29 | APRIL 2019
Industry
Asia Pacific THE INDUSTRY MAGAZINE FOR ASIA
KOLLMORGEN KBM MOTORS AS A BYWORD FOR ACCURACY IN LASER CUTTING
4 LEUZE ELECTRONIC RSL 400 SAFETY LASER SCANNER
10 SECO TOOLS OVERCOME THE ONGOING CHALLENGES OF LONG-REACH MACHINING
14
MITSUBISHI ELECTRIC VFDS HELP FARMS GROW OPERATIONS
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29 | Industry Asia Pacific | April 2019
THE INDUSTRY MAGAZINE FOR ASIA
HMS INDUSTRIAL NETWORKS
KOLLMORGEN
4
LEUZE ELECTRONIC
8
7 LEUZE ELECTRONIC
10
SIC MARKING
SECO TOOLS
12
14
MITSUBISHI ELECTRIC
SECO TOOLS
17
PYROGUARD
21
18 MITSUBISHI ELECTRIC
22
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Chief Editor • Bruno FORGUE +33 6 3789 2089 Contributing Editors • Emmanuel AHOSSI • Nessren BAZERBACHI • Romain CLASS • Maria DE PABLOS • Anna HARDALOUPAS • Sofiane JEDIDI • Marie RESPINGUE • Christophe VERGUET
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NEWS
THE PRECISE GEOMETRY OF 3D CUTTING KBM MOTORS AS A BYWORD FOR ACCURACY IN LASER CUTTING
KOLLMORGEN TTEngineering TOP600 machine.
Pipes for industrial and residential flue ducts are made using machines by KOLLMORGEN Direct Drive motors.
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he production of automation systems for sheet metal forming for sectors such as air conditioning, flue ducts and the automotive industry is the core business of TTEngineering. Located in Lomazzo near Como in a modern building of more than 2,000 m2, the company has also gained expertise in the cosmetics, medical, packaging and assembly sectors. More than 1,500 systems running in factories all over the world and exports accounting for well over 90% of total turnover are sources of pride for the company whose service department is able to respond precisely, quickly and punctually, even remotely.
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To meet the ever more pressing needs of the market in terms of delivery time and performance, TTEngineering has concentrated on a design that can satisfy performance requirements in terms of acceleration, precision, productivity and flexibility.
During a meeting in Parma during the SPS trade fair, the Como-based company set out its requirements to KOLLMORGEN. The motion control specialists proposed direct drive technology as the optimal solution for doing away with the complex mechanical transmission that involves drive belts and gear motors. In doing so, TTEngineering embraced the concept of a direct drive motor. “We see two big advantages with Kollmorgen: it is a global brand that offers design consultancy and after-sales services of a high standard,” explained Massimiliano Crespi, who was Head of Engineering & Production at the time of this particular project and is now Managing Director at TTEngineering “The approach of the Kollmorgen staff during the design phase was outstanding.” The final tests provided the anticipated responses and allowed us to launch the TOP600 onto the market little more than a year later. TOP600 machine for pipes for flue ducts The TOP600 is a machine for the 3D cutting of pipes intended for use as flue ducts for all sectors, from industrial to residential, produced with a range of materials.
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TTEngineering TOP600 machine with KOLLMORGEN KBM direct drive frameless motors, front detail
The TOP600 is a Siemens CNC 5 interpolated axis laser cutting cell suitable for machining pipes with a maximum length of 1,500 mm, with a diameter of between 3” and 30” and thicknesses of 0.4 to 2 mm, made from steel, iron, or copper. The patented pipe clamping system has been created with a CNC self-centering spindle. This machine is aimed at companies operating in the HVAC and chimney pipes sectors. Depending on the combination of materials, thickness, and laser power, it is possible to cut at variable speeds of up to 20 m/min.
configuration. The only changes are to the source used and, therefore, the type of cutting head used.
It is a modular machine which can be used by one operator who manually loads/unloads the pieces or in a “fully automatic” mode, integrated into an automated line where a robot loads/unloads the pieces.
The design of the machine also benefits, becoming flexible and compact, ensuring stable performance over time, remaining constant even with a high number of cycles (no downgrade).
At the same time as updating the direct drive equipment with a torque motor on the rotation spindle, new software has been developed that allows for cutting with beveling. TTE has its own cad cam platform and sophisticated cutting management software with predictive mathematics to compensate for out of roundness errors: the machine provides perfect cuts even for pieces that are slightly out of gage.
The KBM™ Series has been developed to be integrated directly into the machine, using its own bearings to support the rotor; it provides a high level of performance whilst allowing for a smaller size. There is a wide range of standard motors (14 sizes with varying lengths); different configurations and options are available depending on the requirement, and changes to the shared design can be made quickly and cost-effectively. “The performance offered by the Kollmorgen KBM™ series motor is so high that they even prompted us to redesign part of the frame and the cutting automation,” explained Mr. Crespi. “The use of the
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There are two versions available, the TOP600 Plasma and the TOP600 Laser, depending on the cutting technology used. The two machines are identical in terms of their
KBM Frameless Motors, modern direct drive technology As an alternative to the technology that has been used in the past, namely precision gear motors and belt drives, KOLLMORGEN recommended a KBM™ series direct drive motor to TTEngineering that can offer greater flexibility and a range of different speeds so the machine can be adaptable and produce pipes with differing diameters.
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TTEngineering TOP600 machine with KOLLMORGEN KBM direct drive frameless motors, rear detail.
KOLLMORGEN KBM direct drive frameless motors, group
motor also enabled TTEngineering to patent an automated pipe clamping system.” Properties •F ully encapsulated stator windings •P TC thermistor overload protection •R are-earth neodymium iron boron magnets •F ail-safe bands over rotor magnets •R oHS compliant •U L and CE certification •O ptimizations include rotor hub dimensions, rotor length, diameter, mounting features, windings, insulation, connection type, and much more •O ptional latching digital Hall effect sensors are pre-aligned and factory-installed
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Benefits • Direct load connection eliminates the need to maintain gearboxes, belts or pulleys • The absence of backlash and displacement provides a more responsive system • The removal of coupling devices reduces overall machine size • Embedded motor enables a compact machine design, helps protect intellectual property • Huge selection of standard motors and extensive customization options
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Conclusion The profitable collaboration with Kollmorgen continues with a new objective: TTEngineering is working on a product which will replace mechanical cutting with a high-tech laser and Kollmorgen linear motors will again be of great assistance in this case. Authors: Ilario Manzi, Key Account Manager, KOLLMORGEN Italia. Angelo Trombetta, Direct Drive & Mechanical Transmission, KOLLMORGEN Italia. Elisabetta Redaelli, Marketing Communication, KOLLMORGEN Italia. www.ttengineering.it www.kollmorgen.com
NEWS
NEW IXXAT REPEATER SERIES FOR CAN FD AS WELL AS CAN
Adding to the existing Ixxat® line of CAN bridges and gateways, HMS Networks now presents four new Ixxat CAN FD repeaters, all supporting both the new CAN FD standard as well as traditional CAN.
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ith the new Ixxat CAN FD repeaters, HMS enables very flexible networking in existing CAN systems as well as in new, modern CAN FD-based systems.
With the fiber optic version, it is possible to bridge distances with high electromagnetic interferences or to design applications with very high demands on galvanic isolation.
The repeaters enable CAN FD and CAN components to be networked using more effective tree and star topologies, as well as allowing the implementation of drop lines. No configuration is required in the process which makes operations and commissioning extremely easy for users.
The repeaters come with slim plastic housings for DIN rail mounting, and the CAN connection is made via screw terminals. www.ixxat.com/repeater
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The Ixxat CAN FD repeaters are available with two and four channels for copper-wired networking (versions CANCR100 and CAN-CR300) and for copper and fiber-optic connectivity (CAN-CR110/FO). All repeaters have a galvanic isolation of 1 kV, except for the CAN-CR120/HV version which withstands up to 3 kV.
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LEUZE ELECTRONIC ONCE AGAIN LISTED IN THE WORLD MARKET LEADER INDEX
As champion in the Optical Sensors category, Leuze electronic is once again listed in the 2019 world market leader index compiled by the University of St. Gallen, making it one of 14 world market leaders located in the Esslingen district, South Germany.
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euze electronic was included in the world market leader index (WMF index) of the University of St. Gallen as the champion in the field of optical sensors for the first time in 2016. To qualify for the champions category, a company must have an annual turnover of more than €50 million and earnings through exports of at least 50%. Additional requirements are that the company must have its headquarters based in the DACH area (representing the regions and countries with German as their official language) must be active on at least three continents and must also be the market leader in its relevant segment.
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In total, 516 German world market leaders are listed in the WMF index. They employ around 6 million people worldwide and generate a turnover of 1.5 trillion euros. Leuze electronic with its headquarters in Owen/Teck is one of a total of 14 world market leaders in the Esslingen district. The WMF index is generated through objective research and transparently presents the world market leaders in the DACH area. The selection criteria and the values determined are disclosed and the entire index is made accessible to the public. The creation and scientific direction of the project is in the hands of Prof. Dr. Christoph Müller of the HBM School of Entrepreneurs, which is part of the Executive School of Management, Technology & Law of the University of St. Gallen. Cooperation partners of the project include the Academy of German World Market Leaders and the weekly business news magazine “Wirtschaftswoche”, who once again organized the annual summit conference of world market leaders which took place in Schwäbisch Hall at the beginning of February. In reply to the question as to how
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Summit conference of world market leaders which took place in Schwäbisch Hall from February 5 to 7, 2019.
a company becomes a world market leader, Ulrich Balbach (managing director at Leuze electronic) explains: “The entire Leuze electronic company pursues a consistent focusing and differentiation policy – in other words, concentration and focusing on the industries intralogistics, packaging industry, machine tools, automotive industry and lab automation.” In these industries the sensor people have specific expertise and many years of experience.
possibilities and customer benefits. This is what drives us to invent new products, of which there are many more to follow,” explains Balbach. www.leuze.com
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For this purpose, Leuze electronic has established a unique industry and key account management system and is a competent partner who, in collaboration with its customers, can offer innovative solutions for the most complex of tasks. Another recipe for the success of the company is the concentration on its core technological competence in the product areas of switching and measuring sensors, identification systems, image processing and data transmission solutions and occupational safety components and systems. “When these technological competences are applied to the above-mentioned industry segments in a targeted fashion, this results in specific applications in which we endeavor to achieve market leadership worldwide in a consistent and targeted way - a goal that has has already been achieved in some areas. Decades of experience in these areas, a high degree of technological competence and the willingness to take the risk of making new discoveries make us a unique partner for our customers. This is because real innovation that leads to growth can only be found where there is a correct balance between technological 29 | Industry Asia Pacific | April 2019
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ON SAFE PATHS
The RSL 400 safety laser scanner combines safety with a detailed measurement value output for AGV navigation.
The RSL 400 safety laser scanner not only ensures that automated guided vehicles (AGVs) are operated safely by means of protective and warning fields, but it also simultaneously captures the measurement values for the navigation software.
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hen the triangulation principle is used for navigation, AGVs are usually equipped with two different sensors: one for safety and one for navigation. The new RSL 400 safety laser scanner from Leuze electronic offers a true alternative: not only is it capable of handling the safety aspects, but it also provides all measurement values for the AGV's navigation based on the natural-navigation principle. In addition to that, the measurement values have an extremely high angular resolution and accuracy.
This is important to precisely determine the position of the AGV. This means that only one scanner is needed for safety AND navigation. Measurement value output of the RSL 400 is optimised for navigation software that functions according to the principle of natural navigation with SLAM (Simultaneous Localization and Mapping). With each revolution of its deflection unit, which last 40 milliseconds each, the safety laser scanner emits 2700 light pulses. These are scattered in all directions on obstacles. Parts of the scattered light are transmitted back to the scanner and used to calculate the distance to the obstacle.
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Similar to a map, the navigation software contains an image of the respective room, including all fixed boundaries. The current position of the AGV is then calculated by comparing the measurement values to the map. This concept is referred to as natural navigation. The more detailed and exact the measurement values of a scanner are, the more precisely the AGV can navigate. With 29 | Industry Asia Pacific | April 2019
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an angular resolution of 0.1 °, the RSL 400 can capture the environment in high detail over the entire measurement range up to 50 m. This is achieved through a particularly narrow laser spot that maintains its perpendicular shape over the entire scanning angle. It also reduces incorrect measurements, the likes of which can occur on edges.
This enables safe and reliable reduction of the speed of AGVs. With a scanning angle of 270 °, the RSL 400 can also cover the front and side areas of AGVs at the same time, i.e., around the corner. With these features and a maximum operating range of 8.25 meters, even large AGVs can be fully safeguarded with only two RSL 400.
An eye on obstacles How far away is the obstacle? In addition to the angular resolution, the distance values are also important. With a typical error accuracy of <30 mm, these are highly precise. In addition to that, the values are not affected by the reflectance of the object, whether it is a reflector or a black wall.
The safety laser scanner is available in various models. The product range includes nine functional variants, three of which with data output for AGV navigation. All variants are available for the four operating ranges of 3.0, 4.5, 6.25, and 8.25 meters. Models with PROFIsafe/PROFINET interfaces are also available. These interfaces make it much easier to integrate the devices, particularly when many different protective field configurations are used. www.leuze.com
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The additional output of the received signal strength value for each beam allows autonomous detection of reflectors by the navigation software. When beams strike a reflector, the values differ greatly from any other environment. This makes simple and reliable detection possible. In addition to the navigation aspects, there is no lack of safety: the compact RSL 400 safety laser scanner offers up to 100 switchable protective and warning field pairs. Thanks to this high number, the protective fields can be adapted to the respective movement and load conditions as well as the speed of the vehicles in many different ways. And in 4-field mode with 50 switchable field sets, the device can monitor up to four protective fields simultaneously.
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SIC MARKING LAUNCHES THE NEW XL BOX!
The XL Box marking laser has been improved to meet new users’ requirements.
It keeps all the advantages that have made it a bestseller and a key reference for integrators:
The 2 major innovations that have been especially developed for integrators:
• A powerful SIC Marking fibre laser source (20, 30, 50W) already renowned for its reliability (MTBF 100 000 hours) to perform any kind of marking: text, logos, 2D Datamatrix…
Our new laser controller rack FU4 This rack meets 13849-1:2015 standard requirements and has been awarded the maximal PL(e) (Performance Level =e) to manage the safety loops of the automatic door and emergency stop. This excellent level grants the user the full safety of our laser and makes it one of the safest lasers in the market, as our competitors’ products are usually awarded a PL(c) level.
• A solid housing with an automatic door giving access to the marking area by three sides, and Laser Class 1 certified security (EN60825-1). • A standard chassis for immediate integration into the production line. • An unrivalled quality-price ratio in the market.
Our controller includes a touch screen to give easy access to menus: this allows for simple and user-friendly parameter setting and a simplified diagnosis aid.
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Finally, all fieldbus communication cards (ProfiNet, Ethernet IP, etc.) are available for easier integration into your network or connection with your PLC.
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A robot mode By designing this new operative mode, SIC Marking has taken in charge the Laser Class 1 security. The laser housing can be directly integrated into the production line or the robotic cell through an interface in touch with the lineâ&#x20AC;&#x2122;s PLC. Easier integration (shorter study and installation delays) and reduced costs of the whole laser marking function are therefore the greatest assets of the new XL Box in robot mode. Various additional options are available such as 3D marking or integrated Datamatrix 2D code reading, etc. In case of specific requests, SIC Marking will dedicate a skilled project team made up of 20 engineers (mechanical, automation, IT, etc.) to meet all customer specifications. www.sic-marking.com
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OVERCOME THE ONGOING CHALLENGES OF LONG-REACH MACHINING
A number of current trends in manufacturing are magnifying the difficulty of creating precision bores and performing turning operations with extended-length tools. Demand for tighter tolerances and unfailing repeatability grows continuously. New high-performance workpiece materials are more difficult to machine, boosting stress within the machining system. To save time and money, manufacturers are consolidating multiple parts into single monolithic workpieces that require machining of deep bores and turning of complex components on multitasking machine tools.
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anufacturers seeking to overcome these challenges must study all elements of their machining systems and apply techniques and tools that will assure success. Among the key elements are machine stability, tool holding, workpiece clamping and cutting tool geometry. In general, solid fixturing, rigid tooling and careful tool application make up the basic foundation for accurate, productive boring and long-reach turning processes.
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Producers of oil and gas, power generation and aerospace components are prime candidates for updated tooling and techniques because they regularly deal with large, complex parts with features that require the use of extendedlength tools. Many of the parts are made from tough alloys that are difficult to machine and thereby produce high, vibration-generating cutting forces. In general, nearly any manufacturer can benefit from improving productivity and reducing costs in long-reach boring operations. 29 | Industry Asia Pacific | April 2019
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Deflection and Vibration Deep boring is distinguished from other cutting operations in that the cutting edge operates in the bore at an extended distance from the connection to the machine. Long-reach internal turning operations feature similar conditions, and both these boring and turning operations can involve holes with interrupted cuts, as is the case on workpieces like pump or compressor housings. The amount of resulting tool overhang is dictated by the depth of the hole and can result in deflection of the boring bar or extended-length turning tool. Deflection magnifies the changing forces in a cutting process and can cause vibration and chatter that degrade part surface quality, quickly wear or break cutting tools and damage machine tool components, such as spindles, and cause the need for expensive repairs and long periods of downtime. The varying forces result from machine component imbalances, lack of system rigidity or
NEWS Toolholding To maximise rigidity, a boring bar or turning bar must be as short as possible but remain long enough to machine the entire length of the bore or component. Boring bar diameter should be the largest possible that will fit the bore and still permit efficient evacuation of cut chips. As chips form and break, cutting forces rise and fall. The variations in force become an additional source of vibration that may interact in sympathy with the tool holder’s or machine’s natural mode of vibration and become selfsustaining or even increase. Other sources of such vibrations include worn tools or those not taking a deep enough pass. These cause process instability, or resonance that also synchronise with the natural frequency of a machine’s spindle or the tool to then generate unwanted vibrations. A long boring bar or turning bar overhang can trigger vibration in a machining system. The basic approach to vibration control includes the use of short, rigid tools. The larger the ratio of bar length to diameter, the greater the chance that vibration will occur. Different bar materials provide different vibration behavior. Steel bars generally are vibration resistant up to a 4:1 length to diameter of bar (L/D) ratio. Heavy metal bars made from tungsten alloys are denser than steel and can handle L/D of bar ratios in the range of 6:1. Solid carbide bars provide higher rigidity and permit up to L/D of bar ratios of 8:1, along with the possible disadvantage of higher cost, especially where a large-diameter bar is required.
sympathetic vibration of elements of the machining system. Cutting pressures also change as the tool is periodically loaded and unloaded while chips form and break. Negative effects of machining vibrations include poor surface finish, inaccurate bore dimensions, rapid tool wear, reduced material rates, increased production cost and damage to tool holders and machine tools. Machine Rigidity and Workpiece Fixturing The basic approach to controlling vibration in machining operations involves maximise the rigidity of the elements of the machining system. To restrict unwanted movement, a machine tool should be built with rigid, heavy structural elements reinforced with concrete or other vibrationabsorbing material. Machine bearings and bushings must be tight and solid.
More complex and expensive active tooling vibration control can take the form of electronically activated devices that sense the existence of vibration and use electronic actuators to produce secondary motion in the toolholder to cancel the unwanted movement. Workpiece Material The cutting characteristics of the workpiece material may contribute to the generation of vibration. The hardness of the material, a tendency to built-up edge or work hardening, or the presence of hard inclusions alter or interrupt cutting forces and may generate vibrations. To some degree, adjusting cutting parameters can minimise vibrations when machining certain materials. Cutting Tool Geometry The cutting tool itself is subject to tangential and radial deflection. Radial deflection affects the accuracy of the bore diameter. In tangential deflection the insert is forced downward away from the part centerline. Especially when boring small diameter holes, the curving internal diameter of the hole reduce the clearance angle between the insert and the bore.
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Workpieces must be accurately located and securely held within the machine tool. Fixtures should be designed with simplicity and rigidity as primary concerns, and clamps should be located as close as possible to the cutting operations. From a workpiece perspective, thin-walled parts or welded parts and those with unsupported sections are prone to vibration when machined. Parts can be redesigned to improve rigidity, but such design changes can add weight and compromise performance of the machined product.
An alternative way to damp vibrations involves a tunable bar. The bar features an internal mass damper that is designed to resonate out of phase with the unwanted vibration, absorb its energy and minimise the vibratory motion. The Steadyline® system from Seco Tools (see sidebar), for example, features a pre-tuned vibration damper consisting of a damper mass made of high-density material suspended inside the toolholder bar via radial absorbing elements. The damper mass absorbs vibration immediately when it is transmitted by the cutting tool to the body of the bar.
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NEWS Tangential deflection will push the tool downward and away from the centerline of the component being machined, reducing the clearance angle. Radial deflection reduces cutting depth, affecting machining accuracy and altering chip thickness. The changes in depth of cut alter cutting forces and can result in vibration. Insert geometry features including rake, lead angle and nose radius can either magnify or damp vibration. Positive rake inserts, for instance, create less tangential cutting force. But the positive rake angle configuration can reduce clearance, which can lead to rubbing and vibration. A large rake angle and small edge angle produce a sharp cutting edge, which reduces cutting forces. However, the sharp edge may be subject to impact damage or uneven wear, which will affect surface finish of the bore. A small cutting edge lead angle produces larger axial cutting forces, while a large lead angle produces force in the radial direction. Axial forces have limited effect on boring operations, so a small lead angle can be desirable. But a small lead angle also concentrates cutting forces on a smaller section of the cutting edge than a large lead angle, with possible negative effect on tool life. In addition, a tool’s lead angle affects chip thickness and the direction of chip flow. Insert nose radius should be smaller than the cutting depth to minimise radial cutting forces. Chip Control Clearing the cut chips from the bore is a key issue in boring operations. Insert geometry, cutting speeds and workpiece material cutting characteristics all influence chip control. Short chips are desirable in boring because they are easier to evacuate from the bore and minimise forces on the cutting edge. But the highly contoured insert geometries designed to break chips tend to consume more power and may cause vibration. Operations intended to create a good surface finish may require a light depth of cut that will produce thinner chips that magnify the chip control problem. Increasing feed rate may break chips but can increase cutting forces and generate chatter, which can negatively affect surface finishes. Higher feed rates can also cause built-up edges when machining low carbon steels, so higher cutting feed rates along with optimum internal coolant supply may be a chip control solution when boring these more malleable steel alloys. Conclusion Deep hole boring and turning with extended length tools are common and essential metalcutting operations. Carrying out these processes efficiently requires evaluation of the machining system as a whole to assure that the multiple factors involved in minimising vibration and assuring product quality are working together to achieve maximum productivity and profitability.
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Author: The Seco Tools Tooling Systems Product Marketing and R&D Team www.secotools.com
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Productivity through passive damping tools Steadyline tooling from Seco Tools can enable typical long-overhang operations to be performed twice as fast as with non-damped tools while enhancing part surface finish, extending tool life and reducing stress on the machine tool. The system’s passive/dynamic vibration damping technology makes it possible to accomplish certain applications, such use of tools with L/D ratios greater than 6:1 that would not otherwise be possible even at minimal machining parameters. Turning and boring operations to depths up to 10xD in small and large holes can be reliable and productive. The Steadyline dynamic/passive vibration control system functions on the basis of an interaction of vibration forces. In operation, a cutting force induces motion (vibration) in the holder. To counter vibration, the Steadyline® system employs the properties of an internal second mass engineered to possess the same natural frequency as the external envelope of the bar. The mass is designed to resonate out of phase with the unwanted vibration, absorb its energy and minimise the unwanted motion. In the Steadyline® system, the vibration-absorbing mass is positioned at the front of the bar where the potential for deflection is highest, and the mass can damp vibration immediately as it is transmitted from the cutting edge to the body of the bar. The Steadyline? system also includes short, compact Seco GL cutting tool heads that place the cutting edge close to the damping mass to maximise the vibration-absorption effect. The system is adaptable to a wide range of applications and is most useful in rough and fine boring as well as contouring, pocketing and slotting. Seco Tools has expanded its long-reach turning and boring solutions with additions to its series of Steadyline® vibration-damping turning/boring bars and cutting heads. The latest additions include 1.00” (25 mm) and 4.00” (100 mm) diameter Steadyline® bars, GL25 turning heads and a range of BA boring heads for roughing and finishing operations up to diameters of 115 mm. Boring and turning tool heads can be exchanged quickly using the GL connection, which provides centering accuracy and repeatability of 5 microns and 180° head orientation capability. The 1.00” (25 mm) diameter bars with GL25 workpieceside connection include carbide-reinforced bars for the deepest tool overhang challenges up to 250 mm, along with Seco-Capto™, HSK-T/A and cylindrical shank machine-side interfaces. Larger 4.00” (100 mm) diameter bars accommodate existing GL50 turning heads and incorporate Jetstream Tooling® high-pressure coolant technology through BA-to-GL50 adapters. Where conventional tooling options fail, Steadyline® delivers accuracy and confidence in long overhang operations, reducing spindle stress, increasing metalremoval rates, creating smooth surface finishes and extending tool life.
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SECO MINI END MILL SERIES ADDS BIG PRECISION TO TINY TOOLS
Shops that struggle to machine micro-sized workpiece surfaces can now achieve superior surface-finish quality, accuracy and precision with the new Seco Tools JM100 Mini end mill series as part of the wide and continuously expanding Jabro® range of solid-carbide end mills.
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The JM100 Mini is available in tool diameters from 0.2 mm to 3.0 mm (0.008” to 0.118”), corner radii ranging from 0.05 mm to 0.3 mm (0.002” to 0.012”) RE = ±0.005 and overhang lengths from 1.5* DC to 20* DC, with two and three-flute versions.
Targeted to achieve precise surface finishes on mold and die components, the JM100 Mini helps shops minimise secondary benchwork that can increase part processing time. The end mill’s special coating reduces tool wear to help lower overall tool costs and eliminate the need for frequent tool changes. It also ensures smooth and consistent surface finishes that yield exceptional part performance. Tight radius tolerances of ±0.005μ on the tool reduce runout virtually to zero, increasing output and contributing to lower cost per part with high process precision, stability and reliability.
www.secotools.com
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n micro-machining operations with zero visibility of workpieces and cutting tool, the JM100 Mini delivers longer tool life, stability and guaranteed surface quality thanks to its extremely precise geometries, virtually zero runout, advanced coatings and tight radius tolerances.
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WOODWORKING MACHINE OEM GOES 100% MITSUBISHI ELECTRIC
A leading manufacturer of woodworking machinery is leveraging the benefits of the latest automation technology from Mitsubishi Electric.Fed up with the disadvantages of using automation products from a mix of different suppliers, Phoenix, USA-based Unique Machine & Tool Company wanted to find a reliable single-source supply partner.
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he OEM eventually settled on Mitsubishi Electric and, after initial success with VFDs, soon adopted servo motors, PLCs, cables and HMIs from the same supplier. Reliability and brand reputation have subsequently improved immensely, with Unique Machine today making '100% Mitsubishi Electric’ a major part of its sales presentations.
Established in 1969, Unique Machine manufactures highquality automated woodworking machines, used mostly by cabinet shops and door manufacturers in the design of custom kitchens and similar applications. Products include shapers and sanders, raised panel door machines, CNC machining centres, mitring machines, and dedicated cope and stick stations. Back in the mid-1990s, Unique Machine began the transition from manufacturing mostly manual machines, to producing highly automated, extremely user-friendly systems, pushing the limits of then-available technologies.
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“We had a ‘plug and play’ vision that was relatively new at the time,” explains company President Jeremy Lutringer. “To bring it to fruition, we had to use an eclectic mix of products from different automation manufacturers, and that caused a lot of problems. Whenever there was an issue, the different manufacturers would point fingers at each other and not take responsibility. It was very frustrating.” 29 | Industry Asia Pacific | April 2019
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Woodworking machinery manufactured by Unique Machine now features automation products supplied exclusively by Mitsubishi Electric.
In addition to lacking a single point of responsibility, the need to depend on a multitude of manufacturers for different components was adding complexities and driving up costs. “We had to continually write new drivers to make the different components talk to each other, and we also had to have custom cables designed,” explains Software & Controls Engineer Jon Mattson. The way to rectify the situation seemed clear: find and partner with an automation company that could offer a complete product line. Unique Machine came across a major automation supplier that seemed to fit the bill. However, the company soon discovered that the service and attitude of its new partner left a lot to be desired.
But, Mattson notes, the real damage to Unique's reputation was yet to come.
Frustrated, Unique Machine decided to find another supplier, but was committed to proceeding conservatively. “Mitsubishi Electric had been calling on us and we decided to give them a try, but we had been burnt and didn't want to jump from frying pan to frying pan,” explains Lutringer. “We decided to trial their VFDs in the first instance. They're relatively simple components, and since we had used about 10 different brands of VFDs before, we would be able to weigh the relative quality right away.” Almost immediately, the Mitsubishi Electric VFDs showed themselves to be far superior to any brand the company had used previously. MORE INFORMATION
“Their business model was to lock you into software service and upgrade agreements, as well as licensing fees, which had to be paid on an ongoing basis,” says Mattson. “That may be acceptable or even advantageous in some industries, but in the woodworking sector our customers are accustomed to paying for a machine once and having it run for 30 years. Demands for ongoing technical fees just don't fly.”
“Our supplier was not providing very good support; if we had a problem with one of their products they would either put a band aid on it, or not respond at all. Furthermore, they suddenly dropped a couple of products we were using and stopped all support service for them. That made us look really bad to our customers.”
“The reliability of Mitsubishi Electric VFDs was far better than anything we had ever experienced, both out of the box and out in the field,” confirms Mattson. “With our previous supplier, we might experience five or six VFD failures out of 15 machines. However, with Mitsubishi Electric I can't think of a single failure, and we've used many, many more Mitsubishi Electric VFDs.” 29 | Industry Asia Pacific | April 2019
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“We had been using Windows PCs for many years because we liked the flexibility and functionality they allowed for creating full-featured interface screens and, for a long time, industrial HMIs just couldn't compare,” says Lutringer. “This has all changed with Mitsubishi Electric HMIs, which offer a lot of flexibility as well as feature-rich functionality. There was a smooth learning curve and we are very happy with the graphic capabilities, object actions, image sharpness and quality, even compared with full-featured PCs.” Now offering 100% Mitsubishi Electric components in most of its machines, Lutringer feels that the partnership has given Unique Machine a big advantage. “100% Mitsubishi Electric is definitely something that we highlight in sales presentations,” he says. “Most customers know that having a single, high-quality brand of components on-board makes for easier troubleshooting. Also, I think that the Mitsubishi Electric brand name carries a connotation of quality that no other can match in this space.” That quality, Lutringer notes, is something that Mitsubishi Electric has worked hard to maintain for the company over the years: “We've been very happy with the level of support that we get. Access to engineers, customer service, sales – whatever we need – it's always there. It's in stark contrast to what we've experienced with other automation suppliers.”
Lutringer adds: “Other drives would throw up errors and stop working at the first hint of heat. Woodworking shops can run hot and that was a big problem, but the Mitsubishi Electric drives stand up to the harshest conditions and just keep working.” In addition to huge improvements in reliability, the Mitsubishi Electric VFDs are providing a number of other benefits to Unique Machine and its customers.
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“Mitsubishi Electric drives are very easy to program,” states Mattson, by way of example. “The interface on the front of the drive and an auto-tune feature that lets you simply plug in the characteristics of a new motor, save a lot of time. And, with other brands, we would have to put in separate braking resistors to stop the motor quickly in an emergency. In contrast, the Mitsubishi Electric VFDs do it on their own, in less than 10 seconds, and without any risk of overheating that can plague resistors. This integrated safety is a big plus as it helps us optimise the safety of our equipment while saving on cost and providing a much neater, clutter-free cabinet that really projects ‘trouble-free’ to our customers.” With the success of the VFDs, Unique Machine has since evolved to a 100% Mitsubishi Electric solution, incorporating servo motors, PLCs, cables, and, most recently, HMIs.
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With Mitsubishi Electric by its side for several years now, Unique Machine has enjoyed some of its greatest successes in nearly half a century of trading. “If we hadn't found a stable automation partner we probably wouldn't have had some of these results,” concludes Lutringer. “Bottom line; I think Mitsubishi Electric adds confidence for us when we ship a machine out the door, while our customers also have confidence in the products because of the automation technology they feature.” Summary Solution • FR-D700 series VFDs • GT25 series HMIs • Q170M motion controller • MR-J4 series servo motors Unique Machine benefits • Highly reliable, even under tough factory conditions • Easy to use, even by untrained operators • Competitively priced Mitsubishi Electric value-added advantages • Extremely responsive, value-added service • Robust, reliable products • Full featured, easy to program components www.mitsubishielectric.com
NEWS
PYROGUARD RAPIDE E120 VISION PANEL GLASS CUTS LEAD TIMES FOR THE INDIAN MARKET
Pyroguard Rapide E120 demonstrates integrity and heat reduction capabilities during testing phase.
Pyroguard, the world-renowned manufacturer of fire-rated safety glass, has achieved significant test success with its Rapide vision panel. Delivering Integrity protection against fire for up to 120 minutes, Pyroguard Rapide E120 is a “tried & tested”, cuttable, easy-to-install solution, which is available through local stockists on short lead times.
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n addition to its fire protection characteristics which see it perform to Integrity classification when tested in accordance with BS 476-22, Pyroguard Rapide E120 boasts a host of complementary benefits including excellent light transmission ratings and greater acoustic values than comparable vision panels. The laminated solution is also fully UV stable, making it suitable for both internal and external applications.
“Coupled with the incredible two-hour integrity this vision panel delivers, it also performs when it comes to light transmission and acoustics, which are key considerations in modern developments.”
Ritesh Chhadwa of Pyroguard, said: “Having delivered firerated safety glass for more than 20 years, Pyroguard strives to develop the very best solutions for our customers, and we’re proud that this ethos has once again been reflected with the ground-breaking results we’ve achieved during testing of the Rapide range.
www.pyroguard.eu
Achieving 120 minutes Integrity Pyroguard Rapide E120 remains resistant to flames and smoke when exposed to fire on one side.
MORE INFORMATION 29 | Industry Asia Pacific | April 2019
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MITSUBISHI ELECTRIC VFDS HELP FARMS GROW OPERATIONS
Three-phase power is often unavailable in rural and remote locations, which is a primary reason why farmers struggle to grow their operations. Any farm looking to run larger fans and motors to help increase storage and handling capacity have thus far been forced into using traditional solutions such as rotary phase converters, which are costly, have big capacitor banks and a high amp draw, running up electricity bills and erasing profits.
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ow, however, increasing numbers are turning to the latest Mitsubishi Electric variable frequency drives (VFDs), which allow a three-phase motor to run from a single-phase electric supply without a phase converter, facilitating greater power and lower energy consumption.
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This trend is evidenced by D&E Equipment of Wilmington, Ohio, which was founded in 1954 by Walter Ewing. An expert in designing and installing bespoke farm infrastructure solutions such as grain storage bins, grain elevators, dryers, augers and grain handling systems, D&E is a family-run company that has built a reputation for quality and service throughout the local agricultural community. With no two installations the same, D&E Equipment’s highly experienced workforce collaborates with each customer to fully understand and meet their specific requirements.
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The challenge Modern agricultural operations make use of on-site infrastructure to store and maintain grain, selling their crop in several batches at different prices throughout the year to help maximise returns. Along with farm consolidation, this trend has helped fuel demand for ever-larger grain storage and handling infrastructure. However, since many agricultural operations are located in remote rural areas, they can quickly reach an impasse, severely hampering their ability to grow. “Unfortunately, many of our customers can only get singlephase power out to their farms,” confirms D&E Vice President of Operations Mike Kees. With three-phase power vital for running the larger fans, motors and other equipment required to increase storage and handling capacity, farmers seeking operational growth have been forced to use a feasible, if far from desirable
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A Mitsubishi VFD installed as part of a dryer control system.
Mitsubishi Electric VFDs can provide a host of problem-solving benefits at farming operations worldwide.
workaround: rotary phase converters. However, such devices are not only expensive, but draw large quantities of electricity.
though they still have a single-phase electricity supply. The VFD provides an immediate opportunity for them to grow their operation in a cost-effective way.”
The solution By working with Mitsubishi Electric and its local distributor, D&E has been able to offer customers a far more attractive solution in the shape of the latest VFDs.
According to Kees, this advantage is usually only the beginning as Mitsubishi Electric VFDs potentially provide a host of further problem-solving benefits. Among them is the capability to allow a “soft start” increase of power draw when firing up equipment. This feature reduces the potential for tripping the overload, lowers the possibility of damaging expensive equipment, and increases service life.
“Basically Mitsubishi VFDs allow us to ‘trick’ a three-phase motor into running from a single-phase electric supply without a phase converter, enabling greater horsepower,” explains Kees. “And since they are only used on the specific motor or other piece of equipment where they are needed, the VFDs are far more power-efficient and economical to run.” The impact of a Mitsubishi Electric VFD on a farm’s operation, Kees notes, can be huge – and instantaneous.
Kees also appreciates how working with Mitsubishi Electric has enabled D&E to create further goodwill with its customers, and maintain and enhance the company’s long-standing reputation for quality: “We are service-driven and stand behind our products, and Mitsubishi helps us in that regard. I don’t think I’ve ever seen one of their VFDs go wrong and require replacement. As a result, with the high
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“A maximum of 15 hp [11.2kW] single-phase power is limiting,” he says. “Installing a Mitsubishi Electric VFD ensures that our customer becomes capable of using larger, faster equipment, while accessing more capacity by increasing the size of their operation. With their single-phase power supply and the VFD, they’re no longer limited on equipment size. A farm can move from, say, 700 bushels per hour to 1200 or 1700 bushels an hour through their drying system by using a conveyor that requires a 30 hp (22.4kW) three-phase motor,
Another benefit of VFDs is their ability to simplify the combination of newly purchased equipment with existing older equipment and make it work effectively for the customer, a common challenge on the farm. If one conveyer, for example, is rated at 5000 bushels an hour and another is rated at 7500 bushels an hour, grain plugging and equipment breakage can occur if the incompatibilities are not evened out.
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NEWS Farms can increase storage and handling capacity with Mitsubishi Electric VFDs.
Mitsubishi Electric automation solutions can be applied to numerous grain-handling applications.
costs of service and downtime on the farm, our customers are very happy.” He also notes that when VFD programming is needed, the customer-focused, partnership-driven attitude of Mitsubishi Electric and its distributor help D&E provide fast, effective service. “Our prior supplier insisted on keeping their system proprietary; if there was a programming issue we had to call and wait for them to come out,” Kees explains. “It could take several days and support costs were high. Contrast that with the Mitsubishi attitude – they actually train our guys on their system so we can do it ourselves, quickly. Again, that is a huge value add. Mitsubishi has a whole different business model and attitude; a partnership rather than a forced dependency.”
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The results Ultimately, working with Mitsubishi Electric VFDs has created an entirely new stream of business for D&E, and stimulated the company’s interest in potentially helping customers apply additional Mitsubishi Electric automation solutions to grain-handling applications such as those relating to PLC controls, networking and temperature monitoring. “Mitsubishi VFDs are turning our service guys into sales people because they are going to farms and constantly seeing where customers can benefit,” concludes Kees. 29 | Industry Asia Pacific | April 2019
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“In turn, this elevates job satisfaction among our staff as anytime you can fix something so effectively for a customer you’re going to feel good about it. In my opinion, VFDs will soon become as common on the farm as motors and augers.” www.mitsubishielectric.com
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COVAL’S LEMCOM MANAGER: VACUUM MANAGEMENT MADE EASY
Especially developed with vacuum handling applications in mind, LEMCOM Manager is a PC software package which allows you, in just a few clicks, to remotely setup and configure LEMCOM vacuum generators as well as run diagnostics.
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acked with numerous functions such as the import/ export of parameters, vacuum-cycle analysis, alarm and operation cycle monitoring, configuration help or even embedded firmware updating, LEMCOM Manager delivers agility, flexibility and availability, to meet the key requirements of the industry of the future.
The LEMCOM series of mini-vacuum pumps, combined with the LEMCOM PC tool, offer the first global solution for vacuum gripping via Industrial Ethernet (PROFINET, EtherNet/IP) and fieldbuses (CANopen). www.coval-inc.com
The application allows all LEMCOM mini pumps to be controlled remotely over the network either by the end user or by COVAL’s technical support teams.
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