group Technology initiatives and quoting parts using complex workpiece information, the subcontractor found it could make 3,000 serious quotes per year. More serious quotes attracted more orders, to the level of 3,200 annually. Most importantly, the bids, based on cost plus profit, averaged more than 30 percent lower than the bids made before the application of Group Technology concepts.

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The faster, more accurate quoting process had two benefits.

There were fewer incidents of erroneous underbidding that negatively affected profit margins, and there were fewer quotes that were inaccurately high and discouraged customer acceptance. Implementation of Group Technology concepts gave the manufacturer more control over what was being done and how much it cost, and reduced the incidence of inaccurate quotes.

Group Technology dictates that instead of thinking through every individual workpiece and its production parameters, parts with similar characteristics are grouped and machined together. In a clear example of this approach, a shop was producing pulleys for a belt-style transmission. For use with different belt sizes, the diameters, widths, and profiles of the belt groove differed from pulley to pulley. The changeover time between machining of different configurations was about an hour and a half.

Conclusion The Group Technology manufacturing organizational strategy (on which Dave Morr from SECO in Australia have done extensive development work) helps manufacturers efficiently handle the challenges of HMLV production.

Traditional productivity-boosting strategies such lean manufacturing and Six Sigma provide proven benefits, especially in HVLM production where operations can be fine-tuned over long runs of identical parts. However, highly diverse, small batch manufacturing continues to grow in prominence, aided by advances in machining technology and digital product design and management. By classifying parts into families and consolidating pricing activities and machining operations, the Group Technology approach provides manufacturers with an efficient way to manage the challenges of the Industry 4.0 era.

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Analysis of the process showed that for each changeover between pulleys the machine was completely dismantled, and all the tools were taken out and cleaned and stored.

To machine the next pulley, most of the same tools were put back in the machine. Under the Group Technology approach, the similar but not identical wheels were grouped as a family. Changeover then involved changing the NC program, altering some machining parameters and sometimes changing the tool that machined the groove profile. Depending on the workpiece, changeover time

dropped from one and a half hours to ten minutes. The key challenge was convincing shop personnel that the parts they were making belonged to the same family and could be machined much more quickly.

Author : Patrick de Vos Corporate Technical Education Manager, Seco Tools www.secotools.com 28 | Industry Asia Pacific | January 2019

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Group Technology and Seco Consultancy Services (SCS) The Group Technology manufacturing organizational strategy is an important element in achieving operational excellence and can be a valuable contributor to a manufacturer’s overall efforts. However, competition forces many manufacturers to focus almost solely on producing a specific number of parts on time at a specific cost and do not have the time or expertise to closely analyse and optimise their business and machining operations.

Seco has created a new branch operation that aims to assist mid-size companies that have resources available to apply to manufacturing improvements but insufficient funds to absorb the high cost of employing a process improvement engineer or work with a big business consulting firm. Seco Consultancy Services (SCS) helps manufacturers balance overall manufacturing and business issues with machining efficiency and economy. SCS is brand neutral and works with the user’s current tools regardless of the brand.

The first step in taking advantage of SCS is a Manufacturing Efficiency Evaluation (MEE) effort that consists of analysis of machining, production system, and operational management performance.

SCS analyses a company’s capabilities and examines issues in preparation, machining and equipment handling. Root causes of capability/asset issues as well as employee knowledge shortcomings are revealed. Preparation analysis includes programming support and standardization of methods and parts.

Machining issues are recognized and handled via method optimization and troubleshooting. Stock and consumption visualization and tool management programs solve equipment handling issues.

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Throughout the SCS program, the Seco Technical Education Services (STEP seminars and courses) offers help in educating manufacturing company staff. A major aspect of the service involves convincing shop personnel to adopt new strategies. Putting a poster on the wall describing the new approaches has minimal effect. That is because the issues most often are not about knowledge, but actually involve personnel who are convinced that the traditional solution is best. The key to success is convincing personnel to recognize the benefits of the new strategies and have the discipline to implement them.

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NEW GRADE OF SECO END MILLS BOOSTS TOOL LIFE FOR DIFFICULT MATERIALS New Jabro®-Solid2 JS750 end mills from Seco boost tool life by 25 percent to 40 percent compared to previous tool technology. As counterparts to the company’s industry-leading JS500 series, the new JS754 and JS755 tools provide cost-effective high performance designed specifically for processing challenging materials typically found in the aerospace sector, including ISO M (stainless steel) and S (heat-resistant super alloys and titanium).

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ithin the new series, the versatility of the various JS754 and JS755 cutter geometries optimizes conventional side milling, roughing and slotting, as well as advanced roughing and dynamic milling operations.

The cutters' smooth peripheral rake faces and strong radius design efficiently evacuate chips while keeping a true radius form. Increased front back tapers enhance speed and reliability when interpolating or ramping for pocket machining.

The broad range of JS754 and JS755 tool variations and features ensures the highest cutting performance. With this new series of end mills, shops can match tool to application with various lengths, OD neck reduction sizes and corner radii, as well as chip splitters and through-coolant options.

Range overview • JS754: 4-flute side roughing, side finishing and slotting, APMXS=2*DC + OD - ø3-25 chamfer and radii offer RE0.2 0.5 1.0 1.5 2.0 3.0 4.0 6.0, normal length - ø6-20 chamfer ICC through coolant, normal length - ø10 and ø12 chamfer including chip splitters, normal length • JS754: 4-flute side roughing, side finishing, APMXS=3.5 – 4*DC + OD - ø6-25 chamfer and radii offer RE0.2 0.5 1.0 2.0 3.0 4.0 6.0, long length - ø10-20 chamfer including chip splitters, long length (advanced roughing) • JS755: 5-flute high volume side rough and side finishing, APMXS=2*DC + OD - ø6-25 chamfer and radii offer RE0.5 1.0 2.0 3.0 6.0, normal length MORE INFORMATION

• JS755: 5-flute high volume side roughing, side finishing, APMXS=3.5 - 4*DC + OD - ø6-25 chamfer and radii offer RE0.2 0.5 1.0 2.0 3.0 4.0 6.0, long length - ø10-20 chamfer including chip splitters, long length (advanced roughing) www.secotools.com 28 | Industry Asia Pacific | January 2019

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THE FUTURE’S BRIGHT

Mitsubishi Electric specialises in practical R&D, where everyone can appreciate the benefits.

Mitsubishi Electric invests substantial amounts of time and resources in R&D activities to develop future technologies and products.

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ome discoveries and innovations are incorporated subtly over many years, while others lead to radical new breakthroughs that disrupt existing markets.

But what of today? What new technologies are available right now that can help advance the manufacturing operations of 2018? This article examines some recent developments of the R&D teams at Mitsubishi Electric, such as a high-performance database that can reduce data storage space by 98.5%, a huge benefit in a manufacturing age increasingly driven by process data collection and analysis. Another exciting development is a concept able to miniaturise the artificial intelligence (AI) algorithm to the point that individual devices can benefit from AI and local ‘deep learning’ processes. The future is bright indeed.

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Data storage in the IoT Among the overlooked challenges of the Internet of Things (IoT) is the large amount of captured data that has to be stored somewhere. Over the years industry has seen megabytes run into gigabytes, and gigabytes turn into terabytes. And it will not be long before engineers are routinely talking about petabytes, exabytes and zettabytes.

One issue with this rapidly expanding data capacity is the cost for storage, back-up and keeping it available 24/7.

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To imagine the scale of the challenge, consider how many sensors, data points and memory stores there are in a typical factory. A single production line can have thousands of sensors, each one generating a data reading every 100ms or less. Over a couple of years, this could add up to hundreds of terabytes of data. Multiply this figure by the number of production lines – and sites – and it is not long before a hefty monthly bill starts arriving from the cloud provider simply for storing data.

With the aim of addressing this issue, Mitsubishi Electric R&D has developed a high-performance database with the ability to reduce the required storage space by 98.5%.

Significantly, because the volume is reduced, the load time for the database is also decreased by around 98%, which in turn means the search time reduces accordingly. All of these results can be achieved using a standard 2-CPU server with 4GB of main memory, an outcome that emphasises practical R&D at its best, where everyone can appreciate the benefit.

Artificial intelligence gets real From blockbuster movies to the doom-laden predictions of sci-fi writers, AI is both scary and hugely exciting. Much of what has materialised to date has been impressive, but of

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Mitsubishi Electric’s ‘Maisart’ means that individual devices can benefit from AI and local deep learning processes.

manually over many hours, simply because the number of trial operations and calculations can be reduced by 98% or more. Maisart-based FA solutions will soon become increasingly common, as will AI deployment in everyday products such as air conditioners and other increasingly intelligent appliances.

Vision-guided robots are a recent example of where Mitsubishi Electric R&D has made a significant contribution to advancing real-life industrial operations.

little practical benefit, primarily because of two key issues.

The first is the tethering of a super computer: if industry really needs that much computing power, it is hard to see how AI will be usable. The second is the realisation that AI, just like a human baby, needs to be taught or shown how to learn some basic rules around the task at hand.

To turn AI into a practical solution for today, Mitsubishi Electric R&D has been focused on both of these key issues.

The result is Maisart (Mitsubishi Electric’s AI creates the Stateof-the-ART in technology). Maisart has miniaturised the AI algorithm to the point where it can be deployed on a single chip embedded in other products. This capability means that individual devices can benefit from AI and local ‘deep learning’ processes, while AI located in cloud environments can be used to co-ordinate between those devices. Think of it as applying AI on a scalable base: machine to line; line to factory; factory to enterprise.

With this issue in mind, the Amazon Picking Challenge was born, whereby robots are tasked with picking a wide variety of small, large, soft, hard, fragile, robust, light and heavy products – and placing them in a packing carton without mis-picking or damaging the goods. Mitsubishi Electric’s MELFA 3D vision for robots proved to be an essential enabler of this process, allowing the robot to ‘see’ what it wants to pick. The system can even enable robots to quickly and reliably pick products that are dispersed randomly in a pick bin. In 2014, this particular Mitsubishi technology won a coveted R&D100 award.

This example, like many others of yesterday, today and tomorrow, means that Mitsubishi Electric R&D successes not only lead the world in terms of technology, but deliver real benefits and create new automation solutions for a brighter future. Moving forward, industry expects an enhanced human, machine and AI environment that will deliver many positive benefits for all concerned. Imagination, it would appear, is the only limitation.

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In the past, deep learning algorithms were expensive and IT-heavy. However, the new automated deep learning technology from Mitsubishi Electric is a world first and critical to future AI deployment without relying on expert knowledge. In fact, the training element of the AI is now 96.7% faster, which means this technology can be applied to faster and more demanding tasks.

Proven track record Of course, Mitsubishi Electric has registered many notable technological breakthroughs over the years. Take interactive vision-guided robots in the postal industry, for example.

The surge in global parcel traffic has been spurred in recent times by the success of online retail giants such as Amazon.

Here, the desire for total automation has been a long-held goal. However, the main challenge has been devising a robot capable of picking a seemingly infinite number of different package sizes and shapes.

http://us.mitsubishielectric.com/en/

In a manufacturing environment, for example, robots could be learning new tasks in minutes rather than being taught 28 | Industry Asia Pacific | January 2019

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TWO KNOW MORE THAN ONE

Fluke Process Instruments provides comprehensive temperature profiling and imaging solutions for high-value glasses, including low-E glass.

Combining two devices using two different temperature measurement technologies, Fluke Process Instruments provides the glass industry with more information on high-value applications like float glass manufacturing, glass tempering, and windshield forming and laminating.

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The manufacturer offers the largest range of thermal barriers in the market and will advise customers on which system setup to use for their applications. The other measuring device, a Raytek MP150 infrared linescanner, scans each glass pane when it exits the furnace. It generates a thermal image and immediately shows up hot and cold spots.

Datapaq Furnace Tracker profiling systems travel through heat-treatment and quench processes. They record the product temperature curves via up to 20 thermocouples cemented to the glass pane. These industry-specific profiling systems consist of a data logger, a thermal barrier, and software with advanced analysis, reporting, and archiving functions.

The series comprises various different spectral models, allowing even low-emissivity glass to be monitored.

In contrast to thermal cameras, the linescanner needs only a very narrow field of view. It is therefore ideal for manufacturing lines with furnace and quench installed in close proximity.

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emperature profiling runs with a data logger enable operators to quickly optimize furnace settings for new products and to identify problems with burners or airflow. They are complemented by a thermal imager installed at the furnace exit for 100 % production monitoring and traceability.

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www.flukeprocessinstruments.com

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NEW SPOT SIZE CALCULATOR APP

The intuitive app calculates measurement spot sizes for infrared pyrometers depending on the mounting distance.

Fluke Process Instruments has released the new Spot Size Calculator app for Android and iOS mobile devices, for desktop computers running Windows 10, and as an online app for use with all common internet browsers.

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t integrates all Fluke Process Instruments infrared spot sensors and thermal imagers as well as legacy Raytek and Ircon devices. Users simply select a product and enter the mounting distance.

The Spot Size Calculator app is available for Android, iOS, Windows 10, and online, and can be downloaded from the respective app stores

The app then calculates the spot diameter or camera field of view. This will help customers find the right spot pyrometer for their installation environment – the measured object must be larger than the spot size to prevent measuring errors. In addition, the app will help customers optimally set up thermal cameras so they focus all areas of interest.

The app supports English, German, French, Spanish, and Chinese. www.flukeprocessinstruments.com MORE INFORMATION 28 | Industry Asia Pacific | January 2019

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INTERROLL’S VERTICAL CROSSBELT SORTER OPENS NEW ERA FOR AOKANG’S DISTRIBUTION CENTER

China’s famous shoe producer, Aokang, has put into operation its new distribution center in Shanghai. The move strengthens the company’s distribution services for its retail and online business in eastern China.

Aokang opted for an automated logistics solution at the center. The Interroll vertical crossbelt sorter plays a vital role in it.

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Our idea was to create a distribution center that benefits as much as possible from automated solutions, so as to maximize the efficiency. We were planning for this project for some three years to find the best solution,” says Guo Yong, general manager at Aokang’s distribution center in eastern China. “Due to limited space and very high distribution demand, it was quite a difficult mission. At last, the Interroll vertical crossbelt sorter emerged as the best choice in terms of space utilization, logistics efficiency and reliability. Handling 100.000 pairs of shoes daily is a huge task that only can be achieved with the right partners.”

The overall solution with the Interroll vertical crossbelt sorter is designed for a capacity of 7,000 boxes per hour including 6,000 cartons and 1,000 shoe boxes, with 10 destination chutes serving 1.500 retail shops and another 10 destinations for online business providing a capacity of up to 50,000 online orders per day. The reliability and mechanical strength of the Interroll sorter has been proven worldwide.

Positive drive of the mechanical crossbelt sorter is achieved via high-performance helical geared motors, which control the speed precisely and ensure high efficiency and accuracy, even for sensitive goods. “We are very impressed by the excellent performance of the Interroll crossbelt sorter, which makes sorting extremely easy,” Guo says.

China’s footwear industry continues to experience rapid growth, and China has already become the world’s largest footwear producer and exporter. As the Internet has expanded the traditional sales channel of retail to online, the development of the footwear industry is flourishing, increasingly fueled by large demand. Take women’s shoes as an example. According to a report released by ASKCI

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Consulting, the average annual growth rate of China’s market for women’s shoes in the past five years was 8.7 percent. In 2016, the size of China’s market for women’s shoes reached 224.7 billion yuan. The number is expected to exceed 260 billion yuan in 2018.

“We are very proud to work with such a great Chinese company as Aokang. As a global company, Interroll is more than happy to support our customers and end users with our extensive experience and expertise and enable them to become leaders in their fields of business.” adds Dr. Ben Xia, Executive Vice President of Interroll Group and the Head of Asia Operations. www.interroll.com

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ING. E. VEZZADINI USES INTERROLL IN ITS BUTTER PACKAGING MACHINERY

The Italian company is the market leader for butter packaging machinery and has selected Interroll Drum Motors to help convey its delicate product on its machines.

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nterroll, one of the world's leading producers of highquality key products and services for internal logistics, is providing stainless steel drum motors—certified by the European Hygienic Engineering and Design Group (EHEDG)—for the machinery used by Ing. E. Vezzadini & C. S.r.l. in Reggio Emilia, Italy.

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Ing. E. Vezzadini expressed his satisfaction with what he considers a significant technological improvement in the prestigious company's machines: “We have been designing and building automatic packaging machines for dairy products and cooking fats for over 60 years”. “Our market is the entire world; to maintain our leading position in our field, we need to focus on continuous improvement. To this effect, Interroll has enabled us to take a huge step forward, not only in terms of technology but also in terms of sustainability and quality.”

Interroll Drum Motors are perfect for use in the food industry as their IP66/IP69k rating satisfies EHEDG hygienic equipment design criteria, follows the Ecolab cleaning procedure, and complies with US Food and Drug Administration (FDA) and European Union EC 1935-2004 regulations.

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Ing E.Vezzadini & C. S.r.l.'s packaging machines are mainly used in creameries around the world, as well as by food processing companies producing cheese spread and margarine.

Packaging machines for this type of product combine precision mechanics and electronics, and the extent to which the machines can be customized is extremely high.

Vezzadini products are distinguished by their premium quality and artisan manufacturing. The company's automated machines must produce packs of butter at a rate of 100 blocks a minute.

All of this has to happen with the utmost precision and the greatest possible fluidity.

The decision to use an Interroll Drum Motor was influenced by the company's need to make its packaging machines less bulky, more efficient and 100 percent safe with regard to hygiene. The high-efficiency Interroll Drum Motor is easy to fit, covers a vast range of services and is virtually maintenance-free.

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Ing. E. Vezzadini chose Interroll Drum Motors after seeing the clear benefits of using less bulky drum motors in place of conventional gear motors. The fact that the motor, gearbox and bearings are housed inside the drum means that drum motors require a lot less space than other types of motors.

The belt conveyor can be made more compact and installed in smaller spaces. Moreover, drum motors are considerably faster and easier to fit: On average, in fact, they can be installed in 25 percent less time than is required to install a conventional drive system with multiple components, according to a recent study by the University of Parma.

Reducing the number of components results in lower costs to manufacture the belt conveyor and purchase the components themselves.

Low-wear Interroll Drum Motors provide full performance even in harsh environments where water, fine dust, grit, chemical substances, fats and oils are present. They can even be subjected to high-pressure cleaning.

Interroll Drum Motors offer up to 78 percent efficiency in asynchronous design and as much as 83 percent efficiency in synchronous design, clearly demonstrating just how energy efficient they are. They have no protruding parts and, with their fixed external shafts, they are probably the safest

Claudio Carnino, Interroll Italy Commercial Director and Country Manager Italy, sees this as confirmation.

“Ing E. Vezzadini’s decision is yet a further confirmation of the superiority of Interroll's Drum Motor,” he said. “This also has been verified by a recent comparative study conducted by the University of Parma. The Interroll Drum Motors are enabling Ing. E. Vezzadini to progress in terms of efficiency, reducing the bulkiness of its machinery and ensuring hygiene. The Interroll Drum Motors are the only motors certified by the EHEDG.” Since 2017, Ing E. Vezzadini has been a partner in the global Rolling On Interroll program, which is designed to provide long-term support for machine manufacturers and system integrators, as well as to encourage involved partners to share their experiences in creating efficient materials handling solutions.

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Moreover, thanks to their smooth, stainless steel surface and fully encapsulated hermetic structure, Interroll Drum Motors are exceptionally hygienic.

motors on the market for ultramodern handling systems.

Being internal, the components of the motors are protected from outside influences, which means they require almost no maintenance.

www.interroll.com

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ALTERNATIVE SURFACE TREATMENT IN HYGIENIC ENVIRONMENTS

The innovative nsd tupH surface treatment by NORD DRIVESYSTEMS makes aluminium as corrosion resistant as stainless steel.

NORD DRIVESYSTEMS has developed the nsd tupH anti-corrosion treatment for use in demanding environments with stringent hygiene requirements. The innovative surface treatment, which makes aluminium drives extremely robust and durable, also impressed the Australian company Smalte Conveying Solutions.

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he nsd tupH surface treatment from NORD DRIVESYSTEMS provides an outstanding anticorrosion protection for gear units, smooth surface motors, frequency inverters and motor starters in washdown-optimised cast aluminium housings. By means of a special process, the aluminium surface has similar corrosion resistance properties to stainless steel. It can be easily cleaned and is largely resistant to acids and alkalis. Even the use of high pressure cleaners or contact with many types of aggressive media is possible, making nsd tupH drives a robust and durable alternative to painted geared motors or stainless steel versions. nsd tupH treatment is available for all NORD products made from aluminium. DIN and standard components, including drive shafts, are manufactured in stainless steel. Fanless motors do not spread germs and are available as synchronous and asynchronous motors with efficiency classes IE2, IE3 and IE4.

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Convincing and economical concept The advantages of nsd tupH drives also convinced Smalte Conveying Solutions, an Australian company which produces conveyor equipment for packaging plants. The company equipped 24 stainless steel conveyors with nsd tupH geared motors instead of expensive stainless steel motors to transport sauces and spreads from a production area to a packaging area and finally to an HMPS packaging machine. As well as the economic benefits, the technical properties were of primary importance: The requirements for hygiene, cleaning properties and corrosion protection were fulfilled. The washdown motors are mounted with standard flanges and have considerably better thermal characteristics than motors with stainless steel housings. www.nord.com

ANTRIEB

DER

n Reliable n Versatile n Global

Getriebetechnik n n n n

Starke Lagerung Geräuscharmer Lauf Korrosionsschutz (AL) Hohe Leistungsdichte

The

n n n

Gear Unit Strong bearings Low noise High power density

Motorentechnik

Steuerungstechnik

Alle Effizienzklassen Weitspannungsbereich (380-420V) n Auch als Brems - oder ATEX-Variante

n n n n

n n

The

n n n

Motor High efficiency Global Standards All operating conditions

Alle Umgebungen Schutzklasse bis IP69K Flexible Schnittstellen Skalierbare Funktionalität

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Drive Electronic Compact design Easy commissioning Scalable functionality

Wide power range – Versatile system solutions – High system efficiency

DerAntrieb.com

NORD DRIVESYSTEMS Pvt.Ltd. 282/2, 283/2, plot no. 15, Village Mann, Taluka Mulshi Adj.Hinjewadi MIDC-II, Pune- 411057 Maharashtra INDIA Toll Free No. 1800 200 2042 India@nord.com, www.nord.com Member of the NORD DRIVESYSTEMS Group

DRIVESYSTEMS

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NEW NORDBLOC.1 BEVEL GEAR UNITS WITH 50 NM

The new two-stage NORDBLOC.1 bevel gear units by NORD DRIVESYSTEMS offer a highly efficient alternative to worm gear units.

With the two-stage NORDBLOC.1 bevel gear unit, NORD launched high performance, washdown-optimised aluminium drives for hygienic applications. Now, the drive specialist expands its successful series with smaller gear units for torques up to 50 Nm and thereby offers an efficient alternative to worm gear units – for example for smaller conveyor belts.

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he new SK 9x0072.1 series has a power range from 0.12 to 1.1 kW and covers speed ratios from 3.03 to 47.67 : 1. The two-stage helical bevel gear units are characterised by high efficiencies, compact design, top reliability and long working life. The high-strength aluminium housing guarantees high rigidity and maximum durability with low weight. Additionally, the modular design provides wide application flexibility due to numerous application and mounting options.

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There are two models available: SK 920072.1 and SK 930072.1. The open housing of SK 920072.1 is lightweight but nevertheless very solid due to its construction. This variant is available with a universal foot flange version.

With its closed housing, the SK 930072.1 is particularly suited for applications with stringent requirements for hygiene and cleanliness. Additional protection is provided by the optionally available nsd tupH surface treatment. The standard version is equipped with a B14 flange. All versions are available with solid or hollow shafts. The motor can be mounted directly without a coupling or adapter (IEC or 28 | Industry Asia Pacific | January 2019

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NEMA). Accessories including torque arms, flanges, covers and fastening elements from the UNIVERSAL series may also be used for this gear unit.

The new, compact and flexible NORDBLOC 1 bevel gear units are particularly suited for intralogistics and packaging technology, and thanks to their washdown design may also be advantageous for the food and beverage industry. The LogiDrive combines these new NORDBLOC.1 gear units with an energy-efficient IE4 synchronous motor and the NORDAC LINK field distributor for an optimally matched drive system. These standardised geared motor variants are highly efficient, and thanks to Plug & Play technology they are extremely maintenance-friendly and benefit from a considerable reduction of spare part stocks, which also results in the reduction of versions. www.nord.com

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SMOOTH BODY MOTORS BY NORD DRIVESYSTEMS IN A NEW MOTOR SIZE

NORD DRIVESYSTEMS has extended its wide range of smooth body motors with size 71.

NORD DRIVESYSTEMS offers a wide range of smooth surface motors for industries and applications with high hygiene standards. In order to fully support the requirements of lower power motors, the drive specialist has now developed an additional motor size.

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he new size 71 smooth body motors are available in three power classes: 0.12 kW, 0.18 kW and 0.25 kW. IE3 efficiency level guarantees resource-saving operation.

Thanks to their aluminium housing (protection class IP66), the motors are protected against corrosion. Additional protection is provided by the optionally available, innovative nsd tupH surface treatment. NORD smooth body motors are fanless and therefore contribute to the non-proliferation of germs during production.

NORD smooth surface motors are specifically designed for easy cleaning and have even and regular surface transitions wherever possible. Thus, cleaning liquids and foam can wash off easily. Due to their washdown design, they are especially suitable for the application in the food and beverage industry. www.nord.com

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The modular design provides wide application flexibility due to numerous equipment options. Variants with condensation outlets (sealed), encapsulated terminal box, standstill heating, temperature sensor, temperature monitor and/or protection class IP69K expand, among other things, the possible uses. The motors are available in various versions. This way they are suitable for the entire NORD range, preferably for use with NORD aluminium smooth surface drives (NORDBLOC.1 helical gear units, NORDBLOC.1 bevel gear units, SMI worm gears).

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PLUG AND PLAY

Kennametal’s new vibration-free boring system boasts a number of technological improvements that allows a plug and play operation.

An array of interchangeable heads that includes screw-on and lever-style clamping mechanisms in positive and negative rake configurations.

Kennametal makes deep boring easy.

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alk into most any machine shop and there’s a good chance you’ll hear it: the high pitch whine of a deep boring operation, the chatter loud enough to have even the most hard of hearing among us scrambling for a pair of ear plugs. It’s a problem that has plagued machinists since the day lathe inventor Henry Maudslay first chucked up a piece of steel and tried to bore a hole through it, and has only gotten worse as metals have grown tougher and more challenging to machine.

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Not anymore. Kennametal’s latest weapon in the war on chatter is one that will have machinists everywhere saying, “I need that.” The new boring system boasts the most effective anti-chatter mechanism ever developed by Kennametal, and also offers an extensive range of indexable heads and shank sizes.

Enter the Vibration-Free Zone Someone who knows all about it is Sam Eichelberger, product engineer for lathe systems engineering and part of the team that developed the internal dampening mechanism. “Perhaps the most important thing to know about the new bar is that it’s plug and play,” he says. “There's no need whatsoever for tuning or adjustments—you simply 28 | Industry Asia Pacific | January 2019

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pull it out of the package, mount it in the turret, and get boring.”

There’s more to the story than making the shop a quieter place to work, however. Eliminating vibration and therefore chatter greatly extends tool life, never mind its positive effect on part surface finish. And when tools last longer, they can be pushed harder, with feed rates, cutting speeds, and depths of cut many industry experts once thought unachievable.

Eichelberger is one of them. He lists a number of features that not only make the vibration-free boring system the most easy-to-apply bar you’ll ever bore with, but also the most productive. These include a serrated, bolt-on connection at the bar’s business end that securely clamps a variety of styles and sizes of indexable heads.

Better yet, the heads themselves have been put on a diet, with a shorter length and lighter weight that provides greater stability, contributing to the bar’s improved performance. They’re also coolant-fed,

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Setting the head exactly on centerline is as easy as bringing the angle finder display to zero and locking the bar in place.

to precisely direct a stream of high-pressure coolant where it’s needed most. The result is hassle-free chip control together with maximum cooling in the cutting zone.

Most important of all is the internal dampener. Said Eichelberger, “The bars are both vibration and maintenance free. Within the bar there sits a mass that's supported by a pair of elastic supports, inside of which sits a dampening fluid. This mass vibrates at a predetermined frequency during machining, attenuating the natural frequency of the bar around it to suppress vibration. There are no wear components to worry about, nor tuning—as Sam mentioned, you just set it and forget it.”

The vibration-free system offers superior performance in boring applications up to 10X diameter deep, Eichelberger explained, much deeper than solid carbide or heavy metal boring bars are capable of. Internal and customer test results show surface finishes as good or in most cases better than competitive “quiet bars,” with significantly more aggressive cutting parameters possible across the board.

Anyone who’s ever struggled to get a boring bar exactly on center will appreciate the fact that setup is extremely easy. “There’s a reference flat on the top of the head that accommodates a visual angle finder,” Eichelberger pointed out. “You just rotate the bar until the indicator reads zero, then clamp it in place.”

Considering the higher cost of a such a boring system, they’ll also appreciate the fact that the heads are replaceable in the event of a crash, avoiding damage to the bar itself. And users of Kennametal’s older boring system will find that their new heads fit perfectly with the use of an adaptor.

“The portfolio for our Imperial bars ranges from one-inch in diameter up to four inches, while the metric version starts at 25 mm and goes to 100 mm,” Gable said. “There are a variety of interchangeable head styles available as well, everything from screw-on positive rake inserts for fine-finishing needs to negative rake, clamp-style geometries for heavy roughing.

The bar’s designed to excel in demanding applications, and that’s exactly what it does.”

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Of course, boring bars are only as good as the method by which they’re clamped in the machine. Kennametal has addressed this critical consideration by supplying machinespecific turret adapters, along with a special split sleeve bushing for maximum rigidity. “That’s the goal of this product,” says Kennametal global product manager John

Gable. “The greatest stability possible and the most effective dampening solution available, period.”

www.kennametal.com

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