Industry USA | 30 - April 2021 by Induportals Media Publishing

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THE ROBOT REVOLUTION IN MANUFACTURING INDUSTRY

4 ROBOMOLD PLASTIC SOLUTIONS ANNOUNCES EXCLUSIVE ROBOTIC MOLDING CAPABILITY

49 ARCS FOR INCREASED OPERATIONAL CERTAINTY IN EMERGENCY SHUT DOWN SITUATIONS

TECHMAN ROBOT SUCCESSFULLY ENTERED THE SUPPLY CHAIN OF MAJOR EUROPEAN AND JAPANESE CAR MANUFACTURERS

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EMERSON INDUSTRIAL AUTOMATION

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14 WEAV3D

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DUNKER MOTOREN

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ACS MOTION CONTROL

SOFTING INDUSTRIAL AUTOMATION

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32 ZS-HANDLING

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CURTISS WRIGHT

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ROBOMOLD PLASTIC SOLUTIONS

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MARKET OVERVIEW English version

THE ROBOT REVOLUTION IN MANUFACTURING INDUSTRY In a short span of 60 years, robots have revolutionised manufacturing and emerged as game changers in industry.

he term “robot”, with Slavic roots denoting labour, was first used in 1920 by Czech writer Karel Čapek in a play about a factory making artificial humans for work. But even before the term was coined, the concept has fascinated human beings from ancient times, with various civilisations exploring the idea of mechanised human forms as servants and companions. Leonardo da Vinci’s Mechanical Knight from the Renaissance period was perhaps the best representation of this effort. The quest gained momentum with the advent of the First Industrial Revolution in the latter half of the 18th Century, when mechanisation actually began replacing human labour. The honour for designing the first modern programmable robot however goes to George Devol, an American inventor who designed a programmable mechanical arm, later called the Unimate. Devol worked to refine this further with Joseph Engelberger, his contemporary and fellow inventor, who is today acknowledged as the “Father of Robotics”. The Unimate was an autonomous, pre-programmed robot designed to perform a task repeatedly. It was first installed in 1961 by General Motors at its factory to move pieces of hot metal. There was no looking back, as the cliché goes, and the evolution of the modern industrial robot truly began.

A sketch of the Unimate designed by George Devol. Image Source: Wikipedia

30 | Industry USA | April 2021

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ABB’s innovative new PixelPaint solution. Image Source: ABB

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An example of robots deployed in Smart Production. Image Source: KUKA Robots

In a short span of 60 years, robots have revolutionised manufacturing and emerged as game changers in industry. Today technologically advanced companies and countries are maintaining their edge over the less robotically inclined, with dramatic results. According to the World Robotics 2020 Industrial Robots report released by the International Federation of Robotics (IFR), a record of 2.7 million industrial robots are operating in factories around the world. The average robot density in the manufacturing industry today has hit a new global record of 113 units per 10,000 employees. The world’s top 10 most automated countries (in descending order) are: Singapore, South Korea, Japan, Germany, Sweden, Denmark, Hong Kong, Taiwan, USA and Belgium and Luxemburg. The fact that all these countries are known for their technological

THE GROWING POPULARITY OF ROBOTS There is no single factor behind the increasing adoption of robots in manufacturing. The most common advantages of robots over their human counterparts are by now too well known – speed, precision and accuracy, besides the ability to operate in hazardous locations. Robots do not get tired, do not make mistakes and do not report sick or need

Michael Otto

Chris Hazlewood

Ralf Winkelmann

Chief Sales Officer of KUKA Robotics

Chief Editor, Factory Automation Promotion Group at Mitsubishi Electric

Managing Director of FANUC Deutschland GmbH

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prowess is no coincidence. Singapore has the highest robot density in the world with 918 units per 10,000 employees. China, with robot density of 187, is the fastest growing market, while Japan (robot density 364) is the largest manufacturer of industrial robots accounting for 47% of global production.

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vacations. Together, these attributes have worked well in increasing production efficiency manifold, while at the same time reducing costs significantly. “There are a lot of things all converging at the same time to create a ‘perfect wind’ for the growing acceptance of robotics. It starts with the internet age and netizens wanting more product choice and shorter delivery periods. This drives the need for faster response from manufacturers but also the need to ensure there are no lapses in quality, and robots are a natural choice to solve both points,” says Chris Hazlewood, Chief Editor, Factory Automation Promotion Group at Mitsubishi Electric. “In parallel, there has been a major expansion of potential robot applications. No longer are robots restricted to an isolated cell to perform highspeed processes, robots and humans are now working side by side. This has been made possible because many of the understandable human safety issues are resolved through new collaborative robot concepts, the use of AI vision systems to make adaptive path decisions and protective solutions like ‘soft skins’ around the robots – all of these innovations reduce the fear factors, increase the usability and speed up the adoption. And finally, there is the realisation in many countries that there are concerns about the future available workforce as the population ages and skills are potentially lost, so again robots are a natural solution to this,” Chris elaborates. Mitsubishi Electric’s line of industrial robots offers high performance and reliability to address demanding applications across many industries.

“Robots offer numerous advantages. They are predestined for repetitive tasks because they work with the highest precision and around the clock without getting tired. They give people the time to tackle more demanding tasks. They compensate for the lack of skilled workers. In times of crisis, these advantages come into their own, also because a lot of thought is given to new applications,” says Michael Otto, Chief Sales Officer of KUKA Robotics, the world’s leading provider of production systems in the automotive industry. The company, part of the Midea Group, is the third-largest manufacturer of robots in the world. Its KR QUANTEC series perhaps has the widest load range spanning from 90 kg up to 300 kg with a reach of up to 3100 mm, with applications across industry segments. However, in other ranges, the company has industrial robots with up to 1000 kg capacity. This is also true of other major OEMs in the segment. THE LARGEST USER INDUSTRY The automotive industry, which was the first to adopt assembly line production in 1913 with the Ford Model T, is also the largest user of automation and robotics today. Close to a third of all industrial robots are used in the automotive industry. A recent IFR report highlights this fact clearly. For example, Germany has a robot density of 346 for general industries, but its automotive industry has a robot density of 1,311. Similar proportion is reflected in the statistics for the US and Japan, the two other leading automobile

Integration of machines with robotics presents a unique opportunity. Image Source: Mitsubishi Electric

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MARKET OVERVIEW

manufacturers, and China is catching up fast. Other than assembly operations, robots in automobile industry are deployed for critical tasks like welding/gluing, painting, machine tending, material handling, pick and place, etc. The auto components industry is also a major user of robots in machine tending and parts transfer operations. At the China International Industry Fair in late 2020, ABB showcased several intelligent products and technologies for the automotive industry, including automotive electronics assembly, quality inspection and an innovative new PixelPaint solution. This uses an inkjet to eliminate overspray, enabling two-tone paint and individual designs to be applied in one pass, without masking and de-masking, making customised painting 50 per cent faster and more sustainable. For the record, ABB is the world’s largest manufacturer of industrial robots with a very wide range of models and applications, and the largest installed base of any robotics manufacturer. Other industry segments that use robots extensively include electricals and electronics; white goods and appliances, metal and machinery; plastic and chemicals; and food & beverages. As for applications, packaging and palletisation is one of the major areas for use of industrial robots, as are material handling and warehousing. Robots today are not just automated mechanical devices but also rapidly gaining capabilities with increasing use of many types of sensors, especially machine vision. This, coupled with artificial intelligence and machine learning, are adding more critical applications in various other industries and processes, like the healthcare sector. ADAPTING TO CHANGE With the impending electrification of automobiles, one major concern is how will the rising popularity of Electric Vehicles impact use of robots in automotive industry, which is one of the largest users? This is especially relevant because EVs have fewer parts and assemblies, and hence are expected to cause a significant change in the process of automobile manufacturing. All major automotive companies today offer the EV option, or are in the process of launching one. That the future of mobility is electric, is now evident going by the emerging trends. But robots will remain on the shop floor even as the industry goes green with EVs, since the automobile industry is now more than ever reliant on advanced manufacturing technologies. This is best illustrated by how automation specialist and industrial robot manufacturer FANUC supports Volkswagen in the expansion of future-oriented drive technologies. In September 2020, the company announced it is supplying a total of around 1,400 robots to the VW plants in Emden, Germany, and Chattanooga, USA. The FANUC robots will be used in body shop and battery production.“The demands on robot technology have changed due to the construction of electric vehicles,” says Ralf Winkelmann, Managing Director of FANUC Deutschland GmbH. “Thanks to our wide range

30 | Industry USA | April 2021

Comau robots are integrated in the different phases of the New 500. Image Source: Comau

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of products, we can react to them reliably and flexibly.” The VW site in Emden is currently being transformed into one of the most modern locations in the automotive industry. From 2022, more than 800 FANUC robots will produce a new generation of VW e-vehicles there. The plant in Chattanooga will be expanded to become the centre of VW’s production of e-vehicles in North America. Starting in 2022, Chattanooga will employ approximately 600 additional FANUC robots. As the world’s fourth largest manufacturer, FANUC, also a strategic partner of BMW, offers more than 100 robot models, the widest range of industrial robots with a payload ranging from 0.5kg-2300k, for any application or industry. Italian industrial automation company Comau, with its wide range of industrial robots, has provided FCA and the Fiat brand with advanced automation solutions for the development of its first fully electric vehicle, the New 500. A total of 187 Comau robots are integrated in the different phases of the car manufacturing process, thanks to the collaboration of a team of Comau experts who worked side-by-side the automaker’s designers to optimise the work lines for Smart Manufacturing. Each robot has been fully equipped by Comau to efficiently carry out all the special processes an electric car requires – from custom-designed handling systems and grippers to a special 3D printed endeffector for moving body components. Comau has also integrated the lines with advanced vision systems to control the quality of the adhesive dispensing system, both during processing and at the end of the cycle. In order to optimise and speed-up inline tool changes, an articulated magazine system was designed to provide the robots with the different types of tools required to perform each application in a fast and easy way. Says Andrew Lloyd, Chief Operating Officer – Electrification of Comau: “Our experience and global leadership in the industrial sector, together with the skills gained in the field of electrification and digitalisation, support the creation of highly innovative, flexible and tailor-made technological solutions. This approach allows Comau to develop projects that look to the future of mobility and renewable energy sources, such as the New 500 full electric, thus responding to the needs of an industrial system in continuous evolution and the demands of an end consumer increasingly attentive to sustainability.” “When you think of the automotive industry and robotic use you probably imagine big robots lifting and welding panels or applying the painting processes that give the car its impressive finish. Actually, robots are used on multiple other areas from haptic testing of the drivers’ console, through to assembly of multiple subcomponents and electronics. In our showroom in Akihabara, Tokyo we even demonstrate the assembly of the in-car entertainment system, by robots,” says Chris Hazlewood. “Furthermore, I saw recently a very innovative use of robots to change car tyres in a shorter time and with recordable security that each wheel, nut and tyre have been correctly installed. The reason I relate these examples is each of these applications will still remain regardless if it is a fossil fuel engine or an EV. In addition, I also think these examples illustrate just

FANUC robots will be used in body shop for Volkwagen EVs. Image Source: FANUC

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EUROPEAN CHARTER FOR ROBOTS AND HUMANS The European charter for robots and humans working together has been officially released by the European Engineering Industries Association (EUnited) earlier this year. The document defines 10 focus areas to shape the future of work. The charter supports the UNITED NATIONS Sustainable Development Goals (SDGs) for 2030. “The transition to an increasingly automated and data driven economy requires changes in work arrangements that need to be adjusted by employers, their workers and government,” says Nobel Prize laureate, Sir Christopher Pissarides, Co-Chair at the Institute for the Future of Work (IFOW). “Industry can help by ensuring that their workers are equipped with the skills and knowledge to thrive in the new economy.” Focus area one puts the human in the centre: The charter wants robots to relieve workers of the dull and lowinteraction work that is not well suited for human nature employees should work like humans and not like machines.

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Focus area two makes it clear that robots must assist humans, not the other way around. Therefore, the European robotics industry advocates a “human-in-command approach”. The other focus areas deal with skills development, human-robot collaboration, the ease of machine use, initiatives especially for young people and strategies tackling demographic change. “2.7 million industrial robots in use worldwide and the increasing use of service robots outside factories rapidly change the way we work,” says EUnited Robotics Chairman, Wilfried Eberhardt. “To actively manage this transition, the European robotics industry has developed the ’Good Work Charter’ and identified 10 focus areas that we need to address now. It is essential to understand that humans will always play a central role in the workplace.” Released by Engineering Association EUnited, the European Charter for robots and humans uts the human in the centre.

MARKET OVERVIEW

how innovative automotive manufacturers are at utilising automation to gain production flexibility and advantage. It’s a trend I don’t see changing and if anything, accelerating as robots may gain new tasks in the building of electrical motors, installation of battery systems, etc.,” adds Chris. WHAT ARE THE FUTURE TRENDS FOR ROBOTS? In the next ten years, more and more people around the world will be working with robots. Automation is becoming mainstream and is finding its way into more and more areas. “Our mission by 2030 is: Automation will be simpler, more intuitive, and thus available to everyone. This will lower the entry threshold. Programming a robot will then be as easy as working on a PC today,” says Peter Mohnen, CEO KUKA Group. According to Mohnen, the increasing width of applications is evident in other industries: “After the coronavirus pandemic, there will be a real push towards more automation, especially in logistics and healthcare, which will have a major impact in the medium term.” Easy access to robotics is KUKA’s ambitious goal – and the company will present the first elements of a preview of an operating system of the future at the Hannover Messe 2021 Digital Edition. Because therein lies the key: simple operation and intuitive handling of automation solutions, which until now have often been reserved for experts.

“Robots will become smarter, more connected, more mobile and more ‘normal’. They will become an ever increasingly familiar sight not only in manufacturing but in our everyday life, from shelf management in the supermarket, to hotel concierge functions and even serving your coffee. Many of these activities are being pioneered now but will mature and become more widespread in the world of tomorrow,” says Chris Hazlewood. Referring to the role of artificial intelligence and machine learning, he adds, “AI and ML will not be something unusual or to be feared, but a background function that enables and supports. Customers will not be looking to buy an AI enabled device but to buy a smart device to fulfil specific tasks.” Conclusion The global economic crisis in the wake of Covid-19 pandemic is expected to shape industrial robot sales in 2021. The 2020 sales of industrial robots were impacted marginally due to the crisis, which is a temporary phenomenon. Digitalisation has unleashed the next wave of automation with emerging technologies helping robots to become even more agile and versatile. The Covid-19 pandemic has also brought home the need for more autonomous factory operations in future, and hence the long-term prospects for industrial robots remain excellent.

“Smart robotics and automation are vital to deal with new consumer trends, demand for product variety or challenges from trade barriers,”says Dr Susanne Bieller, General Secretary of the IFR. “New technological solutions pave the way for more flexibility in production.” Simplification, Collaboration and Digitalisation are key drivers that will benefit robot implementation. Programming and installation of robots has become much easier with digital sensors combined with smart software that allow direct teaching methods, the so-called “Programming by Demonstration”. The task that the robot arm is to perform is first executed by a human. The human operator literally takes the robot arm and hand guides it through the movements. This data is then transformed by the software into the digital program of the robot arm. According to the IFR, in future, machine learning tools will further enable robots to learn by trial-anderror or by video demonstrations and self-optimise their movements. In fact programming of robots is becoming easier across the OEMs. ABB has launched its Wizard Easy Programming software for its IRB 1100 industrial robot, allowing first time users to introduce robotic automation into their production lines without the need for specialist programming skills or any knowledge of RAPID code. “There is a growing demand from industry for robots that can be programmed easily for a wide range of tasks, which is why ABB is expanding the capability of Wizard Easy Programming to support small industrial robots starting with the IRB 1100,” said Antti Matinlauri, Head of Product Management for ABB Robotics. “People have become accustomed to the easy user interfaces in smartphones and other consumer technology. Our Wizard Easy Programming tool uses this concept to take the effort out of programming industrial robots and brings us a step closer to enabling anyone and everyone to use robotics.” 30 | Industry USA | April 2021

S M A R T FA C TO R Y

MONTH’S PRODUCT

EMERSON INTRODUCES ADVANCED REDUNDANT CONTROL SYSTEM (ARCS) FOR INCREASED OPERATIONAL CERTAINTY IN EMERGENCY SHUT DOWN SITUATIONS

ARCS is the only safety system in the industry with individual valve isolation for online maintenance without process interruption.

merson has released its ASCO 141 Series Advanced Redundant Control System (ARCS) to provide a redundant solution for a variety of emergency shutdown valve applications, such as those found in the chemical, power, oil and gas industries. Available globally, it includes various redundant solenoid configurations to enhance the reliability of the process and meet specific safety or reliability requirements in automation processes. The single inlet/single outlet design provides a streamlined installation process compared to traditional bypass systems, while almost eliminating potential failure points.

The ASCO 141 series ARCS is designed for use as a component in safety instrumented systems. Utilizing 1oo2, 2oo2 or 2oo3 voting solenoids to enhance the reliability of the circuit, it functions as a redundant pneumatics tripping device to control the pilot air signal to a process valve actuator. The ARCS features either two or four electrically actuated solenoid valves, visual indicators and a manually controlled bypass or isolation valve. The unique control functionality allows for maintenance of the solenoid valves without having to shut down the process valve. In fact, the use of the maintenance bypass or isolation valve is not required for functional testing of the ARCS unit — a downtime-reducing feature not possible with common bypass functions.

MORE INFORMATION

“By addressing the concerns common with typical bypass systems — particularly those in critical or emergency shutdown applications — our ASCO 141 series ARCS provides a reliable, time-saving alternative,” said vice president of global marketing for Emerson’s industrial automation business, Erik VanLaningham. “Although the use of a common bypass is a typical solution, the end-user doesn’t know if they’ll be able to shut down on demand in the event of an emergency because their redundant system is in bypass mode. This is where our unique ARCS value 30 | Industry USA | April 2021

proposition comes in. The ARCS individual valve isolation option provides increased safety and operational availability during online maintenance to help customers achieve their required SIL rating.” With just a single part number, the ASCO 141 series ARCS features several advances that simplify specification, installation and operation. Supplied as a fully integrated, comprehensive solution using a manifold instead of individual valves, ARCS comes pre-tested from the factory and ready to install. The direct valve-to-valve design eliminates pipework and fittings between the solenoid valves and minimizes leak points for increased reliability and a lower total cost of ownership. A status indicator with feedback helps facilitate preventive maintenance while providing online fault detection. It provides digital input feedback (via pressure switches or Emerson-exclusive GO Switch options) to the control room. And for additional peace of mind, the ASCO 327 series 3/2-way direct acting solenoid valves included on the ARCS manifold are certified to SIL 3 capable (exida) standards. MORE INFORMATION

A direct-acting platform with advanced diagnostic capability and online maintenance features, ARCS is suitable for a wide variety of valve piloting applications to meet both safety and operational availability requirements. www.emerson.com/en-us/catalog/asco-arcs 30 | Industry USA | April 2021

INTERVIEW

’ROBOTS WILL BECOME SMARTER, MORE CONNECTED, AND MORE MOBILE’

Chris Hazlewood, Chief Editor, Factory Automation Promotion Group at Mitsubishi Electric.

Mitsubishi Electric has proven expertise in robotic solutions. What are the factors contributing to the growing popularity of robots? There are a lot of things all converging at the same time to create a ’perfect wind’ for the growing acceptance of robotics. It starts with the internet age and netizens wanting more product choice and shorter delivery periods. This drives the need for faster response from manufacturers but also the need to ensure there are no lapses in quality, and robots are a natural choice to solve both points. In parallel, there has been a major expansion of potential robot applications. No longer are robots restricted to an isolated cell to perform high-speed processes, robots and humans are now working side by side. This has been made possible because many of the understandable human safety issues are resolved through new collaborative robot concepts, the use of AI vision systems to make adaptive path decisions and protective solutions like ’soft skins’ around the robots – all of these innovations reduce the fear factors, increase the usability and speed up the adoption. And finally, there is the realisation in many countries that there are concerns about the future available workforce as the population ages and skills are potentially lost, so again robots are a natural solution to this. How will the rise of Electric Vehicles impact use of robots in automotive industry, which is one of the largest users? When you think of the automotive industry and robotic use you probably imagine big robots lifting and welding panels or applying the painting processes that give the car its impressive finish. Actually, robots are used on multiple other areas from haptic testing of the drivers’ console, through to assembly of multiple subcomponents and electronics. In our showroom in Akihabara, Tokyo we even demonstrate 30 | Industry USA | April 2021

the assembly of the in-car entertainment system, by robots. Furthermore, I saw recently a very innovative use of robots to change car tyres in a shorter time and with recordable security that each wheel, nut and tyre have been correctly installed. The reason I relate these examples is each of these applications will still remain regardless if it is a fossil fuel engine or an EV. In addition, I also think these examples illustrate just how innovative automotive manufacturers are at utilising automation to gain production flexibility and advantage. It’s a trend I don’t see changing and if anything, accelerating as robots may gain new tasks in the building of electrical motors, installation of battery systems, etc. BTW if you want to see that wheel changing application take a look at https://www.youtube.com/watch?v=FGaegBrSJbM Are Cobots with their greater appeal bridging the gap with conventional robots on assembly lines? Collaborative robots are definitely a great addition to the robotic portfolio, and yes in some cases they bridge an existing gap but more frequently they open-up a totally new field of application. To be honest this is one of the most exciting things about collaborative robots in the way they are challenging the way we think about how we do things. However, I think it’s important to understand that actually there are a lot of different robot types, from traditional single arm-multi axis, to multi-arms, delta (or sometimes called spider) robots, twin beam high-speed placement robots, etc. The key thing to remember here is each robot type has a specific strength, so at one end of the scale you have high speed, ultra-precise robots operating with no human intervention, maybe in the middle you have high IP rated robots that are working in environments that may

Integration of machines with robotics presents a unique opportunity. Image Source: Mitsubishi Electric 30 | Industry USA | April 2021

There has been a major expansion of potential robot applications. Image Source: Mitsubishi Electric

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be unfriendly to humans, and at the other end you have collaborative robots who are working very closely with people and consequently will be slower and more typically a little less precise. But there is no doubt, collaborative robots are expanding an already extensive solution portfolio. Use of robots in the service industry is rising – what does this mean for the leading vendors? Service robots are definitely ’on the rise.’ In China recently we saw a restaurant taking orders by mobile phone/2D code, creating/cooking and delivering the dish to the customer – all by various different types of robots. Amazing! In Japan there are robots delivering luggage or small amenities to guests in hotel rooms, so there are a lot of people coming up with a lot of imaginative ways to utilize technology. Will that trend continue? Absolutely! But moving back to the manufacturing environment, there are equally interesting developments there from very innovative, high-density warehouse storage solutions managed by service robots to traditional AGV type parts delivery. What really is exciting is the combination of a traditional robot with an AGV to create the potential of a self-configuring production environment, bringing ’work-stations’ in different orders and configurations by redeploying them at will. For sure the robotic hardware is critical, but then so is the battery systems for such mobile applications. Added to that the use of safety systems to protect workers and vision and AI to manage programless task configuration, now you can understand the answer I gave earlier that there is this “perfect wind” propelling the adoption of robotics, and honestly we are just at the start of it. How has the Covid-19 pandemic affected the industrial robots market? The whole Covid situation is a challenge to us all both on a humanitarian front and on a business and manufacturing front. However, the human spirit is very resilient, and a lot of people have used this regrettable situation to try to find new ways to do things. Social distancing as applied to manufacturing is even more challenging. Often this has meant that factories have implemented a multiple shift system to reduce the number of workers present at any one time. But sometimes that’s simply not feasible because you need a certain level of operational resources to make the manufacturing process work. In those cases for sure the use of PPE for workers is absolute, and the simple addition of screens and barriers are also a big help. But still this does not solve all problems and as a consequence we have seen a real surge in interest in collaborative robots. Typically, these enquiries are applications to support a worker where, potentially in the past there were two workers side by side, but now due to the shift rotation only one is present at any one time. So yes, there has been an increase in interest in robotic solutions, but in addition remote maintenance and predictive maintenance solutions are also garnering renewed interest. Will the growing use of AI and ML provide the muchneeded boost for wider use of robots in industry? Yes, indeed AI and ML are already making their impact felt. However, for most people AI and ML are in some way indivisible. As customers they are primarily interested in what it delivers as a benefit to them not necessarily how it does it, that’s probably more interesting for the engineers!

To try to illustrate how important this is, let me give you a few examples, because to simply say ’AI empowered vision solutions’ do not do justice to the wide range of what that can entail. From applications around vision to support the auto path generation avoiding obstacles and people, to innovations of picking and sorting objects in bins or even selecting and handling natural, delicate items like plant cuttings at a farm where each cutting is basically unique, AI is enabling robots to add more value across a wider range of tasks. But that’s again not the whole story. AI is also allowing us to control robotic grippers in more advanced ways than ever before. Imagine picking up a ’bag’ of washing detergent, as the robot lifts it, two very difficult things happen that needs controlling. As the bag is raised the contained detergent displaces, this changes the centre of gravity of the bag but at the same time can also change the ’shape’ of the bag as the detergent collects at the bottom … and the robot and its gripper have to react in milliseconds to prevent the bag from being dropped and potentially damaged. I could go on about AI enabled maintenance or the benefits of AI being used to potentially control a robot by voice or hand gestures, there is so much happening right now it is fantastic. What are the future trends for robots at Mitsubishi Electric? Robots will become smarter, more connected, more mobile and more ’normal’. They will become an ever increasingly familiar sight not only in manufacturing but in our everyday life, from shelf management in the supermarket, to hotel concierge functions and even serving your coffee. Many of these activities are being pioneered now but will mature and become more widespread in the world of tomorrow. AI and ML will not be something unusual or to be feared, but a background function that enables and supports. Customers will not be looking to buy an AI enabled device but to buy a smart device to fulfil specific tasks; Window cleaning, vacuuming the floor, testing a product, assembling parts … walking the dog?! Will robots become humanoid in appearance and operation? That’s more of a question for society in general, but as is the current case there will not be one ’type’ of robot but a multitude, some for general tasks, others for dedicated tasks. How will we interact with robots? Well, we talk with our smart home assistant to find out the weather, play our favourite music, etc … so why should we not talk with the robots of the future to do tasks or report status? Whatever the future holds for us it is sure to be both exciting and very different than what we can imagine today – and probably a little more mundane. Interestingly, the Japanese Government has a project called ’Society 5.0’ which seeks to understand the balance and fit of technology, business, people and society in general as we grapple with the 4th Industrial Revolution, aging populations, increasing environmental pressures and dwindling resources. Following that concept may just give us all a glimpse of what the future may truly hold and we as Mitsubishi Electric will be there to support both our customers and to help support and improve society as we ’change for the better’.

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B U I L D I N G M AT E R I A L

OLDCASTLE APPROVES WEAV3D COMPOSITE TECHNOLOGY FOR REINFORCEMENT APPLICATIONS IN POLYMER CONCRETE PRODUCTS

Oldcastle Infrastructure, a CRH Company and leading provider of infrastructure products, has approved WEAV3D composite lattice material for reinforcement applications in their polymer concrete and SMC composite products. Ideal for underground energy, transportation and communication applications, WEAV3D composite lattice is a completely non-metallic reinforcement material that provides high levels of durability and strength, as well as resistance to corrosion and other environmental conditions.

nitially developed for a new polymer concrete cable trench designed for 16,000-pound wheel loads, WEAV3D composite lattice was utilized in place of traditional steel wire reinforcement. The lattice is based on a thermoplastic composite material that forms an adhesive bond with polymer concrete and provides exceptional impact and tensile load resistance.

“Using thermoplastic composite materials that bond with Oldcastle’s resin yields the best possible strength and mechanical properties,” says WEAV3D founder and CEO, Christopher Oberste, PhD. “Our composites are also cost competitive with steel reinforcement.”

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WEAV3D’s lattice reinforcement was able to provide targeted strength around the drain holes and ends of the cable trench, reducing the likelihood of damage during transportation and installation. It also eliminates the corrosion that can occur when products are cut or drilled and steel is exposed. This advanced reinforcement will be available for use in a wide range of Oldcastle’s infrastructure products.

As a leader in composite material products and technology, Oldcastle is always looking to utilize innovative materials to bring lightweight, durable and economical products to the market. “The WEAV3D lattice offers flexibility and performance in the design, handling and placement of reinforcement that cannot be matched with traditional steel reinforcing,” says Oldcastle Product Manager, Chris Schultz, P.E.

www.oldcastleinfrastructure.com www.weav3d.com

30 | Industry USA | April 2021

ELECTRONICS

FAULHABER WEBINARS – DRIVEN BY KNOWLEDGE

FAULHABER is starting a series of webinars on exciting topics, such as the development of noise in drive systems, in-depth application know-how and even on helpful tools such as the FAULHABER Motion Manager. FAULHABER

Learn new things, deepen existing knowledge, talk to experts – that’s possible from anywhere, even when working from home. FAULHABER is therefore starting a new series of webinars on exciting topics, such as the development of noise in drive systems, in-depth application know-how and even on helpful tools such as the FAULHABER Motion Manager. Participation is free of charge. Only registration is required.

odern, mobile, multimedia: webinars are a contemporary tool for expanding your own knowledge, for eye-to-eye discussions with experts or for obtaining solutions to specific problems. FAULHABER is therefore starting a series of webinars on various topics related to drive technology. Each webinar is led by an expert from the respective field, with adequate opportunity to answer individual questions. Participation is, of course, free of charge and requires only a one-time registration.

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Current webinars “Motion Controller & Speed Controller” This is the ideal webinar for anyone who would like to learn more about the FAULHABER Motion Controller – the user-friendly, single-axis position controller tailor-made for actuating DC-motors, brushless motors and linear motors from FAULHABER. The presenter was responsible for, among other things, the development of the FAULHABER MC V3.0 generation. The webinar will use a live demonstration of the Motion Manager software to show step-by-step what a typical setup of a FAULHABER Motion Controller (MC V2.5/ 30 | Industry USA | April 2021

MC V3.0) looks like, along with additional information about customisation options and how to select suitable components. Participants have the unique opportunity to discuss all of their technical questions on FAULHABER Speed Controllers or Motion Controllers with an absolute expert. “Noise development in drive systems” Starting with the basics on vibrations, their resonance paths and their mode, the webinar covers the subjective perception of noises and vibrations. Together, we explore the possible causes of mechanical vibrations in a drive system, discuss the appropriate measurement instruments and learn how to use this measurement data to determine the causes of noises. During the webinar, the expert also reveals the best methods for reducing noise. https://faulhaber.com

ELECTRONICS

ETHERCAT WITH DISTRIBUTED CLOCKS

The complete BLDC motor series dPro from Dunkermotoren is now also available with EtherCAT interface.

he dPro versions are available with integrated servo controller (BG 66 dPro EC to BG 95 dPro EC) or as external version (BGE 5510 dPro EC). In contrast to the previous EtherCAT product portfolio, a special highlight is Distributed Clocks and the associated possibility of real-time synchronization. A large number of brushless motors of the BG series in the power range from 10 W to 1100 W are controlled via the industrial Ethernet interface (CoE protocol). Easy integration of the units into the Beckhoff TwinCAT environment is guaranteed with the help of a simply explained “Let’s Connect” manual and the appropriate parameter files (ESI).

Early next year, the EtherCAT drive units will be equipped with another “must have” feature. With the safety function “Safe Torque Off”, the motors will be found in the future in numerous autonomous vehicles (AGV or AGV) or in traditional mechanical engineering. www.dunkermotoren.com

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ELECTRONICS

RUGGED CONNECTIVITY: LESSONS I’VE LEARNED FROM HIGH-END RACING

Electronics play a key role in crossing the finish line first, especially when dealing with ever-changing wind and wave conditions. Fischer Connectors is an official supplier of fiber optic connectors for American Magic, Challenger for the 36th America’s Cup. Copyright: Amory Ross/NYYC American Magic

Top Competitors Take Big Data and the Internet of (Boating) Things To the High Seas in Their Quest for the America’s Cup.

igh-end racing, whether on land or water, is notorious for its secrecy. With the Prada Cup and America’s Cup races in 2021, no one working with any of the hypercompetitive teams would dare give away those secrets.

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Spoiler alert: This isn’t about secrets. Even though Fischer Connectors is the exclusive connectivity sponsor of American Magic – a challenger for the 36th America’s Cup – and has provided connectors and solutions for many racing yachts over the past five decades, we can’t give away any of our trusted partners’ competitive secrets. This article is about the lessons learned working on various racing yachts over time, and how some of the latest connector technology and strategies used in racing can be applied to other real-world applications.

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Racing into 2021 From the moment the America’s Cup AC75 class rule was first published on March 29, 2018, by the current America’s Cup Defender, Emirates Team New Zealand, challenger teams have been designing and engineering their boats within the set rules to give them every possible edge in a temperamental racing environment. In fact, American Magic spent over 76,000 man hours producing its first AC75, DEFIANT. So, what are the stats for an AC75? • Length: 22.76 m • Width: 5 m • Weight 6.4 tons • Crew: 11 • Crew weight: 990 kilos • Construction: carbon fiber and double-skinned soft mainsails • Construction hours: 76,000+ • Design hours: 90,000+ • CNC machine and/or 3D printing hours: 45,000 • Individual parts: 25,000 • Sensors: 400+

Racing yachts such as the UK Team Ineos’ “Britannia” are estimated to have over 300 sensors on board to help guide sailors by giving race teams realtime data on changing conditions. Copyright: Chris Ison

All of this development comes at a significant cost to the teams entering the America’s Cup. To put this into context, the last event in 2017, held in Bermuda and won by Emirates Team New Zealand, is believed to have cost upwards of USD 100 million, with some teams reporting that they had to pay twice this figure to actually become competitive for the Cup. Races can be won or lost in the design, construction, and/or operational phases. Even fractions of seconds are of critical importance in a race for the America’s Cup and for the pride of a nation. Despite huge R&D budgets, it’s ultimately the team of 11 sailors working as one in precise harmony that determines who’ll be the winners on race day. So, the engineering teams do everything they can to give their sailors the advantage.

Given the strict weight criteria for such a “flying machine”, designers and engineers are constantly deliberating over each component used on the vessel: Will it deliver during practice, during the race, once or over time? Is it rugged enough? Is it too heavy? Is it really needed? The Importance of Interconnect Solutions Reliability in both the sensors and connector solutions is essential. Maintainability is critical, as is IP (Ingress Protection) sealing and the ability to withstand saltwater ingress and spray. Elevated temperatures are also a challenge to connector solutions, as most electronics are stored (and operated) in sealed airless compartments and may be exposed to extreme solar heating. Indeed, a black carbon panel can easily reach above 70 °C in the UK sunshine – let alone in New Zealand! These places significant duress on the reliability and functionality of the electronics enclosed within.

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Lesson One: Sensors Create Real-Time Data for Immediate Decision Making Sailors and their support teams operating in high-pressure situations have to deal with many more variables than, say, the driver of a “simple” NASCAR vehicle. Wind speed and direction, water movement, water temperature, hull angle and foil position are all variables in yacht racing that can not only affect each vessel differently, but also change constantly during the race. Sensors are everywhere on the boat, from the foils to the wingsail, gathering data that enable sailors to calculate and use them to their advantage. Additionally, sensors help to adjust strategies or tactics in a

fraction of a second if they get the right information at the opportune moment.

Fiber Optic Plays an Important Role One area of great interest beyond the use of conventional copper wired interconnect solutions is the use of fiber optics for data transmission. In the America’s Cup in 2017, fiber optic sensors were embedded in the race boat foils and in other key components. This allowed the team to measure, 30 | Industry USA | April 2021

Fiber optic sensors embedded in race boat foils can be used to measure the lift, drag and horizontal force generated by the foil in real time. Image courtesy of Epsilon Optics www.epsilonoptics.com/marine.html. Fischer Connectors’ ruggedized optical connectors are used in the UK-based company’s latest sensor system.

This was demonstrated to greatest effect in the 2019 Sail GP event in Cowes on the UK’s Isle of Wight. There Tom Slingsby’s Australian Team utilised the foils in a completely different mode than any competitor, sailing three races with the bow firmly down, reducing the rudder loads, and maintaining control in winds of over 25 knots. The result was three straight wins over the remaining international competitors. Fiber optic devices tend to be smaller and lighter than the conventional copper. The cable is essentially a glass tube less than 2 mm in diameter. It comprises layers protecting the fiber glass that propagates data using light energy, which is converted into an electrical signal at the destination source. In essence, data speeds move in near perfect conditions within the fiber, resulting in the highest data transfer rates, without loss or low delay. Another advantage of fiber optics is the ability to physically embed these miniature single-strand sensors into the laminated carbon structures of the boat, without affecting the structural integrity of the foil or mast/wing section or the functionality of the hardware. These embedded sensors also ensure you can monitor potential breakages of such highly stressed parts of the boat at all times and avoid them if at all possible. Clearly, these items are very asset-sensitive due to cost, material and build time; hence only the most appropriate cabling and connector systems can help ensure longevity and avoid delays in this challenging environment.

analyse, predict and optimise the design of the parts, while keeping stress levels under control. If set correctly, the foil offers both lift and drag, similar to an aircraft wing in flight. “The electronics and data acquisition on an America’s Cup yacht such as American Magic’s Patriot are absolutely crucial to our success,” says Antoine Sigg, Fiber Optic, American Magic. “Loads of data streams are processed constantly, feed models, trigger alarms and help the sailor to make adjustments for wind, attitude and stresses on the boat. It’s essential that the connectivity solution deliver accurate data. The fiber optic solutions from Fischer Connectors help us have simple and reliable connections to many key zones on the boat, especially where lines are connected and disconnected daily. They link the boat system to moving parts, and the robustness of the Fischer FiberOptic Series is used at its full potential to withstand shocks, fast movements and exposure to the elements in a firehose-like environment.”

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In a racing yacht, the foil rake and angle of attack are adjusted for different points of sailing (upwind and downwind) and different wind strengths. Getting real-time information from the sensors through fiber optic connections allows optimisation of the foil angle and load, providing the appropriate lift for any given displacement and wind condition.

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A final significant benefit for the AC75 is the weight advantage offered by this type of fiber optic. When considering electronics control systems on board boats, it’s fair to assume most yachts carry in excess of 60 kg of wire for their control and instrumentation circuits. This weight can be greatly reduced if the traditional copper is replaced with state-of-the-art, high-capability fiber. Data as a Commodity As reported by Martin Whitmarsh, CEO of Land Rover BAR, with all this live real-time data from in excess of 400 sensors per boat*, it’s a veritable treasure trove of data. It’s essential that adequate data connection, onward transmission, storage and subsequent analysis are performed for all modes of sailing and conditions. As a dinghy sailor myself, I consider my surroundings and speed while sailing, just two variables that affect my performance. For these highperformance racing yachts, however, sailors consider up to an estimated 300 variables simultaneously to evaluate and adjust performance, including water time, flight time, speed, boat position, angle, loads, foils and rudder angle. To do this perfectly in a race requires gathering, transmitting, analyse and acting on reliable data. In 2017, it was estimated that Team Oracle’s boat accumulated between 200 GB and 500 GB of data every day. It’s no wonder that so much data crunching is needed to ensure you can optimise the performance of every element for live sailing conditions. This explains the involvement of companies like database giants Oracle and Dell EMC in the last America’s Cup and, more recently, Hewlett Packard for this 2021 campaign. Clearly, reliable data management ensures the boat performs as competitively as possible and defines a clear configuration setup for each and every condition that the boat is raced in. Recent reports from the teams out in New Zealand suggest that the typical data now being collected by this year’s

Catamarans in previous America’s Cup races may not have been the first to utilise “big data” during competitive sailing for real-time and post-race analysis, but they pushed ideas that led to today’s electronics designs. Copyright: Stuart Doe

Cup teams are in excess of 1 billion data entry points. This makes the data collation and sifting activity a significant contribution to the teams’ performance and understanding of the data variables, with significant implications for performance.

resistant to water ingress (IP rated) and harsh saltwater corrosion. As previously mentioned, weight is also a critical performance criterion for any foiling craft, so the provision and support of this technology is often a balance against weight, performance, functionality and cost.

Lesson Two: Connected Technology and the Internet of (Boating) Things To help them race today, every single competitive racing yacht utilises world-leading engineering and design, Internet of Things (IoT) devices, data analytics and data modeling.

The use of real-time data from these sensors is pivotal to both design measurement simulation and actual optimal performance, thereby allowing both prediction and practice of the fastest method of sailing in pursuit of the Cup. This is also true of weather measurement, and wind and wave prediction. If one side of the course is favorable for optimal performance, it’s key to identify tactically how and where patterns of wind will be emerging. This is especially the case in New Zealand, with its interesting harbor course and sheltered racing areas.

Ease of accessibility and interconnectivity between these sensors and any instrumentation are critical and, of course, the performance of any marine-based connector must be

It isn’t just the racing yachts that are outfitted with a myriad of sensors. Chase boats and support vessels are deployed prior to the event to survey, mark out and ensure sailing areas are clear of underwater obstructions. All these vessels use 3D sonar scans and data overlaid on conventional chart plotters, which are updated live via 4G networks. Teams are increasingly utilise the higher bandwidth and live-streaming capabilities of 5G that became available with significant infrastructure updates during the end of last year.

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Modern racing boats take full advantage of the IoT, integrating hundreds of sensors taking various measurements – including state-of-the-art sensors for wind measurement, speed and angle, accelerometers, and a significant number of load sensors buried deep within the mast/rig and foil construction. These load meters are also supported by numerous water-based sensors calculating GPS, depth, turbulence and temperature and, most importantly, speed. This was shown on the SAIL GP event in 2019, when two methods of boat speed were needed to validate the over 50 Knots (57.5 mph!) achieved by both the Australian and UK teams during this race series.

The reduced latency and higher bandwidth of 5G means Emirates Team New Zealand is now able to live stream 30 | Industry USA | April 2021

This life-vest-wearing mannequin was on display at CES 2020, sporting AC75 buoyancy aid fitted with HD Camera with 1080P 30FP/S and Fischer LP360 connectors. Copyright: Stuart Doe/ Fischer Connectors

data and video back to engineers and designers at the base straight off the new AC75 boat. Dan Bernasconi, Head of Design for Emirates Team New Zealand, said in a 2019 Yachts and Yachting interview that the 5G service is a game changer for the team. “There’s a huge amount of innovation in the design and build of the AC75. The boat is a completely new concept, so we need to be able to push the potential of this boat to its extreme in testing,” Bernasconi commented. Prompt onward data transmission in all areas is critical for the teams to support live monitoring and performance enhancement. Broadcast-Quality Communications on Every Boat Transmitting information to the base team for their use is a given, but racing organizations also have technical information available worldwide, broadcasting on multiple platforms and applications, even to devices carried in a spectator’s hand.

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The sailing world first saw the production of stadium-style racing introduced in the late 1990s. These boats, like those competing for the 2021 America’s Cup, were live-streaming on-board video and telemetry data, along with audio, directly to audiences. With ever more information and data from the boats now being displayed live to audiences through traditional broadcasts, interactive apps and across the Web, etc., the races come even closer to those on spectator boats or on shore. All cases require robust and 30 | Industry USA | April 2021

secure connectivity boat-to-boat and boat-to-shore to facilitate this. Lesson Three: Innovation and the Connected Team With enormous budgets on these boats, even for high-end racing, it’s clear that every team is pushing the frontiers of technology, science, innovation and performance of the boat and the crew. That’s only what we know about now, not what’s being kept secret! In years gone by, the crew was there to provide power to drive the winches for sail movement and trim. While this is still the case to some degree, there’s also a small amount of battery support topped up by the crew grinders. Crew role, weight and performance output have now become critical. This means, in addition to data gathered from the boat itself, there’s now far more interest in the biographical data from the crew itself, along with individual communication and data sharing on board the boats. Years ago, wind noise was not an issue for the sailors, who now travel at speeds in excess of 60 mph. Specialist headsets and microphones had to be generated to allow interconnected radios among the team members. Buoyancy aids now hold radios, batteries and multiple interconnects between buoyancy aid and headsets. Each sailor is effectively a network-connected worker and, with today’s technology, it’s possible to monitor individual

The American Magic team reviews data from a practice session. Copyright: Amory Ross

Support vessels and chase boats are also outfitted with communications gear and sensors. Copyright: Amory Ross/NYYC American Magic

heart rates, biometrics, temperature and performance of the entire team. Such monitoring manages the physical elements of the sailing team and adjusts and optimises for peak performance during the critical race season. Applying the Lessons The key to applying the lessons of high-end racing to other, less dynamic, industrial or instrumentation applications is to understand the impact of the data you need. Not everyone needs 400 sensors, but when you do, it’s important to have a connectivity strategy that delivers the data in meaningful, actionable ways. Consider how much data you need to be able to move and how fast it needs to travel. Use the Internet and analytical tools, including artificial intelligence (AI), to make faster decisions that push you forward. Remove unnecessary weight while increasing data transmission with fiber optic solutions. If IoT strategies and technology are available to racing yachts, then they can be available to any application, anywhere.

first across the finish line. However that finish line is defined, always remember the fun of the race. Published on the Occasion of the 36th America’s Cup World Series (ACWS) Race in Auckland, New Zealand, December 1719, 2020. A special thanks to American Magic for use of their photography to illustrate this story. By Stuart Doe, Head of Active Solutions, Fischer Connectors *Martin Whitmarsh, CEO of Land Rover BAR, 2017 www.silicon.co.uk/networks/bar-americas-cup-2-210191 www.fischerconnectors.com/global/en/american-magic www.fischerconnectors.com/global/en

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Ultimately, engineers looking for a solution may be seen to be competing, whether it’s against their actual competition, or simply because the application being designed is a challenging puzzle that needs to be solved with the best, most efficient design. My advice as a sailor: When you need to stay competitive, strive for excellence and aim to be the 30 | Industry USA | April 2021

ELECTRONICS

LANNER RELEASES EDGE AI STARTER KIT FOR INDUSTRIAL AUTOMATION

The Edge AI Starter Kit powered by Intel now enables quick integration of vision based solutions.

anner Electronics, a world leader in the design and manufacturing of intelligent edge computing appliances, announced its collaboration with Intel to launch the Edge AI Starter Kit for industrial automation. Combining Lanner’s Edge AI Appliance with Intel Edge Insights for Industrial, the Lanner Edge AI Starter Kit aims to deliver an all-in-one platform composed of a highspeed camera, Intel CPU and VPU-accelerated computing hardware, and application-tailored software to accelerate time-to-market AI deployment at the industrial edge, such as vision inspection, predictive maintenance and operator monitoring.

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Lanner Edge AI Starter Kit for industrial is powered by the edge compute platform LEC-2290. Integrated with 8th Gen Intel Core i7 CPU (codenamed “Coffee Lake-S”), the Lanner LEC-2290 is a fanless Edge AI Computer suited for harsh, space-confined environments for enabling computeintensive applications for industrial edge AI. The system’s computing capacity can be further expanded via the pluggable Intel Myriad X VPU to implement video processing while the CPU executes machine vision algorithms.

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Intel Edge Insights for Industrial is optimized for Intel technology based platforms like Lanner’s Edge AI Starter Kit. It is an open and modular product validated software that aggregates and processes time series, image/video data at the edge to provide useful insights via edge analytics. Powered by Intel Distribution of OpenVINO toolkit, Intel Edge Insights for Industrial accelerates development, enabling quick integrations of pre-trained models (e.g., Tensorflow, Caffe, etc.) for object recognition, classification, and facial recognition in vision-based solutions. https://www.lannerinc.com/

ELECTRONICS

ACS INTRODUCES IDMSM INTELLIGENT DRIVE MODULE HIGHPERFORMANCE MULTIAXIS ETHERCAT® DS402 DRIVE FOR OEM MACHINE BUILDERS

ACS launches the first in a new line of high-performance Intelligent Drive Module products. The IDMsm is a 2- or 4-axis EtherCAT® DS402 universal servo drive featuring unique control algorithms and processing technologies that enhance the performance of high-precision motion stages. Certified as EtherCAT Conformance Tested®, the IDMsm provides up to 5A continuous and 10A peak per axis with 12-48 VDC drive supply.

“

We’re excited to offer our unique servo control and motion-to-process synchronization capabilities, backed by more than 35 years of high-performance motion control expertise, for demanding applications that utilize any brand of EtherCAT-based controller,” says Jason Goerges, ACS Motion Control General Manager North America and Global VP of Marketing. “High-tech capital equipment manufacturers have a wide range of EtherCAT servo and stepper drive offerings to choose from. When OEM machines must outpace the competition in throughput, accuracy and time to market for sophisticated features, the IDMsm is the drive to win,” Goerges added.

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Product Highlights • Powerful tuning and performance analysis software tools for stage performance optimization • Advanced servo control algorithms for gantries and other multi-axis stage configurations • Intuitive ACSPL+ real time programming with up to 4 simultaneous threads for maximum application flexibility • Standard DS402/CiA402 CoE EtherCAT interface provides connectivity to any EtherCAT master controller • Flexibility to interface with multiple motor types for best technology fit on each axis: brushless, brush, voice coil or stepper • Integral Safe Torque Off (STO), SS1 functional safety capabilities • Certified EtherCAT Conformance Tested® www.acsmotioncontrol.com

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E N E R G Y / P O W E R

NEW OWNER FOR THE FAIST ANLAGENBAU GROUP – THE SOUND INSULATION EXPERT

Faist corporate headquarters Krumbach/Swabia/Germany.

Paguasca Holding AG of Zug, Switzerland, has acquired the FAIST Anlagenbau Group, based in Krumbach, Swabia, Germany, including all subsidiaries, effective December 15, 2020.

he FAIST Anlagenbau Group has a global reputation as a leading expert in industrial sound insulation. The company has two primary business units, Power Systems and Acoustic Systems. The Power Systems division designs, manufactures and installs equipment in two primary areas including providing power stations and their components with sound insulation solutions. In addition, the Power Systems group provides Air Intake Systems, for the low-noise delivery of conditioned intake air for gas turbines and their soundproof housings.

The “Acoustic Systems” business unit supplies industrial sound insulation systems, acoustic measuring and testing facilities, and aeroacoustic wind tunnels for a wide variety of industries. All the systems are primarily designed and built at the Company’s plants in Krumbach and Bremen, Germany and installed worldwide. Some elements of the systems and some specific functions may be supplied by the Company’s foreign subsidiaries. Faist operates in several market segments which are currently affected by the automotive and aviation industry slow downs, as well as by trade wars in some important target industries and regions.

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As a result of these difficulties, the family-owned enterprise, headed by Michael Faist, has decided to sell the company. The Faist family has owned and managed the business in Krumbach for almost 120 years and Michael Faist is now stepping down, after many years as a successful entrepreneur. His objectives in the transaction are to enable the FAIST Anlagenbau Group to achieve continued growth and securing the plants and the jobs that depend on them. Michael Faist: “We are delighted to have found a 30 | Industry USA | April 2021

NEWS

View of a power plant project.

buyer in Paguasca Holding AG, whose aim is to promote the successful further development of the FAIST Anlagenbau Group.”The parties have agreed not to disclose the purchase price. Under its umbrella, Paguasca Holding AG combines a group of companies in the energy sector. Daniel Guggenheim, Group CEO of Paguasca Holding AG: “FAIST is a highly specialised, market-leading provider of industrial equipment with an excellent reputation and the competence to implement complex projects worldwide. We are convinced that we will be able to exploit synergies between the FAIST Group and the companies that make up the portfolio.”

demand for sophisticated sound insulation solutions and we have the competence and the capacity to construct such systems and to install them on site worldwide.” www.faist.de

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As a result of the challenging market conditions, it has been necessary to make some work force reductions, primarily at the Company’s headquarters in Krumbach, Germany. CEO Roger Schmidt: “Unfortunately we had no other choice. 165 jobs will be retained at the German plants in Krumbach and Bremen. We will carry out the personal adjustments as fairly as possible and we are in the process of finalizing transition plans and severance packages for the effected employees.” The two managing directors, Wilfried Thies and Roger Schmidt, foresee great opportunities for the future development of the business: “The contribution of Paguasca Holding AG will enable the strategic realignment of the Company and speed the opening of new markets in a focused and purposeful manner. There is a worldwide 30 | Industry USA | April 2021

SOFTING INTEGRATES CNC DATA INTO INDUSTRIAL EDGE APPLICATIONS

Softing expands its dataFEED edgeConnector product family which is based on Docker technology. The new edgeConnector 840D container supports easy access to data from SINUMERIK 840D controllers and makes it available on edge devices or virtual environments via OPC UA and MQTT. This enables flexible integration of local OPC UA clients and MQTT brokers in a cloud environment and the Industrial IoT.

Following dataFEED edgeConnector Siemens for the connection of SIMATIC S7 controllers, Softing now introduces dataFEED edgeConnector 840D. This software module is the world’s first container application for accessing SINUMERIK 840D Solution Line and Power Line controls. It supports the reading of all process parameters and drive data without the need to intervene in the configuration of the machine tool.

dataFEED edgeConnector 840D allows seamless integration of up to five CNC controllers into a cloud environment such as Azure IoT Edge or AWS IoT Greengrass. It can be used, for example, to check production quality and tolerances, record machine data and integrate it into higher-level management systems or visualize process parameters and other performance indicators. Configuration can be done locally via an internet browser or remotely via the REST interface.

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A central deployment of all connected edge devices with their containers, e.g., for updates or security patches, can be carried out using an optional device management system. “We are seeing an increasing demand in the market for software solutions that can be efficiently managed and run on standard hardware. Our response to this is the systematic expansion of the dataFEED product family to include Docker containers for integrating data from production into innovative and flexible Industrial IoT solutions. In this way, we help users and system integrators close the gap between 30 | Industry USA | April 2021

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dataFEED edgeConnector 840D supports innovative industrial edge solutions. (Source: Softing Industrial)

OT and IT,” says Sebastian Schenk, Product Manager at Softing Industrial. It is planned to grow the dataFEED edgeConnector product family further and, for example, also support the control connection via Modbus TCP or Ethernet/IP. In addition, containers for data aggregation and preprocessing as well as address space modeling are in the planning stage. The options for configuration from the cloud are also to be expanded. dataFEED edgeConnector 840D can be downloaded from online directories like Docker Hub or Microsoft Azure Marketplace and tested for free. More information can be found on the product website. https://industrial.softing.com/products/docker-container/ edgeconnector-840d.html

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M A C H I N E A N D TO O L S

KENNAMETAL INTRODUCES NEW LINE OF PCD TOOLS

A broad selection of PCD end mills in diameters up to 50 mm are available as standard.

Polycrystalline diamond round tools, available with short lead times enable, high efficiency aluminum machining.

ennametal has introduced a new line of PCD round tools for aluminum machining that delivers up to 10 times higher productivity than carbide tooling. The new line of drills, reamers and end mills provides exceptional tool life and wear resistance even in very abrasive aluminum alloys and are available with very short lead times.

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“Our new PCD round tools line enables our customers to machine aluminum significantly faster, for greater productivity on the shop floor,” says Michael Hacker, Product Manager, Kennametal. “In drilling and reaming operations, these tools consistently perform at cutting speeds of up to 900 m/min (3,000 SFM). Milling operations can be performed at an incredible 6,000 m/min (20,000 SFM)—far higher than non-PCD tooling.”

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Long tool life, high productivity gains With through-the-tool coolant capabilities and an MQLready interface, these PCD round tools are ideal for both rough and finish machining. Extremely sharp cutting edges and low-friction rake surfaces eliminate concerns over built-up-edge. Low friction machining also produces superior surfaces in finishing operations, such as reaming. Surface roughness of Ra 0.1– 0.8 μm (0.0025–0.02 μ-in) is achievable – far superior to conventional carbide tooling. PCD grade KD1410 assures extended tool life and is particularly beneficial in the high silicon content aluminum used to make automotive parts like engine blocks or cylinder heads.

NEWS

The PCD round tool line includes a range of holemaking and hole finishing options, including modular reaming heads up to 42 mm in diameter.

The offering at a glance The line of PCD end mills features: - 6 to 50 mm diameter tools - Cutting depths up to 50 mm - Center-cutting, roughing, and finishing geometries - Various rake angles. The PCD drill offering features: - 6 to 20 mm diameter in 0.5 mm increments - Up to 5 x D - Inch and metric sizes The PCD reaming portfolio offers: - 6 to 20 millimeter in diameter in 1 mm increments - Through and blind hole versions - For larger diameters up to 42 mm, the PCD modular reaming system with KST coupling is available.

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“Many of these PCD round tools can also be requested as custom solutions to fit specific customer needs while still maintaining short lead times,” says Hacker. “Kennametal is leveraging its decades of experience with PCD tooling in the automotive industry to make this technology readily available to any manufacturer looking for a cost-competitive and highly productive solution for aluminum machining.” www.kennametal.com

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MEASUREMENT

CONTACTLESS HANDLING OF WAFERS IN THE SOLAR INDUSTRY

Levitating substrate

Gentle and fast handling with ultrasound. Challenges in the processing and handling of silicon wafers Photovoltaic systems or solar modules, which consist of the interconnection of individual solar cells, are known to play an important role in renewable energies. The potential through the energy output of the sun is enormous and through the further development of solar technology, the efficiency could already be significantly increased. The most important semiconductor material for the manufacture of solar cells is silicon.

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Damage often occurs during the production and further processing of silicon wafers. In addition to downtimes and additional cleaning steps as well as readjustments, there are also increased material and process costs. The smoother the handling, the less likely the material is to crack or break.

Furthermore, both sides of the wafer are now frequently coated, as for example in heterojunction technology, in order to generate higher efficiencies. As a result, the handling processes are also becoming more and more demanding to avoid marks, scratches, or particles. Using ZS-Handling’s patented ultrasonic bearing, substrates can float evenly on a film of air generated by vibrations and thus be held without contact during handling. Through a combination of negative pressure and ultrasound, attractive and repulsive forces act simultaneously on the workpiece, thus keeping it at a distance even during transport from above. How does the ultrasonic technology work? The ultrasonic movement of the so-called sonotrode creates a supporting gas film (air or process gas) between the sonotrode surface and the substrate. The substrate floats on the resulting gas film at distances of 10 - 150 micron, depending on the application. In this way any mechanical surface contact is avoided. In combination with negative pressure and the resulting equilibrium of forces (attractive due to the negative pressure and repulsive due to the ultrasound and the weight force), handling or gripping from above without contact is made possible.

30 | Industry USA | April 2021

LeviSolar-Gripper

The physics of the ultrasonic bearing results from the flow dynamics. The gas pressure in the gap between the workpiece and the vibrating surface increases due to the cyclic compression and decompression of the thin gas film. It is therefore necessary to realize a uniform oscillation pattern in order to generate constant floating forces over the entire sonotrode. The vibrations are not transmitted into the substrates and do not lead to any impairment of the substrate material. Advantages With the repulsive forces of the ultrasonic bearing, the substrate can be supported without any friction even at very high speeds. In combination with vacuum, attractive forces can be applied simultaneously, which allows handling from above. In addition, flexible materials can be “smoothed” without contact by this technique, i.e. they can be kept in a uniform, flat position.

The systems can be used in all atmospheric processes and in up to 20% partial vacuum processes. This requires fewer resources, such as energy or compressed air, than a standard air bearing. This has a positive effect on the energy and cost balance for the handling systems of ZS-Handling. Exemplary requirements of a use case: In a clean room environment of ISO 6, silicon solar wafers are to be separated from a stack without contact and handled from above before they can be inspected and sorted. They are then placed on matrix trays and coated in the subsequent process. The wafers have a size of 156x156 mm and a thickness of 120-180 µm. A cycle time of 1.8s (2,000 wafers per hour) is to be achieved for the gripping process, with a time for picking up and placing of 0.1s each. For transport via linear belts (from above and below), speeds of up to 7,200 wafers per hour are to be achieved. At the same time, the breakage rate should be minimal with the highest possible machine availability.

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The principle of operation of ZS-Handling handling systems is similar to that of a conventional air bearing, but no compressed air supply is required. This means, for example, that in a clean room environment the laminar airflow unlike with Bernoulli grippers - is not disturbed by high flow velocities and no particles can penetrate through external air or via pipes. Also, the costs for the compressed air supply can be saved in production lines.

By avoiding surface contact and without dynamic turbulence in the ambient gas, no damage, micro-scratches, micro-cracks, or contamination can damage the substrate. Handling on machined or coated surfaces is possible without contact, allowing more degrees of freedom in process and machine design. During handling, a high level of flatness of the substrate is achieved as well.

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Basic elements of the contactless conveyor

The solution of ZS-Handling includes the Modular Waferhandling-System, which can be combined from different modules as required. First, the LeviSolar-Gripper is required, which is connected to an axis system provided by the customer. The gripper picks up the topmost solar wafer from the stack, which is repeatedly brought to the same height with the help of a servo motor. The combination of ultrasound and underpressure allows to pick up the wafer from the top without any contact. The wafer can be guided vertically and horizontally with high accelerations. To ensure that the wafer does not lose position in the process, the wafer gripper is equipped with four side stops made of PEEK, which are only lightly touched by the wafer from the side.

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To ensure that the gripper does not pick up several wafers at the same time, the so-called “Airsword” is used. This pneumatic separator, which is mounted on four sides of the stack, fans out the topmost wafers of the stack with compressed air blowing in such a way that only the topmost one can be gripped at a time. An optical sensor checks the position of the uppermost wafer and thus the correct function of the Airsword. This optional module, which does not require ultrasound, was desired in this case due to its advantages despite compressed air.

30 | Industry USA | April 2021

The wafer is then placed on a non-contact conveyor, the LinearLevi-Conveyor, where it is transported to the next process which is inspection. Despite fast speeds, only very low forces have to be applied due to the floating state of the wafer. Lateral belts ensure the feed and prevent the orientation of the wafers from changing. A slight inclination is sufficient to achieve sufficient frictional forces at the edges through gravity to accelerate and decelerate the wafer. The edge of the wafer is only loaded by a fraction of its own weight. A LinearLevi-Inspection module is integrated into one section of the conveyor belt. In this case, the sonotrode is made of glass so that the quality of the wafer can be checked by optical measurement technology from both sides during the non-contact transport. The wafer surface can also be inspected through the glass without any problems. At the end of the module there is a gap of approx. 25 mm for a further sensor, over which the wafer can slide without any problems. After inspection, the wafers are picked up without contact by the LinearOverhead-Transport module using simultaneously underpressure and ultrasound and are then transported further from above. Defective wafers are ejected here. The wafer floats below the surface of the linear unit and can also be moved and accelerated without friction. The wafers are centered via pins that are attached to belts.

• Airsword for separating the wafers • LinearLevi-Inspection Module • LinearOverhead Module (Transport, Pick & Place, without belt) • Loading of matrix trays

In order to subsequently place the wafers on the matrix trays, which are also moving, the underpressure is switched off at the correct position, causing the wafers to be gently unloaded at the appropriate location. Summary The entire process flow is fully automated. The Modular Waferhandling-System enables all processes that are found in the handling of wafers. Loading and unloading, conveying, separating, gripping, inspecting and sorting can be realized in one system and at high speeds. Using ultrasonic technology, the wafer is kept at a distance on both sides throughout the modular system so that no micro-scratches or contamination can occur. Thanks to the careful handling, the customer’s breakage rate could also be significantly reduced. This also reduced the downtimes associated with rejects and optimized the process flow. www.zs-handling.com MORE INFORMATION

30 | Industry USA | April 2021

MEASUREMENT

ROHDE & SCHWARZ AND IHP FIRST TO CHARACTERIZE D-BAND FREQUENCIES IN OVER-THE-AIR TEST SETUP FOR 6G AND AUTOMOTIVE RADAR Academia and key industry players have identified the D-Band, ranging from 110 GHz to 170 GHz, as a candidate frequency band for beyond 5G and 6G mobile communications as well as for future automotive radar applications. Rohde & Schwarz continues its pioneering sub-THz research efforts with focus in this frequency range, reaching new milestones. In collaboration with IHP, Rohde & Schwarz has performed the industry’s first full 2D/3D antenna characterization of transceiver modules operating in the D-Band.

imilar to 5G networks and devices supporting mmWave frequencies, antenna systems and RF transceiver modules for future mobile communications standards or automotive radar applications will share the same features that make their testing a challenge. Their wide frequency range, a greater number of antenna elements and the lack of conventional external RF connectors will demand testing over-the-air in a shielded environment. Wireless communications test expert Rohde & Schwarz and IHP GmbH (Innovations for High Performance Microelectronics) have transferred this test method successfully into sub-THz range: They demonstrated the first full 2D/3D over-the-air measurements of a radar module at D-Band frequencies. The test setup consists of the R&S ATS1000 antenna test system, the R&S ZNA43 vector network analyzer and the R&S AMS32 antenna measurement software from Rohde & Schwarz. The R&S ATS1000 antenna test system is a compact and mobile shielded chamber solution for OTA and antenna measurements, ideal for 5G mmWave applications. To cover the D-Band frequencies, extensions from Radiometer Physics GmbH, a Rohde & Schwarz company, are used in the setup, which allows direct frequency conversion at the probe in both transmit and receive directions. No mechanical modification or additional RF cabling to the antenna test system is necessary. The setup can measure the amplitude and phase coherent response of a DUT radiating in the D-Band. Fully automated 3D-pattern measurements including post-processing can be performed in a short time thanks to the R&S AMS32 software options for nearfield to farfield transformation and the highly accurate precision positioner.

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IHP provided four different devices under test (DUT), based on the same D-Band radar transceiver chipset but with different antenna structures, including on-chip single and stacked patches with air trenches and an on-chip antenna array. The over-the-air characterization verified the wider bandwidth provided by the stacked patches than that by the single patch.

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The performance of the various DUTs was characterized by spherical measurements, using two different setups. By increasing the angular theta step-size from 1 degree to 5 degrees, the total test times for a DUT could be reduced from 70 minutes to 12 minutes. By comparing the different DUT designs based on the obtained measurement data, researchers of IHP were able to analyze the effect of the finite on-board reflector area on the radar sensor FoV (fieldof-view). Prof. Gerhard Kahmen, Managing Director of IHP, says: “Sub-THz frequency systems are getting more and more attention in research and many fields of applications. The Rohde & Schwarz OTA test system, extended to D-Band, provides an excellent way to characterize radiation patterns of the complex antenna structures, realized in our D-Band radar chips, in a time-efficient and precise way. For IHP, these measurements are valuable to understand the physics of the antenna structures and to further improve their performance. The very successful cooperation with an industrial partner leading in the field of wireless and mmWave communication shows the benefit of close interaction between research and application.” Alexander Pabst, Vice President of Systems & Projects at Rohde & Schwarz says: “We are excited to work with such an excellent partner as Innovations for High Performance Microelectronics on advancing our industry-leading test solutions for over-the-air testing. These joint efforts will help researchers and key industry players to test and characterize antenna systems and transceiver modules for future automotive radar applications and wireless communication standard, that we eventually call 6G.” For further information on OTA measurements in the D-Band watch the video at: https://www.rohde-schwarz. com/uk/knowledge-center/videos To learn more about of the initiatives of Rohde & Schwarz beyond 5G, go to https://www.rohde-schwarz.com/ wireless/B5G

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30 | Industry USA | April 2021

MECHANICS

ACE CONTROLS INTRODUCES DROP-IN REPLACEMENT DAMPERS FOR PV SOLAR TRACKER APPLICATIONS

ACE Controls has introduced a line of replacement dampers for PV solar tracking systems — the SOL-28 Series. These drop-in replacements offer the same great quality as original equipment (OE) dampers, with the same sizes and specifications.

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he SOL-28 Series is designed to protect against the effects of vortex shedding and wind galloping during high wind events. With products ranging in resistive forces up to 12,000 N and with lengths up to 44 inches, the SOL-28 Series dampers will absorb the kinetic energy exerted by the wind and are designed to move according to the tracker’s natural frequency — typically between 0.8 to 1.2 Hz. Their load-limiting design includes an override feature inside the damper that prevents the resistive force from rising as the wind speed increases, protecting against seal failure or structural damage.

Additional features and specifications include: - Ready to mount, with no additional configuration or parts required - A wear-resistant surface coating - Heat-treated for long life - Operating life of up to 2 million cycles - Wide operating temperature range of -30 to +80 °C - Salt spray corrosion resistance up to 480 hours per ASTM B113 - A high-temperature wiper on the seal package to prevent contamination.

Units also absorb high torque forces that the solar tracker structure may encounter. They are passive and have little resistance during normal operation of the tracker to allow the use of a smaller gear motor. SOL-28 features a rugged construction to withstand harsh conditions.

ACE Controls carries a large inventory of SOL-28 dampers to satisfy any size order. Customers can cross-reference their damper at www.acecontrols.com by simply adding the OE part number to the ACE Controls part number (SOL-28-OE part number). Prices range from ~$68 to ~$85, and orders ship within three days with ground freight included. https://www.acecontrols.com/us/products.html

30 | Industry USA | April 2021

MECHANICS

CURTISS-WRIGHT LAUNCHES NEW MOTOR SUPPORT PROGRAM FOR EXLAR® UNIVERSAL ACTUATORS

Curtiss-Wright’s Actuation Division today announced the release of its new ASSIGN™ motor program for Exlar® FTX and FTP Series actuators. These high-force/duty cycle, electric, rod-style actuators now provide the ability to support the mounting of almost any motor.

he Exlar FTX Series actuators offer continuous load force ratings to 178 kN (40,000 lbf), speeds to 1500 mm/sec (59 in/sec), and stroke lengths from 150 mm (6 inches) to 900 mm (36 inches). The Exlar FTP Series actuators offer continuous load force ratings to 356 kN (80,000 lbf ) and speeds to 401 mm/sec (15.8 in/ sec), and stroke lengths from 150 mm (6 inches) to 900 mm (36 inches). The versatility of these actuators makes them suitable for a wide range of factory automation applications.

The new ASSIGN (Any Servo, Stepper, Integrated, Geared, or NEMA) configuration capability simplifies selection of a wide range of motors, allowing customers to choose in-line or parallel mount configurations that accommodate a larger variety of motor dimensions. The program substantially increases the number of motor/actuator combinations available when using Exlar FTX and FTP Series actuators, giving customers the ability to use the best motor for their application. Exlar is a business unit of Curtiss-Wright’s Actuation Division. For more information about Curtiss-Wright’s Exlar business, please visit https://www.cw-actuation.com

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30 | Industry USA | April 2021

MECHANICS

NEW ROLLON LINEAR GUIDE HANDLES HIGHER LOADS, SOLVES MISALIGNMENT

Rollon has introduced its Compact Rail Plus — part of its new generation of high-performance linear guides. This rugged unit features a new design to handle higher loads while maintaining the Compact Rail product family’s self-aligning capabilities.

ompact Rail Plus is designed for demanding applications such as those involving higher loads, high speeds, fast accelerations or harsh, dirty operating environments. Its design features double-row ball bearings for greater load capacity in both radial and axial directions, new rails with convex raceways for added rigidity and steel sliders with longitudinal seals to protect internal components from dirt and contaminants. Inductionhardened raceways in select models ensure quiet operation and a long lifetime, and different surface treatments are available to resist corrosion.

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Like its Compact Rail counterparts, this compliant guide can align itself to less-than-perfect mounting surfaces. Available with a choice of four different sliders, Compact Rail Plus allows two rails to be combined with different sliders to create a self-aligning system that can compensate for misalignment errors on two planes: axial up to 3.5 millimeters and radial up to ±1.3 degrees.

Taken together, Compact Rail Plus’ features and capabilities will allow users to: - Choose the best structure according to their accuracy requirements. - Easily mount the linear guide on non-machined structures. - Reduce total assembly time. - Deploy the guide in harsh environments. In addition to high load and self-alignment capabilities, Compact Rail Plus also offers: - A C-profile that contains the sliders and the rolling elements, keeping dimensions compact. - Adjustable preload. - Nitrided, black oxidated and polished raceways. Compact Rail Plus is well suited for a broad range of applications such as cutting machines, medical technology, packaging machines, photographic lighting equipment, construction and medical technology, robots and many other automated machines and equipment. www.rolloncorp.com

30 | Industry USA | April 2021

M A C H I N E A N D TO O L S

PULSE TECHNOLOGIES AWARDED SILVER ECOVADIS MEDAL FOR SUSTAINABILITY AND ETHICS

Pulse Technologies, an advanced technology, engineering and contract manufacturing company for medical, aerospace and commercial applications, has been awarded a Silver EcoVadis Medal recognizing its efforts to run sustainably and ethically.

his medal acknowledges Pulse as a growing leader in sustainability, and this score puts it in the top 25 percentile of all companies tested by EcoVadis. “We’re dedicated to manufacturing only the highest quality medical and aerospace components and assemblies,” says Steve Trinter, Director of Global Sales and Marketing for Pulse. “Quality and innovation are at the core of everything we do, and so we plan to increase our score and achieve even greater sustainability moving forward.”

Launched in 2007, EcoVadis has risen to become one of the world’s most trusted rating systems to ensure companies are strong in several categories, including the environment, human labor rights, ethics and sustainable procurement. Each company submitted for evaluation tests is tested according to strict criteria for its industry, and the results are dynamic and improvement-oriented. www.pulsetechnologies.com

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30 | Industry USA | April 2021

PROCESS

COVAL INTRODUCES A VACUUM CHAMBER FOR GRIPPING PROTECTIVE MASKS

Coval’s CVGM series mini vacuum chamber is designed to handle light and porous objects, such as protective masks, but also fabric or leather cut-outs.

ltra-light and compact, weighing only 300 g and measuring only 130 x 60 mm, the Coval CVGM vacuum chamber can be easily integrated in a automated system. It is ideal for robotics and cobotics. The chamber has a modular design and features a stainlesssteel gripping interface that can be easily dismantled to allow frequent cleaning.

On request, COVAL develops customized solutions for automated applications in different sectors, such as packaging, food processing or plastics processing. Coval’s experience as a supplier of components for vacuum automation and complete grippers, enables it to assist manufacturers in defining the best technical solution. Coval’s reactivity meets the precise demands and constraints from customers and the market: the CVGM vacuum box was designed in response to the Covid-19 epidemic. Coval solutions are used all along the production chain, from the individual handling of objects, to the palletization of complete layers at the end of the line. https://youtu.be/-Ual36IlHoI

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https://www.coval-inc.com/

30 | Industry USA | April 2021

S M A R T FA C TO R Y

SIGMA-NETICS RUGGEDIZED PRESSURE TRANSDUCERS WITHSTAND RADIATION, FATIGUE AND HIGH PRESSURES IN HARSH ENVIRONMENTS

Sigma-Netics, Inc., a global manufacturer of pressure switches, pressure transducers, metal bellows and metal bellows assemblies, offers durable pressure transducers that can withstand radiation, fatigue, submersion in underwater vehicles and high pressures in excess of 30,000 PSI. - A submersible vehicle depth transducer. This compact, 90-gram model features shallow diaphragm sensors and a configurable flange design for outboard or inboard bulkhead installations. Units include an all-welded hermetic construction that resists shock and vibration. Due to their ruggedized design, these pressure transducers meet the requirements of demanding industrial and aerospace applications—including deep space missions. Other notable features include combined temperature and pressure measurement, remote electronics modules, wide standard temperature ranges (-65° to +250°F) and more. As with our bellows, bellows assemblies and pressure switch products, Sigma-Netics offers customized solutions for cases in which standard catalog products will not meet an OEM’s application requirements.

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Available models include: - A general industrial pressure transducer with wetted material alternatives, extended thermals and pressure ranges to 25,000 PSI. - A radiation-tolerant MV/V pressure transducer, which features custom ATP, NDE traceability and low mass for tight installations. - A high-pressure, fatigue-rated transducer for pressures in excess of 100,000 PSI. Units are available with extended temperature compensation ranges, high-level analog and digital outputs and ±0.25-percent FSO accuracy. - A multipurpose aerospace pressure transducer, which features shunt calibration, multi-temperature thermal sensor characterization and cryogenic options. - A miniaturized aerospace pressure transducer. This lowmass, highly accurate unit weighs in at less than 90 grams. Units feature a ¾-inch outer diameter, pressure ranges up to 10,000 PSI and a variety of wetted material options.

www.sigmanetics.com/products/pressure-transducers

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S M A R T FA C TO R Y

COMPANIES JOIN FORCES TO SOLVE VENTILATOR ISSUE

Cygnus Manufacturing Company is a leading manufacturer and supplier of high precision products and components for the medical device, transportation, energy, and aerospace industries. CMC provides fullservice manufacturing from prototype through production.

s an FDA compliant and ISO 13485 medical devices certified manufacturer, a leading US ventilator company approached CMC at the start of the COVID-19 pandemic requesting expeditious assistance to substantially increase its production of a specialty valve in response to the country’s shortage of lifesaving ventilators.

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The ventilator company had a chrome on brass part which required measuring thirty-one data points after the part was manufactured and also after it was plated. Importantly, as a medical device manufacturer, they needed CMC to document all measurements. CMC currently manufactured this valve, but the substantial increase in required production volume in a compressed time frame necessitated a much faster and more automated measuring capability. CMC needed precision optical instruments designed to scan and measure cylindrical parts in seconds, not minutes. CMC turned to Inspection Technologies to identify a metrology solution for this emergency production. As an OGP® representative, Inspection Technologies suggested a TurnCheck, a precision optical instrument, equipped with system software that is both intelligent and intuitive. 30 | Industry USA | April 2021

Since CMC needed a solution immediately to ramp-up production, Inspection Technologies worked with OGP to expedite the TurnCheck order and production. OGP was able to fast-track the delivery. Craig Harding, Chairman and CEO of Cygnus Manufacturing Company, stated, “We were extremely pleased with the speed of OGP’s responsiveness and the high-quality performance of the TurnCheck system, allowing immediate increased ventilator production to help meet the country’s demand during this crisis.” OGP President, R. Stephen Flynn added, “It is with great pleasure that we were able to meet the expectations of this customer to enable the manufacturing of such an important product during this difficult time.” https://www.ogpnet.com/ https://www.cmc-usa.com/ itgage.com/

S M A R T FA C TO R Y

ROBOMOLD PLASTIC SOLUTIONS ANNOUNCES EXCLUSIVE ROBOTIC MOLDING CAPABILITY

Robomold Plastic Solutions, a division of Gemini Inc., announces that it has partnered with AMS, a leader in automation robots, to be the exclusive provider of robotic plastic molding capabilities for North America.

obotic plastic molding delivers high-precision heat and material control, allowing part designs to benefit from reduced materials consumption and finished part weight without sacrificing strength or durability. In-mold layering of different compounds and coatings enhance the technical properties of the most complex and high-value designs.

“Robomold Plastic Solutions is a uniquely qualified manufacturing partner with capabilities in part and tooling design, production and value-added modifications, and final testing and certifications,” said Dan Sauber, Product Manager, Robomold Plastic Solutions. “The addition of robotic molding furthers our ability to bring the most complex molded plastic designs to reality,” Sauder added.

ITAR certified and manufacturing to the highest tolerances with customers ranging from military to industrial and commercial OEMs. Robomold Plastic Solutions provides product engineering support, tooling, and testing to the most demanding industry quality standards, including Mil Spec 810, Mil Spec 648, and IPX.

www.robomold.com

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30 | Industry USA | April 2021

S M A R T FA C TO R Y

SENSORS WITH ATEX CERTIFICATION AND SIL2/PLD CERTIFICATE Don’t go airborne, but better safe than sorry if your application or its environment is at risk of explosion. TWK introduces a new safety encoder for explosion protection according to ATEX, Zone 1/21. Additionally with certificate for functional safety SIL2/Performance Level d. There are many different applications. Simple and complex. Inexpensive and expensive. Non-hazardous and hazardous. Some of them are even explosive. The medium-sized company TWK has suitable sensor technology for almost all areas of application to convert mechanical into electrical measured variables or into electronic data.

he basic principle is: Safety first. In the context of the risk of explosion, the product range has been expanded with regard to sensors with ATEX certification. In addition to the sensors for zones 2 (gas) and 22 (dust), which have been available for a long time, a new generation of encoders with the future-oriented PROFINET interface is now offered (also with PROFIsafe profile), which is also suitable for zones 1 (gas) and 21 (dust). These are compact enclosures made of aluminium or stainless steel with cable connection, which not only offer the wellknown robustness and reliability, but also unrestricted use in potentially explosive atmospheres as devices of ATEX group II, cat. 2, gas up to IIC and dust, as well as group dust IIIC. The certification is valid for, among others: ATEX, IEC-Ex, North America Class 1/2 Div. 2 and EAC-Ex. Of course also with SIL2/PLd certificate, if desired.

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A wide field of application is the oil and gas industry. The vapours and gases that occur are explosive and any assemblies that come into contact with them must have the appropriate suitability. For example, if loading cranes, which are usually equipped with ample sensor technology - e.g. encoders - are used in ATEX zone 1, the new TRT78/ S3-ATEX encoder with PROFIsafe interface can be used. It offers functional safety (SIL2/PLd) and explosion protection for Zone 1: safety in a double pack. The explosion protection is achieved by means of a flameproof enclosure with special cable glands in which the electronics are inserted. It withstands the explosion of a defective component. No sparks or heated gases can escape through the openings. Furthermore, the enclosure prevents dust from penetrating (IP6x). Since the surface temperature of the enclosure does not exceed 100 °C, gas and dust cannot ignite. Although the features of the sensors are increasingly complex and the functions more extensive, the prices have not exploded. On the contrary. Optimised designs and production methods significantly increase efficiency and reduce costs. You can find more information about the product at: https:// www.twk.de/en/products/rotary-encoders/8845/rotaryencoder-trt/s3-sil2?c=20

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S M A R T FA C TO R Y

PORTESCAP BRUSHLESS DC MOTORS ACHIEVE ISO 13485 CERTIFICATION FOR RESPIRATORS

Portescap, a leading global manufacturer of miniature and specialty motors, announces that its slotless brushless DC motors for respirators have received ISO 13485:2016 certification. Thanks to this compliance, medical device original equipment manufacturers (OEM) can be confident their motion control system has been manufactured to the highest quality standards.

xpanding on ISO 9001, this standard contains specific requirements for parts traceability and risk management activities throughout the design and development stages. It also requires process and software validations at defined intervals. Presented by independent risk management and quality compliance firm, DNV GL, ISO 13485 compliance is an important part of Portescap’s quality management system and demonstrates its consistency in design, development, production, storage and distribution.

As a result of ISO 13485 compliance, OEMs can be certain that products manufactured at Portescap’s 72,000-squarefoot facility in Mumbai, India meet the highest standards for quality and consistency. The plant currently includes over 1,100 staff and is outfitted with machining, winding and injection molding equipment, as well as an electrostatic discharge (ESD) safe assembly facility. www.portescap.com

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30 | Industry USA | April 2021

S M A R T FA C TO R Y

GUIDED CONTAINER AND TRAY IDENTIFICATION MADE EASY

A new addition to the BCL series: the stationary 1D bar code reader 200i.

Leuze is introducing the latest addition to the BCL series with the new stationary bar code reader BCL 200i. It supports guided container and tray identification, especially suited to tight installation spaces on the conveyor line.

s an expert in the field of identification, Leuze has been producing bar code readers since the 1990s. The company has continuously developed its product portfolio in this sector. LEUZE bar code readers meet numerous intralogistics requirements and are thus suitable for a wide range of applications. With the BCL 200i, Leuze is now expanding its BCL series with an additional stationary bar code reader.

Small but powerful The new BCL 200i is a 1D bar code reader with integrated industrial interfaces and simple PROFINET configuration. The device can be configured directly in the control via the GSDML file. The compact design makes it suitable for applications in tight spaces, such as on or between conveyor lines. This compact design also features a side cable outlet as well as its dovetail connection.

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Specialized for guided container and tray identification The new BCL 200i is particularly suited for the detection of 1D codes in guided container reading, regardless of whether the bar code is printed vertically or horizontally on the label. The same is true for guided tray identification when various moving trays are horizontally marked with 1D codes. The device features integrated Ethernet TCP/IP and PROFINET interfaces. The web-based configuration tool enables remote diagnostics from anywhere in the world. Detection through code reconstruction technology The integrated code reconstruction technology (CRT) enables the BCL 200i to read even bar codes with small line heights as well as damaged or smudged labels. With the aid of the CRT decoder, bar codes can also be read at a large 30 | Industry USA | April 2021

The new BCL 200i is particularly suited to guided container identification.

twist angle. The resulting decrease in no-reads significantly increases system availability. Activation without additional sensor system Thanks to automatic reflector activation (autoReflAct), the new stationary bar code reader can be activated without an additional sensor system. This is achieved by directing the scanner with reduced scanning beam towards a reflector mounted behind the conveyor path. As long as the scanner is targeted at the reflector, the reading gate remains closed. If the reflector is covered by an object such as a container with a bar code label, the scanner activates the read procedure. The label on the container is then read. The read procedure is completed as soon as the scanner has a clear line of sight to the reflector again. https://www.leuze.com/en/usa/

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30 | Industry USA | April 2021

S M A R T FA C TO R Y

QUICK SERVICE RESTAURANTS URGED TO PROTECT THEIR COVID INVESTMENTS

Quick service restaurants across the US are being urged to protect their investments in COVID-adapted facilities, as the global health crisis continues to change the shape of the sector.

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he advice comes from specialist hardcoated film provider MacDermid Enthone Industrial Solutions, which notes that COVID-19 and social distancing have significantly changed consumer behavior throughout the past twelve months, bringing structural changes to the restaurant industry that could last long after mass vaccinations have been completed. In an attempt to keep their doors open and continue trading through multiple lockdowns, quick service facilities adapted quickly last year, ramping up outdoor dining, introducing curbside pickup and embracing self-service, contactless ordering systems.

In 2020, MacDermid Enthone reported a sharp increase in enquiries from quick-service restaurants in its unique cleanliness support technology for restaurant surfaces, and is urging these facilities to view structural changes as long-term, warning that even after populations have been vaccinated against COVID-19, anxieties and concerns about dining out could well remain. It states that this could be the catalyst the industry needs to embrace a new future, where self-service touchscreens and enhanced cleanliness become the norm. Protecting these new surfaces from degradation, bacteria and other elements will enable quick service establishments to protect their structural investments and transition towards long-term dining changes, while continuing to give customers the cleanliness confidence they need to eat out. Anna Harris, R&D Project Manager at MacDermid Enthone Industrial Solutions, said these requirements are already driving a trend for fitting dining surfaces with hardcoated films containing built-in antimicrobial protection: “Quick service surfaces and equipment such as counters, tables and touch-screens are prone to bacteria build-up, degradation

30 | Industry USA | April 2021

over time and damage caused by high-touch traffic and cleaning chemicals.” “We’ve been working closely with the food service industry to explore and implement restaurant-specific solutions using our Autotex AM film, which has built-in Microban® product surface protection. We see this as an essential service, since every premises is different and every surface needs the right treatment. Autotex AM provides the printed overlay with solid protection against constant daily handling and rigorous cleaning and helps to keep the surface clean, even in between cleaning regimes. This means that touch screen and high-touch surfaces in every setting can be kept clean, robust and aesthetically attractive, as quick-service restaurants adapt to new ways of doing business.”

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“Protecting some of the structural changes implemented last year could be critical to ensuring short-term investments become long-term advantages. New solutions such as hardcoated films with built-in antimicrobial technology are part of the sector’s transformation and are making a real contribution as quick service facilities continue to adapt to rapidly changing circumstances.” https://industrial.macdermidenthone.com/

30 | Industry USA | April 2021

S M A R T FA C TO R Y

UNDER THE SURFACE

Non-destructive testing of composite materials.

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n yacht and boat building the most commonly used materials are the so-called composites. By cleverly combining the positive properties of at least two components, they often have outstanding features - some of them even specially adapted to their respective areas of application. It is hardly surprising that they are also used for high-performance applications in the aerospace industry, in power engineering, e.g. for wind turbines, in medical technology, in sports equipment manufacturing and in the automotive industry. However, wherever there are bindings, these can also “break” - be it through external influences or material fatigue. Regular tests are therefore indispensable. The iX-600 portable inspection system from UNX Technologies Co., LTD. Taiwan provides contactless inspection of multilayer composites, even for large surfaces. It uses image processing to detect weak points that are invisible to the human eye. In addition to a thermal imaging camera, a uEye board level camera with autofocus from IDS Imaging Development Systems GmbH is used.

30 | Industry USA | April 2021

Especially, in maritime applications the demand for composites is continuously increasing. In addition to floor elements, side walls, ceiling panelling or doors, also toilet compartments and separation units made of composite materials can be supplied. Moreover, load-bearing parts such as floors, walls or roof panels are possible and provide considerable weight savings. A classic example of a composite material used here is CFRP - carbon fibre reinforced plastic. It has a high stiffness and is very light at the same time. Or also GFRP - glass fibre reinforced plastic, a material made of plastic and fibreglass. It is cost-effective and yet very high quality. With such lightweight construction materials, the individual components are not combined into a single material, but exist virtually side by side. Therefore, damage such as bubbles, pores, foreign inclusions and delamination (peeling off of layers) can occur due to manufacturing processes. Even during operation, i.e. while the vehicle is moving, the strength of the material can be impaired, for example by an impact event. An impact against a composite panel can leave no visible damage on the outside. Inside, however, it will still lead to a reduction in compressive strength. Regular testing of the materials is therefore not only sensible but also vital for safety. Yacht manufacturers usually use the

Portable inspection system iX-600. Demo recording.

ultrasonic or impact-echo method to detect defects. This is based on the use of sound waves. It was developed in the 1980s for testing reinforced concrete components and is currently widely used. However, this process requires contact between the parts and is time consuming. Application UNX Technologies Co., LTD. Taiwan offers a real alternative. The portable inspection system iX-600 enables a non-contact and therefore guaranteed non-destructive inspection (NDI Non-Destructive-Inspection) of composite materials. Testing can be carried out with regard to detachment, delamination or porosity. The material properties are analysed beneath the surface and thus defects in the interior of the material are detected. The system also captures large inspection areas or curved structures effortlessly - without requiring a material sample in advance. For composite materials with multilayer structures, the iX-600 can also be used in addition to the manual sequential ultrasonic scanning described above to replace point information with area information.

Using the example of the outer skin of a motor yacht, the procedure can be explained in simple terms. The board level camera records the current image of the area to be inspected exactly parallel to the thermal imaging camera during the inspection. With the help of an image-processing technology, the system can quickly detect defective areas by analysing and matching the image data and display their relative position. All measurement results are clearly displayed and documented in the image. The delamination defects for example (green frame in the picture) can then be easily located for repairs. Industrial camera with autofocus UNX Technologies was looking for a compact camera for the mobile system that would also allow quick changes between different focal planes. “The iX-600 is a portable device. It must therefore be small and light. The same applies to its components, of course. In addition, the integrated camera must have a computer-controlled autofocus function due to the different working distances,” explains Dr. Yu-An Lai of UNX Technologies.

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The special feature of this: The fault location can be determined quickly and precisely. In addition to the infrared thermal image for evaluating the general temperature distribution on the test surface, the UNX system receives parallel image information from the integrated industrial camera. Thus it determines the exact defect status of the material. The decisive factor is therefore the combination of an infrared camera with a board-level camera with autofocus

from IDS, paired with a built-in industrial computer with a 7-inch touch screen and the associated software. The instrument, patented in Taiwan, is mobile and does not require an additional external computer.

The uEye LE AF USB 3.1 Gen 1 boardlevel camera from IDS meets all these criteria. It is suitable for the use and control 30 | Industry USA | April 2021

Inspection of the outer skin of a yacht. Evaluation result of the iX-600.

of liquid lenses and offers a practical autofocus function. This allows for optimally focused images at variable object distances. The automatic system is based on an “active” liquid lens control and can be easily triggered by software. Depending on the application, the autofocus can be individually configured and ensures perfectly sharp images in no time at all. UNX has specifically chosen the model UI3881LE AF with S-Mount lens mount. The camera is equipped with the 1/1.8’’ rolling shutter CMOS sensor IMX178 from the Sony STARVIS series and enables a resolution of 6.41 MPixel (3088 x 2076 px) at a frame rate of up to 58 fps. In addition to its high resolution, the sensor scores with speed and sensitivity, so that excellent images are achieved even under low-light conditions. The UI-3881LE AF has a twist-proof USB Type-C connector as well as USB power delivery and can be easily integrated into embedded systems. Due to its compact design (36 x 36 x 20 mm) it can be installed in the smallest space and is perfectly suited for classic machine vision applications and tasks in the fields of microscopy, medical technology, metrology and traffic monitoring. It is also predestined for installation in small industrial devices, such as the iX-600 from UNX Technologies. The Taiwanese company uses the IDS Software Development Kit to integrate the camera. IDS Software Suite is a free software package that is exactly the same for uEye industrial cameras (model designation “UI”) and can easily handle a mixed operation of USB 2.0, USB 3.0, and GigE uEye cameras. In addition to the camera drivers, it contains sample programs in various programming languages such as .NET. “This shortened our development time considerably,” explains Dr. Yu-An Lai.

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Outlook The iX-600 inspection system focuses on the market for non-contact and thus non-destructive testing of composite components. A market that holds a lot of potential. This is because the areas of application for composites are often sensitive. Whether in maritime applications, as described here, in space travel, medical technology or sports equipment construction - the load-bearing capacity of the materials used is essential and makes regular testing indispensable.

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However, UNX Technologies is also considering applications that will require industrial cameras with higher resolution or C-mount lens connection in the future. Here the company has the “sister camera” UI-359xLE AF in mind. Just like the UI-3881LE AF model used in the iX-600, it offers the possibility of focusing liquid lenses conveniently via the camera using software. On the sensor side, however, it is equipped with a 1/2” rolling shutter CMOS colour sensor from ON Semiconductor, which delivers an extremely high resolution of 18.10 MPixel (4912 x 3684, 20.0 fps), 4K Cinema (4096 x 2304, 38 fps) and Ultra HD (3840 x 2160, 40 fps). No matter which variant is used, the compact and powerful industrial cameras open up countless application possibilities. In mobile solutions, such as the iX-600, they make everyday work easier for the user in every regard and at the same time ensure greater safety. For those who can “see-through”, know what is happening under the surface. https://www.ids-imaging.us/

S M A R T FA C TO R Y

NEW WEBSITE OFFERS PRACTICAL GUIDE TO MAKING DECISIONS ON DIGITAL MANUFACTURING INVESTMENTS

“Digital Manufacturing from Mitsubishi Electric” demonstrates a framework that enables management to make decisions on step-by-step investments

Industry 4.0 and digital processes are indispensable for future manufacturing growth. While many companies understand the importance of automation, they sometimes struggle to make it a reality. They need a strong partner with the know-how to guide them.

itsubishi Electric has a 100-year history of supporting manufacturers, plus a prolific track record for achieving factory automation at its own and other manufacturers’ facilities. The approach embodies the Japanese philosophy of Kaizen that is now recognized worldwide.

This website also introduces some examples of how customers achieved real ROI around energy reduction, productivity improvements, and cost reductions ranging from 30% to over 90% with the use of Mitsubishi Electric’s e-F@ctory digital manufacturing solutions.

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The company’s new website titled “Digital Manufacturing” demonstrates a framework that enables management to make decisions on step-by-step investments to maximize profitability and accelerate growth. This approach, called the “Smart Manufacturing Kaizen Level (SMKL),” is a maturity model to help manufacturers navigate their way through the digital morass by defining shared key actions and expected outcomes across their organization with the target of achieving a high ROI from their digital manufacturing initiatives.

Key Points 1. Ensure everyone in your team shares a clear understanding of where you are with regard to digital manufacturing, where you think you need to be, and how you will plan to get there by using a practical review and planning tool. 2. Match your steps to your own company’s individual needs, budgets, objectives and execution speed. 3. Utilize suppliers’ know-how for smooth execution, even for complicated processes, based on years of experience. 4. B enefit from optimal solutions offered through collaboration with global experts.

For more, visit the new website “Digital Manufacturing from Mitsubishi Electric” at https://www.mitsubishielectric.com/fa/sols/digitalmanufacturing/en/index.html 30 | Industry USA | April 2021

S M A R T FA C TO R Y

NORD OFFERS VERSATILE, ROBUST DRIVE SOLUTIONS FOR THE BAKING INDUSTRY

With its lightweight, corrosion-resistant gear units, smooth surface motors, and variable frequency drives, NORD DRIVESYSTEMS is a powerful partner for the baking industry. The company’s strong, reliable drive solutions for mixing and agitation processes further extend the drive technology specialist’s product portfolio.

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ORD DRIVESYSTEMS offers efficient and hygienic drive solutions for the baking industry, meeting their special requirements for hygiene, reliability, and robustness. This includes agitators, conveyor systems, weighing and filling plants, packaging machinery, and more. NORD’s innovative variable frequency drive technology guarantees high positioning accuracy and safe implementation of dynamic sequences. The drive units can also be controlled individually, for example, they can regulate kneading and conveyer speeds in order to prevent blockages or control the dough process. Due to their modular structure, NORD drive units are also service and maintenance friendly.

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For the baking industry, addition of the nsd tupH sealed surface conversion treatment provides an outstanding anti-corrosion treatment for gear units, smooth surface motors, variable frequency drives, and motor starters with cast aluminum housings for extra protection in washdown environments. The fan-less smooth surface motors do not spread germs and operate with very low noise. Strong Drive Packages for Mixing and Agitating Applications CLINCHER Parallel Shaft Gear Units and the UNICASE Helical Bevel Gear Units are ideally suited for the demands of mixing and agitating applications. With torque capacities of 638,000 lb-in and 442,000 lb-in respectively along with extensive input designs and mounting options, NORD has the best fit for any application. They can also be supplied with foodgrade minerals or synthetic oil and bearing lubricants as well as a variety of gearbox and motor washdown protection options. These products are extremely low maintenance with long service life. When combined with NORD drive

NORD DRIVESYSTEMS offers a wide range of reliable, high-quality drive systems for the bakery industry.

electronics, you have a complete, reliable package from a single source. Robust Equipment Options NORD DRIVESYSTEMS offers application-specific equipment options that combine high performance and efficiency without the need for costly custom components. Each drive unit is specifically configured for the application it will be used for, such as agitators and mixers with high process-related radial and axial bearing loads. This includes an agitator version (VL2) with increased bearing distance and reinforced output shaft bearing, as well as a Drywell version (VL3) with additional oil slinger, dry cavity, and oil leak detection port.

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Additionally, within NORD’s paint portfolio, NSDF3 and NSDF3+ food duty paint is typically used for food production and packaging areas. This makes it the perfect solution for the bakery industry due to its compliance with environmental regulations and corrosion prevention. The paint systems used by NORD DRIVESYSTEMS are resistant to chemicals and have been tested for their resistance to all common substances which could have a negative effect on the environment. NORD paints are food-safe while being USDA and NSF compliant. https://www.nord.com/us/

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S M A R T FA C TO R Y

EFFICIENT. HYGIENIC. COMPACT. NORD IE5+ MOTORS OFFER NEW LEVELS OF ENERGY EFFICIENCY

NORD has announced the release of their most efficient motors to date. The new IE5+ permanent magnet synchronous motors are extremely energy efficient and compact for demanding conveying applications, with smooth surfaces that also make them an ideal choice in washdown and other harsh or highly regulated environments.

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he existing generation of NORD IE3 and IE4 motors already offers impressive efficiency, but the new IE5+ technology takes this one step further, delivering even more efficiency at low speeds and partial loads, resulting in additional operational cost reduction. IE5+ motors are extremely versatile and can be used for a wide range of applications including food and beverage, intralogistics, airport baggage handling, and post and parcel industries that frequently operate at partial loads or reduced speeds and may need to quickly adjust load size and speeds.

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NORD IE5+ motors deliver power ranging from 0.5 HP – 1.5 HP, torque ranges from 14.2–42.5 lb-in., and speeds from 0–2,100 rpm, all in a single motor frame. When these motors are combined with NORD gear units and variable frequency drives, they become part of a complete, single-source cabinet or decentralized drive solution that is engineered for high performance. This solution offers a significant size and weight decrease over the IE3 and IE4 motors. The IE5+ series takes full advantage of NORD’s modular concept to reduce variances within a system. This helps operators reduce Total Cost of Ownership (TCO) due to reduced spare part inventory and minimize administrative expenses, as well as set up leaner manufacturing, logistics, storage, and service processes. NORD engineers work directly with customers to tailor each solution to their specific needs and they are frequently able to provide specialized, highly precise drive solutions entirely from NORD’s standard product offering, eliminating the need for costly custom components.

NORD IE5+ Synchronous Motors.

For washdown applications, aluminum IE5+ gear units with nsd tupH surface conversion provide several advantages over traditional stainless-steel units, most notably their size and weight compared to stainless motors with similar efficiency ratings. NORD IE5+ motors are made of solid aluminum alloy and can weigh as little as 15.4 pounds versus much heavier stainless units of the same size. This, along with total lengths starting at only 9", makes commissioning and servicing much easier, even in tight spaces. NORD’s IE5+ motors are available with a variety of surface protection options, including high-solid paints for basic indoor use and severe duty paints for outdoor, food, and chemical protection. For harsher or demanding environmental conditions, IE5+ gearmotors are available with NORD’s patented nsd tupH sealed surface conversion which makes IP69K protection class coating possible. All housing components are surface treated to prevent corrosion along with shafting and hardware in stainless steel to allow NORD units to last longer, even in extreme conditions. MORE INFORMATION

https://www.nord.com/us/

30 | Industry USA | April 2021

S M A R T FA C TO R Y

RED LION INTRODUCES NT4008 GIGABIT LAYER 2 PROFINET SWITCHES

PROFINETperformance without compromise.

With copper and fiber options in both Fast Ethernet and Gigabit configurations, as well as advanced security and traffic control, Red Lion’s NT4008 combines the power of PROFINET real-time data exchange with the performance and trusted reliability only Red Lion can deliver. This helps to ensure the success of Industry 4.0 initiatives worldwide.

Red Lion’s NT4008 are UL Class 1, Division 2 and ATEX listed for use in hazardous and ordinary locations, ABS certified for shipboard applications and EN50155 certified for rail applications, ensuring reliable operation in nearly any environment. The IP-30 metal DIN-Rail enclosures, redundant 12–58 VDC power inputs, wide -40 to 75 °C operating temperature ranges and up to 50G shock resistance handle even the most extreme industrial conditions.

www.redlion.net

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ed Lion is excited to introduce NT4008, a new 8-port Gigabit managed Industrial Ethernet switch series. The NT4008 series switches are certified to meet PROFINET PNIO v2.34 Conformance Class-B standards to ensure seamless integration into PROFINET networks using standard PLC configuration and management tools.

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S M A R T FA C TO R Y

RED LION EXPANDS SIXTRAK® LINE OF INDUSTRIAL RTUS

A Rugged, Flexible Solution for Monitoring and Control in Extreme Environments.

ed Lion Controls announces the expansion of its SixTRAK line of industrial RTUs with the launch of ST-IPm-8460 powered by the Red Lion Workbench, which uses an IEC61131-3 compliant editor and runtime engine. Designed for applications that need increased processing and communication speed and storage, the new RTU provides the flexibility and reliability that customers require and expect from Red Lion to monitor and control equipment. The ability of the ST-IPm-8460 to operate in harsh and hazardous locations is achieved through UL Class I, Div 2 certification, an ABS listing, and an operating temperature range of -40 °C to 70 °C.

The combination of ST-IPm-8460 and Red Lion Workbench can easily support large, complex projects across multiple devices. The Red Lion Workbench provides customized control, standard language support, powerful debugging/ monitoring tools, project automation, and controller redundancy. Whether your application monitors a few data points or thousands, the ST-IPm-8460 can be easily configured to meet your needs using Red Lion’s EtherTRAK-2 I/O modules. Available for private labeling, the ST-IPm-8460 also offers dual power inputs and support for redundant Ethernet networks for increased uptime, while a multitude of communication ports and supported protocols enable connectivity to a variety of field devices. MORE INFORMATION

www.redlion.net

30 | Industry USA | April 2021

S M A R T FA C TO R Y

DATAFEED OPC SUITE EXTENDED INCREASES THE POSSIBILITIES OF DATA INTEGRATION

dataFEED OPC Suite Extended V5.10 further increases the possibilities of data integration.

The new version V5.10 of Softing’s dataFEED OPC Suite Extended offers MQTT subscriber functionality and extensive options for data preprocessing.

ersion V5.10 of Softing’s dataFEED OPC Suite Extended has been released. With the help of the new MQTT Subscriber, data can be received from an MQTT Broker and transmitted to other applications via OPC UA or written to a controller. This allows, for example, a recipe manager to be implemented in the cloud. In addition, extensive and flexible data preprocessing features now permit the execution of mathematical and logical calculations. Use cases include converting a temperature value from Celsius to Fahrenheit or filtering out a specific bit of a word.

“The dataFEED OPC Suite Extended makes the provision of production data for IoT cloud applications simple and secure,” says Andreas Roeck, product manager at Softing Industrial. “With each update, we are working to further expand the possibilities of data integration and make them even more flexible. This way, we offer our customers and partners a future-proof solution.” dataFEED OPC Suite Extended is a complete package for OPC communication and cloud connectivity in a single product. The suite can be used to access the controllers of leading suppliers and to connect to IoT devices.

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A free trial version of dataFEED OPC Suite Extended V5.10 is available for download from the Softing website: https://data-intelligence.softing.com/

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S M A R T FA C TO R Y

NEW FACTORY DIGITIZATION SOLUTION AVAILABLE ON SERVICENOW’S NOW PLATFORM

New Factory Digitization solution modernizes factory operations to enable workers to be more effective and efficient and improve practices with actionable insights.

lat4mation today announced Factory Digitization, a new solution built on the ServiceNow Now Platform, to enable manufacturers to improve production efficiency with mobile workflows that allow operators to manage tasks and consume knowledge on the shop floor. As part of the ServiceNow Partner Industry Solutions marketplace, Factory Digitization provides manufacturing plants with the ability to decrease downtime, increase worker efficiency, and easily implement continuous improvement practices.

The solution is available here on the ServiceNow Industry Partner Solutions marketplace.

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Plat4mation’s Factory Digitization will combine the company’s consultancy services for manufacturing business process optimization with the capabilities of 4Industry, a digital manufacturing operating system (DMOS) aimed at increasing Operational Equipment Effectiveness (OEE) and the ServiceNow Now Platform, equipping organizations with the tools they need to take advantage of all that Industry 4.0 has to offer.

Highlights include: - The DMOS, built on the ServiceNow Now Platform, boosts the employee experience through mobile and paperless workflows, taking factory productivity to the next level. - T he platform, which easily integrates with any existing factory technology systems, supports five key manufacturing processes within its mobile task management interface: Autonomous Maintenance, Planned/Preventative Maintenance, Safety, Health & Environment (SHE) policy adherence, Knowledge Management and Continuous Improvement. - Data from each of these processes is collected to provide a holistic dashboard view with actionable insights and reporting capabilities.

www.4industry.com

30 | Industry USA | April 2021

S M A R T FA C TO R Y

TECHMAN ROBOT SUCCESSFULLY ENTERED THE SUPPLY CHAIN OF MAJOR EUROPEAN AND JAPANESE CAR MANUFACTURERS

Collaborative robots that can be flexibly applied to a small-volume but large-variety production line, focus on human-robot collaboration and facilitate smart manufacturing are emerging.

ompared to other industries, the level of automation in the automotive industry is much higher. The latest report from Kenneth Research predicts that the shipment and sales revenue brought by collaborative robots in the automotive industry will increase by 43% every year by 2022.

The well-known Japanese car manufacturer adopts Techman robot to process the final quality check of all detailed assembly inspections. Techman Robot helped the customer to install the “next generation smart inspection system” utilise a customised stand including‍ four Techman collaborative robots. Besides the built-in smart vision, 36 external front and rear cameras were also installed. Moreover, each collaborative robot is equipped with three types of lenses, including short, middle and long.

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The Japanese car manufacturer mentioned that among their global production lines, this is the only one using the automated optical inspection (AOI) system and AI smart inspection solution. The ceiling-mounted arm can move inside/outside the car elastically to inspect items including wipers, horn, seats, seat belts, steering wheel, dashboard, centre console, remote control, fog lamps, and stickers, etc. All inspection data can be photographed and saved enabling quality traceability as well as guarantee the outgoing quality. The leading Japanese car manufacturer commented that TMflow, the innovative and user-friendly interface of Techman Robot, allows the well-trained insider to quickly 30 | Industry USA | April 2021

NEWS

program based on different car types or demands without asking the system integrator to come to the factory, and thus achieves a significant reduction of time, manpower and cost. Meanwhile, the built-in smart vision allows the customer to record all inspection data more efficiently to improve quality and implement data archiving and traceability which cannot be realised by manual inspection. Since 2018, Techman Robot has become an officially approved supplier of “Continental,” another world-famous manufacturer in the automotive industry, and started to improve the automated process in its signature factory located in Budapest, Hungary. This factory mainly produces telematics control units (TCU) for car manufacturers. Techman Robot not only optimised the pick and place application, but also enabled the customer to save the cost of installing a third party camera with the built-in smart vision.

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Moreover, the customer could also swiftly copy the program to different stations through “TM Landmark” to significantly reduce the time of training a collaborative robot to recognize the position and object. The “Plug and Play” gripper can run tests quickly to reflect the project performance in time. Techman robot, with the built-in smart vision, is the best choice to meet the smart manufacturing demand of highly flexible production in the automotive industry. www.tm-robot.com 30 | Industry USA | April 2021

TRACEABILIT Y

MARKING ON ALUMINIUM, A SIC MARKING SPECIALITY

Aluminium is a material with many advantages. It combines lightness and mechanical strength. In addition to its corrosion resistance, it is also an excellent thermal and electrical conductor. Capable of being 100% recycled, the use of aluminium is constantly increasing in industry.

A material used in many sectors of activity Aluminium is used in a very large sector of activity, particularly in aeronautics and shipbuilding, electrical and electronics industry and rail transport. It is also particularly appreciated in the automotive industry. In fact, many car manufacturers and equipment suppliers opt for this versatile material for the manufacture of car chassis, steering columns and power steering components. It is also found in the manufacture of turbo bodies, engine crankcases, cooler or automatic air conditioning elements. Aluminium also plays an important role in the fast-developing field of NEV (New Energy Vehicles), particularly in the manufacture of electric battery casings and other electronic components.

Various marking requests As the use of aluminium is so varied, so are the traceability requirements. Indeed, the marking requirements are of a very different nature and require barcode, Datamatrix, alphanumeric or logo marking. In addition, there are several constraints linked to the nature of the aluminium (anodised, alloy, etc.) but also to the customer’s requirements, particularly in terms of marking contrast or depth. It is not uncommon to be asked for a marking capable of being visible after the application of any coating or of resisting various surface treatments such as shot-peening for example.

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Perfectly adapted products from SIC MARKING SIC MARKING, the world leader in industrial traceability, has been committed for over 30 years to providing the most appropriate marking solutions to meet the challenges associated with the identification of aluminium components. Its experience has enabled the French group to offer a technically superior range of scribing, dotpeen and laser marking machines, as well as a large number of automatic reading solutions for Datamatrix. The SIC MARKING laser product range is particularly suitable for marking aluminium components both in series and 30 | Industry USA | April 2021

NEWS

individually. It consists of lasers that can be integrated with various options: - 3D function for marking on complex shaped parts - Vision function for fast and reliable barcodes and Datamatrix reading - Rotary axis for cylindrical parts marking The range is completed by 3 stations (L-BOX, XL-BOX and XXL-BOX) allowing to have a dedicated marking station. This can be integrated into a production line, or used as a stand-alone marking station. Small, medium and even large production runs are possible. The resizing of the boxes, the creation of specific tooling, the addition of additional movements (Z axis, rotary axis) are options available on request.

SIC MARKING was also recently used to provide a major German equipment manufacturer with the most suitable solution for its requirements. The customer wanted to mark a 7 x 7mm DMC code on air conditioning compressor pistons to facilitate their internal traceability. These codes needed to be marked deep enough to allow proofreading even after shot peening and tinning. All this in reduced cycle times. After various marking tests carried out by our dedicated project experts, the chosen solution was a 50W fibre laser, its power enabling it to carry out deep marking in record time. SIC MARKING also includes markings on NEV battery components, turbo bodies, identification plates for electric motors, engine cylinders… In addition to providing marking solutions that perfectly meet customer needs, SIC MARKING offers personalised support and a reactive after-sales service. www.sic-marking.com

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Many years of solid experience The SIC MARKING lasers, which are favoured by many customers, are a great success with ETIs and large companies that need to mark their aluminium components. For this reason, the international group with 300 employees has had the opportunity to prove all the qualities of its solutions by taking up the challenges offered by major automotive equipment manufacturers. Among these challenges was a particularly complex request from a major Japanese player in the automotive sector who wanted a station dedicated to marking Datamatrix codes on power steering components. The solution had to withstand a constraining environment (humidity, dust), fit into a small space and adapt to different part numbers. Based on its many years of experience, SIC MARKING was able to offer a compact customised station equipped with an HD laser automatically controlled on 2 axes, for fast and high-contrast marking. It is protected by a dust and moisture protection

system, making it easy to integrate into a difficult industrial environment.

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Industry USA | 30 - April 2021

Articles inside

SOFTING

RED LION

PLAT4MATION

TM ROBOT

SIC MARKING