Industry Asia Pacific | 30 - July 2019

30 | J U LY 2 0 1 9

Industry

Asia Pacific THE INDUSTRY MAGAZINE FOR ASIA

NEW SINGLE STAGE NORDBLOC.1 HELICAL GEAR UNITS

13

SMS CONCAST DEVELOPS ACTUATOR-DRIVEN OSCILLATION WITH DIRECT DRIVES BY KOLLMORGEN

34 LEUZE ELECTRONIC EFFICIENT AND PROCESSCONTROLLED ACCESS GUARDING WITHOUT MUTING SENSORS

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PCVUEÂ 12: THE OPEN, SECURE AND MOBILE SCADA/IOT PLATFORM!

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IN THIS MAGAZINE...

6 INDUSTRY 4.0 AND IOT EXPAND SMART SENSOR APPLICATIONS 9 Cv-x series multispectrum: flexibility and ruggedness in visual inspection 10 Smart position sensor 11 New photoelectric sensor for demanding applications 13 New single stage NORDBLOC.1 helical gear units 14 Nelson automotive rebrands as Avistud 16 Rugged sensors for small-scale process technology - Detect temperatures using direct media contact

18 REDEX Tension Multi Roll Leveler is used on Tinning Line for the First Time in China 22 Kennametal introduces its Mill 4-12KT, the next generation of tangential shoulder milling

24 Toolholders Pinpoint Coolant and Eliminate Turning Operation Interference 26 Efficient and process-controlled access guarding without muting sensors 29 SIC Marking continues to grow internationally!

30 “Safety at work – how can machine tools and systems operate safely and efficiently?”

33 How to turn a small and medium-size company into an intermediate-size one in 2 years?

34 To get the casting die oscillating 37 New 35ECS Ultra EC Brushless Motor 38 New frequency inverter from NORD: Versatile, Networked, Powerful 40 PcVue 12: The open, secure and mobile SCADA/IoT platform!

42 Mitsubishi Electric helps Oliver upgrade existing slicing machine

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.

Published by www.ipmediaonline.com

INDUPORTALS

MEDIA PUBLISHING

EDITO Bruno FORGUE Editor-in-chief

OFFSHORING, BACKSHORING OR JUST RELOCATION? After a significant wave of “offshoring” in past decades, the “backshoring” of industrial activities is becoming increasingly frequent.

So what’s going on?

Offshoring. For those not old enough to remember the advent of offshoring, the first wave of industrial relocation from Europe to China took place between 1965 and 1970 to start serving a newly emerging market – the Far East. Fast-forward 20-25 years and many factories began closing in the West, largely to the benefit of wealth creation in lower-cost economies in Central and Eastern Europe. Following the fall of the Berlin Wall in 1991, former Soviet countries escaped poverty by becoming subcontractors to Germany, and later to other countries in Western Europe.

In the same decade, North American studies predicted the displacement of more than 3 million white-collar jobs to India (including more than 500,000 computer scientists). By the early 2000s, China had become “the factory of the world”, while the 2010s saw Brazil develop its domestic market and begin attracting international manufacturers.

Labor costs, labor force, skills, industrial real-estate costs, legal and tax benefits, proximity to raw materials, emerging markets… the motivations for offshoring are often diverse, and never simple.

In any case, the impact on industrial production has always been significant.

And the story didn’t stop there.

Backshoring. In recent years, industry has been in reverse. For some, the factories are coming back. For others, the factories are leaving.

The reasons are many: reduction of transport costs and delays; new taxes on imports; jobs creation; coordination between teams (design-production-marketing); quality improvements; protection against espionage; skills development; carbon footprint reduction; demand from original customers; and new customs constraints, to list but a few. Here again, a multivariable equation that is neither simple nor basic. However, once the decision is made, it is considered that in 10, 20 or 30 years, the professions have evolved. The know-how has changed. Production techniques and methods have moved on.

In fact, this change is becoming a tremendous accelerator for the development of digital factory concepts. A full-scale field of application for new technologies, materials, equipment and software.

All these new products and solutions contribute to factory 4.0, and they can be found every day in these columns.

Localization. Many factories are now moving closer to the customer to limit costs. Cheap labor or advanced digitization of the plant? In reality, the production method adapts to the market in which the plant is located. So in a way, the manufacturing process is always “localized”!

Enjoy reading!

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THE INDUSTRY MAGAZINE FOR ASIA

NORD DRIVESYSTEMS

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13 AVISTUD

14 BALLUFF

REDEX

KENNAMETAL

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18

22 LEUZE ELECTRONIC

SECO TOOLS

24 LEUZE ELECTRONIC

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SIC MARKING

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26 SIC MARKING

KOLLMORGEN

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34

PORTESCAP

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NORD DRIVESYSTEMS

ARC INFORMATIQUE

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ADVERTISERS: NORD 12 • LEUZE 17 • MEPAX 25

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MITSUBISHI ELECTRIC

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INDUPORTALS

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NEWS

MARKET OVERVIEW

INDUSTRY 4.0 AND IOT EXPAND SMART SENSOR APPLICATIONS Although sensors have been important devices in manufacturing and process plants for many years, today they have a particularly crucial role to play. Thanks to a number of enhanced features, matched by high levels of flexibility and increasingly compact dimensions, the latest smart sensors have become stars in the world of Industry 4.0 and the Internet of Things (IoT). For users, smart sensor evolution means greater profitability provided by more productive assets.

Author: Sílvia Bruin Pereira

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his thinking is confirmed by Bruno Kim, Marketing Manager at KEYENCE. “A smart solution may bring several benefits; for example, inspection reliability using such a system undeniably becomes superior to that performed by a human operative,” he says. “After all, automated inspection is not subject to human bias, thus ensuring higher repeatability and process speed.

Reduced downtime is also of relevance, thanks largely to an evolution in technology that has increased the ruggedness of inspection instruments to suit harsh environmental conditions on the shop floor. As a result, productivity is enhanced. Time and expenditure reductions also appear on the list of benefits, as much higher productivity means less labour costs.”

KEYENCE has great confidence in its vision system for surface inspection. The company has recently released its multi-spectral technology, which includes lighting in several spectrums, in order to obtain the best application stability and contrast. Featuring a method of capture that is unique in the market, clients benefit from a rugged design which provides inspection results free from subjective interpretation bias.

MORE INFORMATION

Measurement reliability, downtime reduction and faster calibration, asset costs and time savings; all these benefits provided by smart sensors are connected in the opinion of Gustavo Takizawa, Application Engineer at HONEYWELL Sensing and IoT Division. “However, I would say that measurement reliability is the key to smart sensor success,” he states. “Once sensor measurements are reliable, the benefits provided imply less maintenance requirements since it is possible to predict system anomalies and, therefore, increase asset [employee] efficiency and, at the same time, reduce costs.”

HONEYWELL uses several technologies in its sensors dedicated to the measurement of pressure, humidity, temperature and position, including MEMS (Micro Electro Mechanical Systems) and ASIC (Application Specific

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ROCKWELL AUTOMATION

NEW S MARKET OVERVIEW

KEYENCE

MORE INFORMATION

HONEYWELL

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NEWS MARKET OVERVIEW Integrated Circuits), with the objective of collecting data accurately and reliably. The company’s SMART (Superior Measurement. Accurate. Reliable. Thinking.) Position Sensor, for example, is a highly reliable ASIC using an array of integrated circuits to detect magnetic fields (Hall effect sensors) for enhanced object position sensing.

According to ROCKWELL AUTOMATION Product Manager, Maurício César Brichesi Filho, the ROI calculation for smart sensor applications will be based on the previous conditions of the equipment/line where they are installed. For example, factors such as downtime caused by equipment failure, reduced product quality and lower OEE (Overall Equipment Effectiveness) all need to be included in the equation. “Smart sensors are capable of reducing maintenance costs by reducing the equipment/line MTTR [Mean Time To Repair],” he says. “They are capable of providing contextualized information of actual field conditions in real time, so the end user is able to make fast and efficient decisions.”

The smart sensor technology of ROCKWELL AUTOMATION is implemented by means of three components: advanced diagnostic sensors (IODD Advanced); IO-Link technology to deliver more data to the control system; and the advanced integration of sensors and controllers, a unique feature in the market.

INDUSTRY 4.0 AND IoT “With Industry 4.0, the main issue is the potential for establishing communications between the sensor and the information network, plus process automation,” states Kim. “As a particular point of note, we’ve been noticing intense market interest in automatic inspection solutions.” Kim finds it difficult to predict the type of sensor that will command the biggest market share, because that depends on each specific application. “Considering that the market has been looking for inspection automation options, it is possible that sensors related to this kind of application will play a major role from now on,” he says.

“Industry 4.0 and the IoT influence and demand very decisive growth in the smart sensor market, since the world needs process optimization, assets and increased profitability,” says Takizawa. “Smart sensors are basically the heart of Industry 4.0 and the IoT; they play a major role in fast, efficient and reliable data acquisition.”

Of course, growing competition in worldwide markets calls for technology updates on a yearly basis. “The combined sensor is likely to play a major role in the next few years”, hopes Takizawa. “This kind of sensor is capable of collecting several types of data. An example of a combined sensor is our HumidIcon, which combines temperature and humidity in a single sensor, with a digital output for communication.

If a sensor is capable of combining information (pressure, humidity, temperature, position, etc.), equipment space will be more optimized, easing the path from design concept to reality.”

MORE INFORMATION

Similarly, Brichesi reiterates that the growth of Industry 4.0 and the IoT is based on the modernization of sensors and actuators. “According to the ISA-95 standard, sensors and actuators are in level 0, and are responsible for providing reliable information to the analytical and management systems,” he says. “If bad quality information is provided, the performance of analytical technologies and ML 30 | Industry Asia Pacific | July 2019

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[Machine Learning] will be affected.” Brichesi adds that the main applications are in analogic technology (pressure, temperature, distance) which, besides enabling productivity, reduce the cabling costs of field devices. For this reason, Brichesi is convinced that analogue sensors will play a key role, since it is easier to implement this type of sensor than digital counterparts such as distance, colour and condition sensors.

FUTURE Which industrial segment will have the greatest demand for smart sensors in the near future is considered, for the time being, a guessing game by Kim. “Even if several companies come up with similar products, the way they are made will be, in most cases, quite distinct,” he states. “I believe that all active players in product manufacture are candidates to drive higher demand for such items. The principle which must be considered is that every product submitted for processing is subject to inspection, to make sure it is within quality parameters”, Kim explains.

According to Takizawa, agriculture, energy and medicine will be demanding more and more smart sensors as the technology keeps evolving. “A combine harvester, for example, may use position sensors, IMUs [Inertial Measurement Units], pressure, temperature, speed and current sensors, GPS, and several other types,” he says.

“Furthermore, these markets demand real-time monitoring of the data provided by such sensors, so that equipment operators can make fast decisions. The medical and energy markets are those demanding the most up-to-date technologies capable of providing high-accuracy data collection, mainly in healthcare, so that a doctor may analyse data from several patients in real time. Additionally, trending this data will increase system reliability and decrease eventual failures.”

Brichesi predicts that the industrial segments set to take most advantage of this technology will be food and beverage, automotive and tire manufacturing, as well as general manufacturing. “These segments already use several sensor types across their industrial facilities that are connected to conventional I/O cards,” he explains. “The lack of information to the user caused by this type of setup creates serious consequences, such as plant shutdowns and decreased operational reliability. However, by applying the latest sensor technology, they will experience a marked increase in production and reliability.”

According to a survey carried out by Markets and Markets, an Indian company specializing in quantified market research, the industrial sensor market was valued at €14.24 billion in 2018 and is likely to reach €19.23 billion by 2023, an annual growth rate of 6.16%. The survey points out that this increase is being propelled by growing demand for Industry 4.0 and IoT strategies, by the surging wireless sensor market and the burgeoning demand for industrial robots.

Smart sensors are expected to evolve quickly, particularly in size, performance and cost. As a result, the use of smart sensors will become more widespread as the IoT improves and renders important data transmission safer.

This progression will lead further industries to adopt smart sensor technology.

NEW S MARKET OVERVIEW

CV-X SERIES MULTISPECTRUM: FLEXIBILITY AND RUGGEDNESS IN VISUAL INSPECTION

This series uses Lumitrax™ technology, where the final image is obtained by superimposing several images captured at various lighting angles.

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V-X Series Multispectrum uses an innovative inspection algorithm. High-speed monochrome cameras are used together with eight-colour lighting, a configuration that promotes accurate applications, even with subtle hue variations.

This series also uses Lumitrax™ technology, where the final image is obtained by superimposing several images captured from multi-angle lights, in order to minimize reflex and maximize contrast. Such capability enables users to easily generate images that would otherwise require a lot of experience and editing time.

In short, this vision system offers the most advanced hardware and software, providing more flexibility and ruggedness in visual inspection applications, while simultaneously offering intuitive, simple operation. www.keyence.co.uk

MORE INFORMATION 30 | Industry Asia Pacific | July 2019

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NEWS MARKET OVERVIEW

SMART POSITION SENSOR

This is a combination of an ASIC (Application Specific Integrated Circuit) and an array of MR (magnetoresistive) sensors.

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he Smart Position Sensor is one of the most adaptable and lightweight sensors available on the market, enabling highly accurate motion control, and enhanced operational efficiency and safety.

A simple non-contact design eliminates mechanical failure mechanisms, reduces wear and tear, improves reliability and durability, and minimizes downtime.

MORE INFORMATION

The Smart Position Sensor is a non-contact solution for absolute position sensing with enhanced accuracy.

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These sensors use a combination of an ASIC (ApplicationSpecific Integrated Circuit) and an array of MR (magnetoresistive) sensors to accurately and reliably determine the position of a magnet attached to a moving object, so that its position can be determined or controlled. www.honeywell.com

NEW S MARKET OVERVIEW

NEW PHOTOELECTRIC SENSOR FOR DEMANDING APPLICATIONS

This high-performance sensor provides long-distance detection and increased environmental tolerance for industries such as food and beverage, material handling, and packaging.

A

pillar of Industry 4.0, the Allen-Bradley 42AF RightSight M30 photoelectric sensor from Rockwell Automation is built with improved environmental resistance and long-distance detection in a mid-sized, rightangle housing, and offers the flexibility and performance required for a wide range of demanding applications.

MORE INFORMATION

Developed with IO-Link capability, these sensors are easily integrated into automation architectures, providing data and diagnostics directly from/into a control system to help minimize downtime and increase productivity. Using this capability, the sensor can provide information such as signal strength, location, proximity alarms and timing functions, which increase operational efficiency and decrease plant downtime. The 360-degree high-visibility LED power and status indicators further assist in set-up, monitoring and troubleshooting. www.rockwellautomation.com

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DER ANTRIEB Reliable. Versatile. Global.

Sealed Surface Conversion System Geared motors from NORD DRIVESYSTEMS with nsd tupH are the optimal choice for use in challenging environmental conditions.

THE GEAR UNIT

THE MOTOR

THE DRIVE ELECTRONIC

n Strong bearings n Quiet running

n High efficiency n Global standards

n Compact design n Easy commissioning

NORD GEAR Pte Ltd | Tel +56 2659118 | info.sg@nord.com

nord.com

MONTH'S PRODUCT

S M A R T FA C TO R Y

NEW SINGLE STAGE NORDBLOC.1 HELICAL GEAR UNITS

The new single stage NORDBLOC.1 helical gear unit from NORD DRIVESYSTEMS provides high output torques and maximum radial and axial load capacity.

NORD DRIVESYSTEMS has extended its range of single stage NORDBLOC.1 helical gear units with three larger sizes. The new drive units provide high output torques as well as maximum radial and axial load capacity.

W

ith its single stage NORDBLOC.1 helical gear units the NORD DRIVESYSTEMS range includes innovative drive units with high efficiency and long service life. The drive specialist has now extended its successful series with three larger sizes.

The three new products SK 871.1, SK 971.1 and SK 1071.1 have powers from 0.12 to 45 kW and cover the torque range up to 1,000 Nm. Thanks to optimised bearings, they can reliably handle large axial and radial forces. The robust, cast iron gear units are therefore optimally suitable for pumps and agitators.

The innovative NORDBLOC.1 helical gear units impress with their high efficiencies, compact design and ultimate reliability. They do not have any separating joints or closing caps. This increases the stability of the product and at the same time provides a smoother surface on which neither liquids nor solid materials can accumulate. The FEMoptimised UNICASE housing ensures maximum strength and rigidity.

MORE INFORMATION

The modular design provides wide application flexibility due to numerous configuration and mounting options.

All variants are available as flange mounted (B5 or B14), or foot/flange mounted versions. Options for IEC and NEMA motor mounting as well as a wide range of equipment variants for shafts, bearings and lubrication can be flexibly implemented. www.nord.com

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AU TO M OT I V E

NELSON AUTOMOTIVE REBRANDS AS AVISTUD

Global automotive stud welding leader Nelson Automotive has announced a complete rebrand of its business to customers, stakeholders and industry peers.

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he newly launched brand, AVISTUD, reflects the total separation of the Nelson Automotive business from the brand of its former industrial parent Nelson Stud Welding. Nelson Automotive was initially created as a standalone automotive company following the sale of Nelson Stud Welding from Doncasters to Stanley Black & Decker in April 2018.

MORE INFORMATION

AVISTUD, whose name represents the Automotive, Versatile and Innovative stud welding that the firm brings to the industry, will focus solely on providing high-tech products to car manufacturers and their suppliers. In December 2018, the company announced a major new deal to supply Daimler AG with innovative technology equipment for the production of Mercedes Benz C-class and S-class ranges.

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Henning Stams, chief executive of AVISTUD, said: “The automotive industry is demanding more speed and flexibility from its manufacturing processes than ever before. We have adapted our business to meet the automotive sector’s requirement for more lightweight, high-strength materials, electric vehicles and faster manufacturing processes.”

Eduard Kirchner, head of AVISTUD’s engineering group, added: “We are the leading technological innovator in stud welding with a strong team of experienced engineers.

Under our new brand of AVISTUD, we will be one hundred per cent focused on serving the global automotive market, where customers already trust our innovation and versatility to help deliver the vehicles of the future.”

AVISTUD is at the forefront of innovation in the sector. For example, its SPEEDPORT feeding system enables a single unit to weld more than 40,000 studs in a day. The company also offers an extensive range of manual and automatic systems, as well as robotic weld heads for high production environments.

NEWS

With its global physical presence in many countries in Asia, Europe and the Americas, products will continue to be developed and manufactured in Germany, where its dedicated team of more than 100 employees is focused on creating the next generation of stud welding systems, pushing the boundaries of speed, performance and durability.

“Our team is committed to researching, developing, and bringing to market the best new processes for our clients– whether that be for systems for new production facilities, or upgrades to existing plants. We look forward to announcing the future investments and developments already in the pipeline.” concluded Stams. www.avistud.com

MORE INFORMATION 30 | Industry Asia Pacific | July 2019

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MEASUREMENT

RUGGED SENSORS FOR SMALL-SCALE PROCESS TECHNOLOGY DETECT TEMPERATURES USING DIRECT MEDIA CONTACT

Balluff is expanding their range of sensors for media-contacting temperature detection, in hydraulic power units for example. New are a temperature sensor with display, a temperature transmitter as well as a PT1000 sensor .The version without display is especially compact and vibration-resistant, whereas the versions with the turnable and highly readable display offers high operating convenience and flexible installation.

D MORE INFORMATION

epending on the version, the BFT sensors provide PNP switching outputs, analog signals 0...10V /4...20mA or work as a PT1000 sensor. They are simple to install by threading into the process using a standard process connection with G- and NPT threads. Integrating them requires just a 4-pin M12 plug on the sensor.

Continuous monitoring of process media on machines and equipment contributes greatly to process security.

Values that need to be maintained are pressure, level and temperature. When for example in a hydraulic system you need to monitor the temperature of the hydraulic fluid, you can do this reliably using our BFT media-contacting temperature sensors. Monitoring the temperature within the hydraulic loop guarantees correct fluid viscosity and thereby the best performance of a machine. Critical process conditions such as a temperature limit can be controlled directly via the switching output. An analog output provides continuous measurement results. The BFT temperature sensors also stand out when it comes to monitoring the cooling water, lubricants and compressed air, making them ideal for a variety of applications. www.balluff.com

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SMARTER PRODUCT USABILITY

GUARDING WAS NEVER THIS GOOD. SAFETY LASER SCANNER RSL 400 With two autonomous protective functions, an operating range of 8.25 m and a scanning angle of 270°, the RSL 400 sets new standards in safety sensor technology.

easy handling.

Rolf Brunner, Head of Product Center – Laser Scanners

www.leuze.com info.sg@leuze.com AZ_210x139_RSL_400_uk.indd 1

19.12.2014 15:49:00

SMARTER PRODUCT USABILITY

SMART IS, WHEN A PROFINET GATEWAY IS ALREADY INTEGRATED INTO OUR SAFETY CONTROL Thanks to the integrated interfaces and additional gateway modules you can integrate our safety controls into all common fieldbuses.

integrated connec

tivity.

Phone 01480 408 500 – www.leuze.com - info.sg@leuze.com

Alexander Mielchen, Product Management Safety

MECHANICS

REDEX TENSION MULTI ROLL LEVELER IS USED ON TINNING LINE FOR THE FIRST TIME IN CHINA

Mr. Pascal Vieugué, Managing Director of REDEX and Baosteel representative officially signed the cooperation agreement.

Empowering Baosteel to Expand its International Market Share.

E

lectrolytic tinplate (ETP) is one of high-end products by cold rolling and deep processing, a new type of highvalue-added corrosion resistant material. Due to its non-toxicity and excellent corrosion resistance, Electrolytic tinplate has found its wide applications in food packaging, beverage packaging, medical and chemical packaging industries. With the expectation of replacing aluminum packaging gradually, the prospects of this new material is very high.

MORE INFORMATION

From the view of the development trend of the technology, both tin plate products and tin coating are getting thinner.

As a result, the production technology is becoming more complex and difficult and has become the high-level production line in the manufacturing field of thin electrolytic tinplate in metallurgical industry.

In addition, canning and printing processes using tinplate sheets as raw material are extremely sensitive to strip shape.

The cold rolling process of black steel also produces a considerable amount of internal stress in strip steel, causing tinplate flexures easily when such stress is released during downstream deep processing of shearing.

The use of REDEX Tension Multi Roll Leveler eliminate the flatness defects of strip steel in Metallurgy and improve the shape of strip. Therefore, it is common to include a REDEX Tension Multi Roll Leveler in the tinplate production line.

It has become one of the benchmarks that measure the technical level of the electrolytic tinplate production line.

Collaborating with Redex, Baosteel made breakthrough in mass production With the development of tinplate applications, many domestic steel mills have begun to construct electrolytic tinplating units. Some have even introduced large advanced continuous tinplating units with high output. Baoshan Iron & Steel Co., Ltd. (“Baosteel”) is one of them.

Currently, Baosteel has become one of the leading domestic companies in the field of tinplates and double cold reduction

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NEWS

REDEX PMR 1300 Tension Multi Roll Leveler can be used in modernization of the existing tinplate production line as well as an addition in the new tinplate production line.

(DCR) technology. In order to better meet the production requirement on the flatness of DCR tinplates (the product after rolling process/Annealing/Single or Double Redution SkinPass ), Baosteel planned to upgrade its 1420 cold rolling No. 2 tinplating unit (C217) to one that can produce both SR (Single Reduction) and DR (Double Reduction) tinplated products.

the entire cleaning section to eventually realize fully automated operation and avoid noise pollution;

The C217 unit of Baosteel is reported to have a total production capacity of 180,000 t/a. The unit uses continuous annealing (CA) black steel strip and DCR black steel strip.

While the original design of C217 unit did not include a Tension Leveler, it was unable to run mass production. As such, there was an urgent need to add a tension Multi roll leveler to the production line.

This created a great challenge for many vendors. Thanks to its compact REDEX Tension Multi Roll Leveler and experiences of successful applications at large steel mills abroad, the perfect evaluation scores on technology and business practices set REDEX apart from other outstanding vendors.

Because of the tight schedule and the production line having the necessity of running continuously, Baosteel set the bar high in open tendering.

Next, it must upgrade the motors, drives, and other electrical equipment at the same time. It was also required to upgrade

Being the First to REDEX Tension Multi Roll Leveler, its Applications Have Been Proven Worldwide The PMR 1300 used by REDEX on Baosteel's tinning line production Tension Multi Roll Leveler jointly developed

by ARCELOR PACKAGING International, IRSID, and REDEX, following the RDI development standards of CECA. MORE INFORMATION

First of all, the vendor needed to provide the tension leveler and supporting equipment that are advanced, reliable, easy to maintain (including front and back tension bridle rollers) to ensure the continuous and stable operation of the units and provide good performance in the cold rolling production line.

Finally, since the tinnings lines of Baosteel were required to run around the clock, the time for equipment delivery, installation and commissioning must be kept as short as possible.

PMR 1300 Tension Multi Roll Leveler can apply force on both tensile and bending deformation of the strip at the same time to achieve precise elongation control.

Thus, all fibers in the strip are stretched to the same length to obtain excellent flatness of the strip and effectively eliminate the internal stress of steel strip.

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It took only 8 days for REDEX to install, debug, and put into production nearly half a month ahead of the schedule.

Mr. Jiang Ling, General manager of REDEX (Shanghai) Co., Ltd., said: “This Tension Multi Roll Leveler is specially designed for very thin and hard steel strip with very limited residual elongation. It integrates our proprietary mechanical drive system and strip steel elongation control system, offering higher precision of strip steel elongation and tension without the risk of breaking the strip steel. In addition to modernizing an existing tinning line, it can be integrated into a new tinning line, ideal for materials in DWI, SR, and DR material grades with better effect on wave, coil set, crossbow, bending, micro buckle, and internal stress, etc.

MORE INFORMATION

It is worth to mention that the unit adopts the high quality innovative multi-roller compact design. The overall assembly and installation precision is below 0.02 mm. It also provides closed-loop intermesh gap control and closed-loop crown adjustment control, applicable to any strip steel. It can carry out reliable permanent setting of various thickness to ensure an advanced flexible Tension Multi Roll Leveler process with high efficiency and low energy consumption. The Tension Multi Roll Leveler effect can be increased by 50 %.”

The unique features and advantages of REDEX Tension Multi Roll Leveler has extensively been proven in a long term in applications at large steel mills such as ArcelorMittal, U.S. Steel, ThyssenKrupp, Tata Steel, POSCO, CSN…

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Easy and fast installation. REDEX Tension Multi Roll Leveler result exceeds expectation Since the tinning’s lines are required to run around the clock, the time for equipment delivery, installation and commissioning must be minimized.

“At this point, our strengths were fully reflected. Under normal circumstances, the installation and commissioning would take two to three weeks. Our product was preassembled in the factory prior to delivery, requiring no onsite assembly. To ensure a successful acceptance, we also sent three French engineers to the work site.

As the result, it took only 8 days to complete the entire process of installation, commissioning and production nearly half a month ahead of the schedule, Mr. Jiang Ling added, “Baosteel held very high standard for acceptance.

They ran all products once before reviewing for acceptance.”

On the other hand, the feedbacks from Baosteel after two years of using the REDEX Tension Multi Roll Leveler indicate that: the improvement of strip shape performance (especially DR plate) is obvious; secondly, the operating speed is very stable with good coating result; the stable and failure free operation ensures the 7/24continuous production. In addition, the values fully meet the assessment for continuous production (e.g. the wave IU is improved from 100 to 4 and the longitudinal C-warp is reduced from

NEWS

It was the first time for REDEX to work with Yaskawa Electric Corporation, a Japanese funded company to complete the modification of Baosteel 1420 cold rolling No. 2 tinplating units (C217) and eventually realize the full automation of the operation.

the previous 50 mm-15 mm to the current 20 mm-10 mm), showing clearly technological advantages.

Establishing the New Standard in the Industry.

Empowering the Steel Manufacturers to Expand Their International Presence According to Mr. Jiang, for the past 5 years, REDEX Tension Multi Roll Leveler has dominated the tinplating application market with No. 1 market share. The cooperation with Baosteel allows REDEX Tension Multi Roll Leveler to be used on the tinplating production line in China for the first time.

It has helped Baosteel in solving the mass production issue of their tinning line and set a new benchmark for industry development.

MORE INFORMATION

With the growing domestic demand for high-end food packaging, beverage, packaging, medical and chemical packaging, the tin plating production line is deemed to gradually take over the place of the traditional aluminum lines. When the time comes, suppliers with the technologies of advanced tinplating units and supporting equipment such as REDEX Tension Multi Roll Leveler will be one step ahead in the international market competition and in a position to pursue for further development. www.redex-group.com

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MECHANICS

KENNAMETAL INTRODUCES ITS MILL 4-12KT, THE NEXT GENERATION OF TANGENTIAL SHOULDER MILLING

Mill 4-12KT has tangentially mounted inserts with four cutting edges per insert for reduced tooling costs.

New tangential shoulder mill features an innovative triangular-shaped margin design providing cutting edges with exceptional strength.

K

ennametal today announced its new Mill 4-12KT, the next generation of tangential shoulder mills, producing high quality floor surface finishes for nearly all steel and cast iron applications.

“The Mill 4-12KT uses15% lower cutting forces, an important consideration with today’s lighter duty, 40-taper machine tools,” said Tim Marshall, Senior Global Product Manager.

“That allows customers to feed faster without putting additional stress on the spindle. And in long overhang situations or where the part fixturing is less than optimal, lower forces equate to less chatter, reduced edge chipping, and smoother surface finishes.”

MORE INFORMATION

Mill 4-12KT has tangentially mounted inserts with four cutting edges per insert for reduced tooling costs. Seven corner radii from 0.016” (0.4 mm) to 0.122” (3.1 mm) are available, along with coolant-through, medium and coarse pitch cutter bodies 2” (50mm) to 8” (200mm) in diameter.

With an axial depth of cut range from 0.019” to 0.472” (0.5 to 12mm), Mill 4-12KT covers most shoulder milling applications.

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Multiple factors contribute to significant performance increases, even in aggressive cutting conditions: The tangential, “on-edge” insert design also allows the insert to take advantage of the strength of the carbide thickness more so than radially mounted inserts found on traditional milling cutters.

A shallow pocket design, allows the core size of the cutter body to be very robust. The axial and radial seating surface designs provide exceptional stability.

The Mill 4-12KT is the perfect complement to Kennametal’s existing shoulder milling portfolio. This includes the Mill 4-11 and Mill 4-15, cutters known for their ability to generate shoulders with high quality wall surface finishes. www.kennametal.com

NEWS

The innovative triangular-shaped margin provides cutting edges with exceptional strength.

Mill 4-12KT cutter bodies are available in medium and coarse pitch.

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MECHANICS

TOOLHOLDERS PINPOINT COOLANT AND ELIMINATE TURNING OPERATION INTERFERENCE

Coolant-through tooling components and connectors that interfere with grooving, parting off and other turning operations become a thing of the past with the new additions to JETI (Jetstream Integrated) tooling from Seco Tools.

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xpansions to the range of MDT (Multi-Directional Turning), X4 (grooving and parting off ) and 150.10 (parting-off ) tool holders offer interference-free internal coolant capabilities and the choice to switch the underside stream channel on and off as the application requires.

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Jetstream Tooling® provides operational stability, reliability and improved surface finishes as well as application flexibility and the productive convenience of coolant delivery without external hoses, fittings and spare parts that can diminish productivity and raise costs.

Square-shanked MDT, X4 and 150.10 holders are available in 20 mm x 20 mm (0.787" x 0.787") and 25 mm x 25 mm (0.984" x 0.984") sizes. MDT holders accept inserts in 2, 3, 4, 5, 6 and 8 mm (0.0787", 0.118", 0.157", 0.197", 0.236" and 0.315").

105.10 holders accept 15-size blades.

For optimized machining, chip control and process reliability, Jetstream Tooling® aims high-pressure coolant directly into the cutting zone through internal channels in the toolholder.

Unlike other tool holders, Jetstream Tooling® Duo provides upper and lower cooling channels with the ability to switch the underside stream channel on and off as needed. With coolant connections on the side and back of these holders, they also function on machines with conventional coolant supplies. www.secotools.com

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OPTIMIZE YOUR INTERNATIONAL PR AND ADVERTISING FOR THE INDUSTRIAL MARKET!

International capability

Outstanding results

Optimized process

More than 100 employees in 35 different countries, ensuring a strong relationship with main local media. Mepax distinguishes itself through its extensive media knowledge and ability to select the best international online/print advertising options. PR can be translated into 35 languages.

35,000 published articles in 2018: EMEA: 48% - Asia: 31% - Americas: 21%. Most of the articles are published in the top 1000 media worldwide.

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

We have developed in house the most advanced PR dedicated ERP, enabling transparency and real-time full online reporting. International media management is then made easy, fast, and efficient for optimal results.

www.mepax.com info@mepax.com

THE MOST INNOVATIVE PR AGENCY

@mepaxIntPR

PLANT SAFETY

EFFICIENT AND PROCESSCONTROLLED ACCESS GUARDING WITHOUT MUTING SENSORS

Innovative strength, a down-to-earth culture and strong commitment are the values that have made WITRON – based in the Upper Palatinate region of Germany – the company that it is today: worldwide one of the market leaders in the planning and realization of highly dynamic warehouse and order picking systems in the field of intralogistics.

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ITRON is constantly working on developing even better, even more cost-efficient logistics solutions for its customers, to make them even more successful. In the area of automation and further optimization of warehouse logistics, the selection of suitable, competent and innovative partners also plays a decisive role for WITRON.

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WITRON relies on creative solutions from Leuze electronic not only in its own production and warehouse logistics.

The company also realizes efficient safety solutions for its customers together with optical sensor manufacturer Leuze electronic. This includes the use of “Smart Process Gating” (SPG), a process developed by Leuze electronic that enables access guarding with material transport to be designed more compactly, simpler and safer.

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Safety first When man and machine meet in a technical environment, it must be possible to stop machine and system parts within a fraction of a second. “The safety of all persons who work in one of the many logistics centers of our customers around the world – whether in industry, retail or service – is the asset most worthy of protection,” explains Stephan Schmid, experienced project engineer in the area of development and control technology at WITRON. This means: appropriate areas are equipped by WITRON with safety devices or fencing that meets the applicable standards and norms so as to eliminate accident risk before it can even occur.

But because it is not possible to completely fence in all areas in which man and machine meet in a networked, mechanised system, WITRON is working on, e.g., conveyor lines with safety light curtains. These must reliably distinguish between people and merchandise.

NEWS

Josef Apfelbeck, Leuze electronic (l) and Stephan Schmid, WITRON (r) have collaborated for many years.

Smart Process Gating - the advantages at a glance • Extremely compact, space-saving system design, since there is no need to make space for muting sensors in front/behind the light curtain.

• Outstanding reliability and availability of the safety device and low installation and service costs at the same time (no set-up alignment, no realignment of muting sensors).

• Easy handling and operation for personnel.

• Even interrupted parts and pallets with distances between loading are reliably transported.

Process-controlled access guarding in intralogistics.

The classic safety solution Especially in intralogistics and in the automotive and packaging industries, affected areas must be safeguarded by optical safety sensors. To unambiguously recognize transported goods as they approach a protective field and to bridge this for passage of the goods at the proper time, muting processes with signal-emitting muting sensors were used across the industry in the past. These sensors were installed in addition to the safety light curtains and enabled pallets and transported goods to move in and out without interruption. In front of and behind the safety light curtain, however, quarters are usually a bit tight. The additional use of bridging sensors often required more space, leading to an even less-compact system design. The installation and service effort for the additional set-up, alignment and realignment of these sensors also resulted in additional work.

“This led WITRON to search for a solution that combines process reliability, system availability and easier operation with one another,” explains Schmid.

WITRON on its test tracks in its company headquarters in Parkstein in the Upper Palatinate region where it was optimized together in detail. “The result is impressive: a clever solution was created that combines the requirements for safety at work with high process reliability and system availability,” explains Josef Apfelbeck, key account manager and specialist for intralogistics at Leuze electronic.

Muting reinvented At that time, Leuze electronic did not yet have a practical answer to this requirement, but did already have a project idea: “Smart Process Gating” – based on its MLC safety light curtains. Leuze electronic presented this to its key customer WITRON in a very early development phase. WITRON was quickly convinced of this idea and accompanied the creative Leuze development in numerous practical tests. “Smart Process Gating” was then put through its paces at and by

With SPG, the first muting signal comes from the process control (PLC), while the second muting signal is generated by the protective field itself. Smart Process Gating requires a controlled material flow so that the necessary PLC control signals are made available in the expected time window.

The MLC 530 safety light curtain variant with Smart Process Gating is TÜV-certified for safety.

With “Smart Process Gating” a new process was created that enables muting processes to be executed more easily, more compactly and more stably. With the SPG principle developed on the basis of its MLC safety light curtains, it is possible to completely forego the previously necessary signal-emitting sensors. Conveyor systems can thus be made more compact. During the operating phase, the risk of misalignment or damage to the sensors is also eliminated as are the costs for their maintenance and servicing. The availability of the entire safety device is thereby increased and other practically oriented risks reduced.

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NEWS

Process-controlled access guarding in the packaging industry.

In combination with a standard control, a performance level PL d can be achieved, which is sufficient for many applications in intralogistics. With a safety control, performance level PL e is also achievable.

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Nothing is possible without Leuze electronic and WITRON are linked by a long-standing customer-supplier relationship that goes back to the early 90s and is based on a trustworthy collaboration with mutual respect. “Many hours of hard development work, joint project planning, discussions, testing on the material locks of test conveyor lines with WITRON as a strong partner at our side have led to an impressive result,” says Apfelbeck proudly. Schmid explains: “Attractive for WITRON are, above all, the stability and high availability of the safety device – all with less work. This is confirmed by our on-site teams and by our customers alike.” Since the fall of 2016, WITRON has used Smart Process Gating and this new technology as a standard solution in all of its projects worldwide – in both the retail sector as well as in industry and the service field. Systems designed by WITRON with SPG as safety devices can now be found in France as well as in Norway or the USA. Like everything that leaves the factory in the Upper Palatinate destined for end customers, the safety modules were tested on the test track in Parkstein by WITRON. WITRON also uses “Smart Process Gating” for its own internal training purposes as well as other sensor solutions from Leuze electronic: whether AMS measuring sensors in WITRON's high-bay 30 | Industry Asia Pacific | July 2019

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warehouse or the BCL 300 bar code reader for identifying codes. A recent addition in the area of high-bay storage devices at WITRON is the Leuze DDLS 500 data transmission photoelectric sensor with EtherCAT interface. “Nothing leaves our factory before we have thoroughly tested a new component or new technology ourselves. We only recommend solutions to our customers that have proven themselves in practical tests – that's our philosophy,” says Schmid: “The Smart Process Gating principle also had to withstand a number of hardness tests. Today, it convinces us on all counts and is used as a standard solution in projects with material flow.”

2019 GIT Security Award for SPG Not only WITRON and Leuze electronic as the inventor of Smart Process Gating swear by the new SPG technology. A jury of experts with representatives from BHE, TÜV, VDMA, ZVEI, integrators and users voted “Smart Process Gating” to the top 10 of the 2019 GIT Security Award. Readers of the GIT Sicherheit, GIT Security and messtech drives Automation trade magazines and their online communities even chose the SPG muting process, which completely forgoes the need for signal-emitting sensors, as the gold winner of the award, thereby also nominating it for the “Best of Industry Award 2019.” www.smart-sensor-business.com www.leuze.com

TRACEABILIT Y

SIC MARKING CONTINUES TO GROW INTERNATIONALLY!

SIC Marking is pleased to announce the acquisition of ZANIBONI s.r.l (Italy). The new name for the company will be SIC ZANIBONI. true experts in the design and manufacture of tailor-made marking and laser traceability solutions. We are now looking forward to starting our collaboration to be able to propose new offers and services to our Italian customers and then to the world” says Jean-Manuel PAUCHET, General Manager at SIC Marking.

As early as 1994, Zaniboni began introducing laser technology into its marking and traceability solutions, becoming so, a pioneer in the integration of this technology.

Mr. Zaniboni (CEO at SIC Zaniboni) states: “In order to ensure our future growth, it was essential for us to join an international group specialized in marking and industrial traceability and was complementary in terms of offer. The choice of SIC Marking seemed obvious to us. What attracted us was their capacity for innovation, their customercentric culture, the wide services portfolio, and finally their international footprint. The fact that SIC Marking has gone for growth for several years has also been a factor of decision because it is not the result of chance and is obviously due to talented people”

In over 40 years, Zaniboni has succeeded not only in establishing itself as a reference in Italy and internationally, but also in establishing strategic partnerships with international groups such as SKF, for which it has delivered several hundred solutions around the world.

New ambitions in Italy (and elsewhere!)

“We are very satisfied with this new acquisition in Italy. It will allow us to strengthen our position not only in Italy, where we will now have around thirty people, but also in several key accounts and internationally. I must say that we were very impressed by the Zaniboni teams’ know-how. They are

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An expert in tailor-made laser marking and traceability solutions Established in 1977, ZANIBONI is located near Turin. The company is specialized in design, manufacture and sale of customized marking and laser traceability solutions for the automotive and mechanical sectors.

www.sic-marking.com

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PLANT SAFETY

“SAFETY AT WORK – HOW CAN MACHINE TOOLS AND SYSTEMS OPERATE SAFELY AND EFFICIENTLY?”

Safety function and high-quality measurement data output in one device.

For a while now, sensors are not only a matter of process control – today one of their primary tasks is to link processes together. With its extensive range of Safety@work products, Leuze electronic optimizes collaboration between man and machine: sensor and control systems, like those of the RSL 400 safety laser scanner, can be integrated intelligently into the processes performed by machines and safeguard these machines in a reliable and tamperproof manner. At the same time, the processes are structured efficiently and cost-effectively.

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Machining work pieces In machining centers, parts of various materials are machined, turned, and drilled. The prerequisite for processing work pieces in complex machining centers with a high degree of precision is having the right tool available for each work step. In addition to checking whether the tool is present and identifying it, the drill or milling cutter must also be monitored for tool breakage. Inductive switches or camera-based code readers clearly identify whether the correct tool is mounted for the respective processing step.

Focused laser photoelectric sensors can – thanks to their very small light spot – reliably check whether even the smallest drills or milling cutters are intact.

Increased level of automation Industrial robots, which can perform a large number of swivel and gripping movements in a very short period of time, are often used for automated loading and unloading of machine tools. Their movement zones must be reliably protected against access over a large area. Before a robot picks up a part, the part must be uniquely identified to ensure that the correct processing step is carried out. This is done using the DCR 200i camera-based code reader. The DCR 200i is a reader used to detect and identify Data Matrix codes. The fast imager, integrated high-performance LED illumination, as well as high resolution in combination with a very high depth of field guarantee reliable decoding, even with fast processes and high object speeds.

Safety-related monitoring of machines and systems Safety laser scanners such as the RSL 400 from Leuze electronic are used for the safety-related monitoring of areas in and around machines and systems. A maximum

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NEWS

RSL 400 safety laser scanner.

Complete safeguarding of two stations with just one safety laser scanner.

operating range, robust operation and simple handling are crucial here. The simultaneous monitoring of four protective fields means the working area can be split up and the speed safely reduced.

In future, an important aspect in addition to the automated loading and unloading of machine tools will above all be the linking together of multiple machine tools in combination with automated production processes. This includes, for example, storage systems that optimize material flow, but also a wide variety of transport equipment such as linear gantries, pallet handling systems and conveyor systems, which all increase the level of automation considerably. For the safeguarding of large access points, safety laser scanners with vertical alignment of the protective field are used, e.g. to detect vehicles and persons.

A further option is safeguarding using multiple light beam safety devices. These devices provide a greater operating range and therefore an efficient solution for safeguarding access points over long distances of up to 70 meters – even “around the corner” solutions with multiple mirror columns

Different safeguarding options are available depending on the respective requirements and application. A comprehensive range of products helps in choosing the best possible solutions to ensure safety at work and also in optimizing collaboration between man and machine.

In-house logistics with automated guided vehicles (AGVs) An AGV, which moves autonomously and flexibly in space, transports blanks into the working area of the robot or machine tool. On completion of the production process, the machined work pieces are collected again.

The transportation path of the AGVs must be safeguarded with safety sensors which monitor the presence of persons and objects. An important consideration here is the flexible adaptation of the protective fields to the movement situation and the different loads. In the case of the triangulation principle, an AGV must be equipped with two different scanners. Unlike the contour navigation principle, just one scanner is needed for safeguarding and navigation. This means that safeguarding and data capture for navigation requires one single safety laser scanner. In other words, the scanner simultaneously also provides

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The RSL 400 safety laser scanner provides a solution for such applications. Its large operating range of 8.25 meters allows large areas to be monitored. With two parallel protective fields and two integrated safety-related switching outputs, only one RSL 400 safety laser scanner can also monitor two stations independently of one another.

are possible. Intelligent products such as the MLD 500 safety light curtain have an integrated laser alignment aid for timesaving and cost-effective alignment. Simple configuration by means of wiring and integrated indicator lights for status display are possible, even over long distances.

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NEWS

RSL 400 – safety-related monitoring of robot working areas.

the measurement data needed for navigation. 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. The RSL 400 safety laser scanner enables such a combined solution.

The safety laser scanner is available in various models. The extensive range of scanners from Leuze electronic includes a total of 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.

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www.leuze.com

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TRACEABILIT Y

HOW TO TURN A SMALL AND MEDIUM-SIZE COMPANY INTO AN INTERMEDIATE-SIZE ONE IN 2 YEARS?

Jean Manuel PAUCHET, Sic Marking General Manager.

SIC Marking is proud to have been chosen by Salvéo Group (www.salveo.fr) to introduce the topic “How to turn a small and medium-size company into an intermediate-size one in 2 years” at the occasion of their website and YouTube channel www.fabricantsdecroissance.com going live.

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t is an honor for SIC Marking that comes as a reward for all the daily efforts made by their teams throughout the world to be an increasingly customer-oriented and competitive player.

This success has been achieved thanks to the cultural evolution that SIC Marking has led, particularly with operational excellence practices. The goal was to place clearly the clients at the heart of processes, understanding what was prominent to them and then, progressively eliminate wastes or “Muda”. A real state of mind “Kaizen” that comes from the Japanese and means “change for the better”.

This recognition has been highlighted in a video where Jean Manuel PAUCHET, General Manager, explains what makes SIC Marking so unique on its market and gratefully praises the results of all SIC Marking’s employees. www.salveo.com www.sic-marking.co.uk

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The involvement from all in “gemba” meetings or “daily management”, both within manufacturing floor and services department, has allowed us to achieve our level of excellence.

The basis of improvement at SIC MARKING, is now driven by each of the employees, in every part of the company and every day. In addition to the operational performance aspect, the human and the teams are also a priority in our culture change.

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S M A R T FA C TO R Y

TO GET THE CASTING DIE OSCILLATING

KOLLMORGEN Frameless Direct Drive Motors.

What's new in continuous casting: SMS Concast develops actuator-driven oscillation with direct drives by KOLLMORGEN. Achieve greater quality with KBM motors while also reducing maintenance costs.

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illet, bloom, slab: Shape is given to the molten steel by the casting die in continuous casting. The casting die can be compared to a mold made of water-cooled copper in which targeted extraction of heat causes the steel to form an outer skin – at first as delicate as a raw egg. So that the freshly formed strand shell does not adhere to the copper wall during this process, the casting die oscillates along the casting plane. An oscillation mechanism helps with this. For the operation of these oscillation mechanisms, SMS Concast developed an electromotive solution with direct drive in an intensive co-engineering process with KOLLMORGEN. CONDRIVE is based on winding-optimized KBM motors – and has what it takes to revolutionize the form process in continuous casting.

In addition to this, the tensile force resulting from the movement profile must not lead to the just-formed shell being torn up again. If this were the case, molten steel would pour out into the system – leading to immediate interruption of casting and subsequent production outage.

As a rule, a sinusoidal oscillation process is employed. What is crucial for this is the time window in which the oscillating, downward-moving, casting die overtakes the steel strand which is also moving downwards, before the forming unit at the lower peak travels back up.

This overtaking process is known as “negative strip time” and defines the time in which the casting powder is able to lie on outer wall of the steel while being pulled off. The oscillating movement of the casting die requires that the fine waves form on the surface of the strand, known as oscillation marks.

Adjustable oscillation heights The ideal frequency at which the casting die should be oscillating in the continuous casting and, above all, at which amplitude, depends on factors such as the quality of the

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NEWS

KOLLMORGEN-SMS Concast, cooling chamber of a continuous casting machine.

KOLLMORGEN-SMS Concast CONDRIVE Machine.

steel, the formulation, the production speed or even the casting die form. The negative strip time typically lies in a time window between 0.08 and 0.18 seconds. “If we don't have this time, we cannot continue to cast. Then the entire mechanics fail to function – that is the friction characteristics between the copper and steel,” explains Kabosch, and he likens it to liquid chocolate cake sticking to the baking sheet and, when removed from the tin, it breaks apart. The interplay between friction force or friction coefficient and the ferrostatic pressure, which acts vertically on the inside of the casting die due to the molten steel, is fragile. “At this point, we use the direct drives by KOLLMORGEN,” explains the SMS Concast developer. The transfer of mechanical processes into a software-based Motion Control opens up possibilities of effectively implementing new movement curves and being able to very flexibly and individually adjust the movement to the differing casting conditions.

In the 118 installation size, the drives deliver torques of 660 Nm and a peak torque of 1000 Nm. The drive is thus in a position to precisely get the oscillation bulk, weighing between 3.5 and 7 tons, into oscillation. On the control side, SMS Concast also opts for KOLLMORGEN – in this case in the design of the S700 servo amplifiers.

What is unique about the production of oscillation is the fact the oscillation is not generated by a revolving eccentric shaft in a rotative continuous operation, but by the recurrent reversing motions of the motor.

What may seem simple at first glance, has brought about very demanding challenges for engineering. The constant reversing leads to questions such as how the heat loss is effectively diverted. Other questions relating to lubrication also emerge.

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The particular advantage is that the frequency, the amplitude and the wave form of the oscillation can be changed. The amplitude is crucial for distance covered within a time window. “Converting a mechanical eccentric shaft for this is only possible during shutdown and takes a long time,” notes Dino Kabosch. Also compared to hydraulic drives for oscillation, the CONDRIVE scores highly since the actuator solution does not require a hydraulic infrastructure and also comes with significantly lower maintenance costs.

Direct drive technology by KBM motors: Compact size The torque motors specially adjusted by KOLLMORGEN to the needs of this application originate from the KBM kit.

Since the motor is no longer making complete revolutions, the grease for standard lubricated-for-life bearings is inevitably suppressed by the rolling elements. The effect of the lubrication is thus no longer guaranteed.

Finally, these three basic conditions have contributed towards KOLLMORGEN equipping the KBM motor with a 30 | Industry Asia Pacific | July 2019

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SMS CONCAST CONDRIVE with KOLLMORGEN KBM frameless motors inside.

KOLLMORGEN-SMS Concast, Cut billets on the cooling bed after leaving the continuous casting machine.

water cooling system so that the heat loss can be effectively diverted. For the long-term effective lubrication of the few bearings of the gearless direct drives, stators and rotors are completely enclosed in an oil bath – which ultimately also securely protects the encapsulated unit against metal dust.

Another advantage results from the eradication of the drive – namely with an eye on continuous condition monitoring of the system and processes. By the KBM motor driving the process without the influence of disruptive gear effects such as play or friction, this ensures an extremely precise control of processes while also very directly and precisely monitoring the process due to the motor data. It is above all key motor data such as power and revolutions which allows the processes to be precisely analyzed – up to and including the incorporation into IoT systems.

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Potential for modernizations “The work has been worth it” – with regard to the findings garnered from a continuous casting machine at Swiss Steel AG, Dino Kabosch is delighted about this new oscillation process. “Two years of development have gone into this – the CONDRIVE is operating very well. Almost too well. We are still looking for faults in the mechanics, but we can't find any. It's a great feeling.”

Currently, CONDRIVE is being developed into a sought-after series product which, thanks to its simple integration and 30 | Industry Asia Pacific | July 2019

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high availability, is very well suited to the modernization of existing continuous casting machines.

Contracts in Spain, India and China mark the success of the solution with the actuator direct drive technology by KOLLMORGEN inside.

Conclusion With CONDRIVE, SMS Concast has developed a system which, due to the encapsulated direct drives from the KBM motor kit by KOLLMORGEN, is virtually maintenance-free.

The innovation offers an excellent precision for controlling the oscillation of the casting die. In contrast to the other drive systems for oscillations (including hydraulic booster cylinders), CONDRIVE combines a simple design with online settings and monitoring of the oscillation curves.

Author: Martin Zimmermann, Key Account Manager, KOLLMORGEN Svizzera www.kollmorgen.com

S M A R T FA C TO R Y

NEW 35ECS ULTRA EC BRUSHLESS MOTOR

Ultra High Speed in a Compact Package.

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reliability of a device without compromising on power and machine throughput and saving energy. The new 35ECSs are an ideal choice for applications such as battery-operated hand tools (industrial tightening devices or drills), factory automation equipment (large fans or vacuum pumps), and also for applications where there are constraints on diameter.

The new 35ECS motor is available in two lengths: the 35ECS60 and the 35ECS80. The 35ECS60 and 35ECS80 motors feature our patented Ultra EC coil technology which provides unparalleled torque and power density with limited core losses over a wide range of working speeds without friction & brush wear. These motors feature our patented high-speed rotor design as well to sustain speeds up to 40,000 rpm. The 35ECS80 is unique and opens new areas for slim/long package with impressive torque capabilities at very high speeds, while the 35ECS60 allows high speed capabilities at very low voltages. Thanks to its rugged design, the 35ECS can sustain peak torque during 2s up to 1.1Nm (35ECS60) and 2.0Nm (35ECS80).

The new 35ECS motors feature a laser welded front flange to ensure the strongest housing to sustain high torque reaction. A temperature probe on the coil head ensures an optimized control of motor performances in heavy duty applications. These motors are offered with hall sensors and a total of 6 different coils to match your speed and voltage requirements. Upon request, Portescap can also provide options for customization including gearboxes, encoders, coil variations and mechanical interface modifications.

The 35ECS motors can be adapted in most applications, including industrial applications, enhancing the life and

www.portescap.com

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ortescap is proud to announce the expansion of the Ultra EC™ range of brushless DC slotless motors with the introduction of the new 35ECS motor. This 2 pole motor offers ultra high speed and power (up to 330W, max continuous) without compromising on the smooth operation and long life you expect from Portescap’s brushless slotless motors.

Portescap is globally ISO 9001:2015 certified and our production site in India is also ISO 13485, ISO 14001:2015 and OHSAS 18001:2015 certified.

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S M A R T FA C TO R Y

NEW FREQUENCY INVERTER FROM NORD: VERSATILE, NETWORKED, POWERFUL

With the NORDAC PRO SK 500P NORD DRIVESYSTEMS has launched a state-of-the-art control cabinet inverter with the latest component technology and ultimate levels of functionality, connectivity and modularity. The inverters have an impressive number of interfaces for communication and field buses, innovative features as well as a number of extension possibilities, so that they can be easily integrated into all automation architectures.

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ith their various versions, the new frequency inverters from the NORDAC PRO family can be optimally assigned to a wide range of application requirements. The functions of the modular series can be extended by plug-in control, safety and option modules.

Users also benefit from a particularly compact design in book-size format. The slim design saves space in control cabinets and enables side-by-side installation. The inverters are available in a power range from 0.25 to 5.5 kW.

Flexible communication options This latest addition to the family carries a large number of interfaces. As well as the standard CANopen interface, a multi-chip for Industrial Ethernet enables the use of the most important real-time Ethernet standards via a single interface. Whether for ProfiNet, EtherNET IP, POWERLINK or EtherCat, the required protocol can be easily set by means of parameters. The devices can also be parameterised via the USB port without an external power supply (programming in the box). The SD card slot for saving and transferring parameters is also a novelty. In addition, five or six digital and two analog inputs, two digital and one analog outputs, two potential-free multi-function relays, an HTL/TTL incremental encoder interface as well as a universal encoder interface are available.

Intelligent and powerful As with all NORD frequency inverters, the NORDAC PRO SK 500P series is equipped with a powerful PLC for functions close to the drive. The precise current vector control can

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NEWS

The new frequency inverters from the NORDAC PRO family provide ultimate levels of functionality, connectivity and modularity.

provide the optimum torque in various load and speed situations and guarantees operational reliability with high overload reserves, which users need e.g. for starting. The inverter operates either open-loop or closed-loop and can operate both synchronous and asynchronous motors. The integrated brake chopper for 4-quadrant operation is a part of the basic equipment for the entire series, as is motor brake management, which is important, e.g. for lifting gear applications. NORD supplies the inverters with integrated STO and SS1.

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Perfect for every application The new NORD solution for control cabinet installation is available as a machine inverter (SK 500P) and as an application inverter (SK 530P and SK 550P). In contrast to the fully equipped application inverter, the machine inverter is an economically optimised device with a reduced number of interfaces, however still performs functionally demanding tasks such as integrated PLC, closed-loop control and positioning. The SK 530P also features an SD card slot, USB interface, encoder interface and the possibility of expansion via an optional SK CU5 module. On the other hand, the SK 550P is the first choice for connection to control systems via Industrial Ethernet.

Sale is expected to start in the fourth quarter of 2019. www.nord.com 30 | Industry Asia Pacific | July 2019

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S M A R T FA C TO R Y

PCVUE 12: THE OPEN, SECURE AND MOBILE SCADA/IOT PLATFORM!

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ARC Informatique is pleased to announce the release of PcVue version 12. PcVue 12 is a forward-looking software solution that provides an open and scalable platform. Built on the latest technologies, it features an innovative web and mobile HTML5 platform based on the EasyMobileTechnology, specifically developed

by ARC for secure and easy deployment. This version comes with an IoT LoRaWAN driver to aggregate data from connected things, and a new Universal Data Connector for limitless interoperability.

A solution for all mobile users WebVue, version 12’s cutting-edge HMTL5-based client, requires no installation nor configuration and allows users to navigate mimics on virtually any touch device. It provides a delightful user experience by ensuring cross-browser compatibility, secured communication with HTTPS and deployment in a context of network segregation.

Deploy a web solution in few clicks!

The EasyMobileTechnology allows you to deploy a secure platform rapidly. It is well suited for deployment of web services and web apps. Built on top of Microsoft Internet Information Server, it facilitates data protection and security for a trusted relationship between users, apps and web services.

TouchVue, the mobile application for immediate action, augments this comprehensive web and mobile offer. Users can now access data from several sites at the same time and display contextual mimics for each alarm they receive. A redesigned interface makes it for a great user experience and optimized performance.

Connect (any) things PcVue 12 introduces a new way to exchange data and unleash interoperability thanks to the Universal Connector.

This SQL bridge connects various data sources from ERP, to Azure database or even social networks among others.

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PcVue 12 extends its connectivity and opens new opportunities to integrate IoT connected objects. With a new LoRaWAN driver, PcVue 12 supports hybrid architectures using traditional automation controllers combined with IoT objects such as wireless and self-powered sensors.

NEWS

New features for vertical markets PcVue 12 includes features designed for the Energy, Industry and Transportation markets.

For Energy, improvements to the IEC61850 and IEC104 for enhancements to substation automation.

For Industry, a series of new Smart Generators to streamline configuration: - Smart Generator for Siemens allows importing the elements of a TIA portal project.

- Smart Generator for OPC automates configuration when the data source is an OPC server.

- Smart Generator for Moxa ioLogik controllers automates configuration of Moxa controllers.

Versatility is at the core of PcVue 12, with infinite capacities of deployment in web and mobile architectures. This flexible platform is designed for every type of user (System Integrators, IT/OT, end-users) and has modules tailored for many markets.

Scan this QR code to download version 12 and join the PcVue community! www.pcvuesolutions.com

For Transportation, a railways systems library including urban, main lines and stations graphics.

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User interfaces and Configuration tools PcVue 12 is continuously improved user-centric features for improved productivity of both developers and end-users.

To initialize a new project in a blink of an eye, the Quickstart application comes with 3 new styles – Industry, Web, and Dashboard – each with light and dark skins, and multiple colored themes.

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S M A R T FA C TO R Y

MITSUBISHI ELECTRIC HELPS OLIVER UPGRADE EXISTING SLICING MACHINE

Better HMI and evolution from PCBs to PLCs pave the way for new market opportunities.

“

Mitsubishi Electric HMIs are very responsive… others we tried were so much slower that you would press a button and it would take so long to work you'd be ready to press again. With Mitsubishi, you'd already be cutting.” – Vance Matz, Project Engineer, Oliver Packaging & Equipment Company

Background Oliver Packaging & Equipment Company of Grand Rapids, Michigan was founded in 1890 as a wood working equipment manufacturing company specializing in furniture production. During the Depression, the company’s expertise in blade technology prompted them to help create an entirely new industry – and, perhaps, contribute to the coining of the phrase “best thing since sliced bread” – with the introduction of the first retail bread slicing machine in 1932. More than eight decades of innovation later, Oliver offers a diverse line of high quality bread, bagel and bun slicers to retail bakeries, delis, supermarkets, restaurants, and similar establishments, primarily in the U.S. and Canada.

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Challenge Oliver’s Varislicer® 2005 bread slicing machine had been in the company’s product line since about 1990. Relying upon a proprietary printed circuit board (PCB) for control and a scrolling 2x20 character display for user communication, the product, although a common seller in some markets, had some limitations, according to Oliver project engineer Vance Matz. For example, with so little display space and capability for output, stores would often have to put up paper signs that would explain how to use the machines 30 | Industry Asia Pacific | July 2019

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NEWS • GT1055-QSBD Operator Interface Screen • FX3G-14MT/ESS Programmable Logic Controller OLIVER Product Benefits • Fast action • Clear user instructions • Detailed troubleshooting Mitsubishi Electric Value-added Advantages • Responsive HMI screen • High quality PLCs • Trusted partner

now almost self-explanatory, even for first time self-serve customers or new bakery employees. Even so, step-bystep instructions can be placed right on the clear, easy to read computer screen – a far cry, he noted, from the image quality of the scrolling dotted messages offered by the old model. Further, technicians are now getting detailed and convenient troubleshooting information right on-screen, so maintenance is much easier as well. And, adding a menu with English, Spanish and French language options was also a breeze – a big benefit for many potential retail customers both in Canada and the U.S. But, Matz noted, he feels that perhaps Mitsubishi’s most dramatic contribution to the redesign came on the speed side.

“Compared to those offered by any other supplier we looked at, Mitsubishi Electric HMIs are very responsive to the touch and very fast,” he said. “Other HMIs we tried were so much slower that you would press a button and it would take so long to work you’d be ready to press again. With Mitsubishi, you’d already be cutting.”

to cut loaves to preferred thicknesses, especially at the self-service bakeries and delis popular in Canada. And, although the machine could theoretically provide on-screen troubleshooting information to repair technicians, the details that were offered could be terse and “kind of cryptic,” leading technicians to opt for diagnostic testing when performing maintenance. So, when in early 2015, Oliver’s PCB supplier discontinued the model of board they were using, the innovative company quickly used the situation as an opportunity to rethink the design of the Varislicer 2005.

“We realized that this would be a good application for a programmable logic controller – it could offer our customers so much more functionality,” said Matz.

Solution Oliver had previously designed equipment using Mitsubishi Electric parts in both their bakery division as well as their sister meal packaging division. Well familiar with Mitsubishi Electric quality and value, they soon spec’d a Mitsubishi Electric human machine interface screen (HMI) and a PLC in their newly redesigned Varislicer 2005.

Right off the bat, he explained, the Mitsubishi Electric PLC and HMI offer huge flexibility. With a big, easy-to-read screen and large, pressable buttons, machine operation is

“Technicians used to have to do all those time consuming tests to get to the heart of any problem. Now the PLC gives them detailed indicators regarding the status of the sensors, the position of the knife arm, the door and more,” he explained. “They can get in and out of there faster – and that’s good for the retailer, and good for us.”

Also good for Oliver is the additional market opportunities that the redesigned Varislicer 2005 is creating for the company in the United States, where, Matz said, consumers tend to demand more modern, more convenient products than do their counterparts north of the border. In fact, Oliver has recently sold a number of the new Verislicer 2005 machines to a large American supermarket chain and several other customers who had not been very interested in the incumbent version.

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“The new machine is a total game changer for us – it offers a completely different level of usability than the old one,” said Matz.

Results Matz reports a number of benefits accruing to the company as a result of the redesign of the Varislicer 2005. One is the decrease in the cost of warranty service calls. Since Oliver utilizes a network of local repair contractors near to each retailer who charge them by the hour, time is, literally, money.

“Mitsubishi Electric really helped us raise the bar on this model,” he said. www.mitsubishielectric.com

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