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26 MARKET OVERVIEW THE EXOSKELETONS ARE HERE

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MARKET OVERVIEW English version

THE EXOSKELETONS ARE HERE While the use of exoskeletons in industry is still at the lower end of the spectrum, there is growing awareness about the benefits of exoskeletons in industrial applications.

I by Milton D’SILVA

n nature, some animals and insects have exoskeletons or external skeletons unlike most other living creatures, including humans, who have internal skeletons or endoskeletons. Crabs, lobsters, cockroaches, grasshoppers and several types of beetles are examples of natural exoskeletons. The early body armour adopted by human beings for combat was inspired by these exoskeletal creatures. The exoskeleton as a wearable device to augment human capabilities is of more recent origin, even as the idea was considered by many early inventors. An early example is a passive spring body brace invented in 1890, which supported the upper body in a stooping position, to relieve fatigue. However, the concept received serious attention only in the 1960s when GE developed the Hardiman in collaboration with the US Army and Navy for military use. Though the project was not successful, it paved the way for further development of the concept.

Example of a natural exoskeleton – the Japanese Spider Crab.

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MARKET OVERVIEW

The highly ergonomic Comau MATE upper body exoskeleton.

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MARKET OVERVIEW

The FORTIS from Lockheed Martin is suitable for handling heavy tools.

Exoskeletons thus made for human beings may be described as mechanical or mechatronic devices attached closely to the body, which support the musculoskeletal system using various mechanical principles. These wearable devices mimic the structure of human limbs, joints and muscles and boost the capabilities, enhancing the performance. Depending on the type, exoskeletons work in different ways, but basically shift the weight from one part of the body to another, reducing continuous strain. Besides augmenting the capacity to carry heavier loads without causing fatigue, exoskeletons also improve the body posture and minimise the risk of injury. Modern exoskeletons, developed mostly during the last two decades, are of two types – active and passive. Active exoskeletons are equipped with sensors and actuators, and powered by battery operated electric motors, pneumatics, hydraulics, or a combination of these systems. Passive exoskeletons are purely mechanical devices and use the restorative forces of elements like springs and dampers. There are further divisions in exoskeletons based on form – upper body, lower body or full body exoskeletons. Based on applications, exoskeletons are divided into two broad categories – medical and industrial. Medical exoskeletons 31 | Industry USA | September 2021

are used in the rehabilitation of patients post-surgery or to assist in those recuperating from paralysis or muscular dystrophy and other disabilities. Industrial exoskeletons also have military applications – in fact these were initially used in defence services and more recently have been deployed in industry. Exoskeletons are variously called exosuits or wearable robots, but unlike robots, which are autonomous and work independent of human support, the exoskeleton works in tandem with the human body, not as a replacement for any limb. This article is basically about industrial exoskeletons used by workers engaged in various activities. In spite of mechanisation and automation of workplaces with various handling equipment like trolleys, hoists, pallet trucks and overhead cranes, there are a lot of activities in industry, which are physically demanding yet cannot be automated. These vary from lifting of heavy loads or working in assembly operations that involve working long hours in standing or bending positions. Also many assembly operations in automotive and aerospace industries involve workers engaged in tasks with their arms continuously stretched upwards, carrying heavy tools. These activities cause pressure on the lumbar spine and/or on muscles in

MARKET OVERVIEW

various parts of the body, which in turn result in work related musculoskeletal disorders or WRMSDs. Growing health concerns Across the developed world – the Americas, Europe, Japan and now even China – the population is ageing and so is the working class – people working in factories and utilities – the typical blue collar jobs where manual labour in various forms is routine. These are also the jobs where the risks of workplace injuries, often of serious nature, are high and WRMSDs are common, adding to the overheads in terms of productivity loss due to sickness and absenteeism as well as high insurance costs. Apart from the unfairness of letting ageing employees go, there is that matter of the younger generation not so enthusiastic about jobs in factories and anything that involves physical activity. The situation is ripe for the induction of exoskeletons on the shop floor. According to a discussion paper published by the European Agency for Safety and Health at Work, over 40% of workers in Europe suffer from lower back pain or shoulder complaints. Furthermore, 63% of workers perform repetitive tasks or frequently work (46%) in potentially hazardous positions. This not only results in injuries and absenteeism, but also costs about 2% of the gross domestic product

of the European Union. Across the Atlantic in the US, the Centers for Disease Control and Prevention states that back pain is the most prevalent work-related health problem. The Occupational Safety and Health Administration estimates that employers pay nearly $1 billion for direct workers’ compensation. Against this backdrop industrial exoskeletons are becoming popular to address the many concerns of worker safety and productivity. The potential benefits of industrial exoskeletons are many, as these are designed to ease the load on the spine, decrease muscle activity and improve the posture, reducing the risk of injuries. Upper body exoskeletons reduce shoulder discomfort and increase productivity in assembly operations. While the use of exoskeletons in industry is still at the lower end of the spectrum, there is growing awareness about the benefits of exoskeletons in industrial applications, especially in automotive, construction, manufacturing and logistics sectors. An expanding market According to a recent analysis by Frost & Sullivan, the global industrial exoskeletons market is expanding rapidly, driven by high injury costs and aging and shrinking skilled workforces across sectors. It is estimated to witness nearly a

The Skelex exoskeleton is powered by FlexFrame Technology.

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The Cray

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seven-fold growth, reaching US$426.6 million by 2025 from US$62.7 million in 2020, up at a compound annual growth rate (CAGR) of 46.7%. (These figures do not include medical or military exoskeletons, only industrial ones.) “Manufacturers are investing in R&D to develop technologically advanced exoskeletons, which improve performance and productivity,” says Anjan Roy, Chemicals, Materials & Nutrition Research Analyst at Frost & Sullivan. “To deploy the latest innovations, manufacturers will focus on the robot-as-a-service (RaaS) model to improve affordability for end users and test products for large-scale deployment.” Among the end-use industries, manufacturing – driven by the automotive sector – held the highest revenue share in 2020 and is projected to top US$271.4 million in 2025. Other manual, labour-intensive industries such as construction and transport will also make extensive deployments of industrial exoskeletons over the next four to five years as companies across these sectors focus on reducing the cost of on-the-job injuries. “From a product segment perspective, active or powered industrial exoskeletons – which are technologically advanced PPE that are powered by batteries or electricity – are expected to have the highest revenue share at 69.9% over the forecast period, whereas passive industrial exoskeletons will constitute 30.1% market share,” adds Roy. Industrial exoskeletons in the market When the Swiss startup noonee launched its prototype Chairless Chair in 2014, German automaker Audi AG was one the first to test the wearable seating passive exoskeleton at its assembly lines at Neckarsulm plant. “With the use of the Chairless Chair, we are continuously improving ergonomics in assembly operations. We also anticipate new applications for colleagues with reduced physical capabilities,” Dr Mathias Keil, Head of Industrial Engineering Methods at AUDI AG, had then stated about the experiment. More automakers have since adopted the ‘Chair-olution’ as noonee called its invention, and it has undergone many refinements since. “Through active sitting on the Chairless Chair, your back and thigh muscles are strengthened while your spine, intervertebral discs and knees are relieved. The Chairless Chair supports a healthy and upright sitting posture and takes preventive action so that pain does not occur at all,” claims the company in its latest flyer made available during the presentation at the Digital Hannover Messe 2021. The new Chairless Chair 2.0 is a passive exoskeleton that allows workers to change easily between sitting, walking and standing.

Swiss startup noonee’s Chairless Chair tested extensively by Audi AG.

German company Ottoblock designs and manufactures the Paexo range of exoskeletons for the back, shoulder, wrist, neck and even the thumb! Paexo was developed based on Ottobock’s nearly 100 years of expertise in the fields of biomechanics, orthopaedic technology and product ergonomics. The company worked with automaker Volkswagen AG and the Institute for Biomechanics and Orthopaedics at the German Sport University Cologne to develop these products. The close cooperation with Volkswagen led to insights in production, work ergonomics

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The Paexo Thumb exoskeleton protects the tip of the thumb.

y X exoskeleton from German Bionic, at Hannover Messe 2019.

MARKET OVERVIEW

and occupational health and safety. At 1.9 kg, the Paexo is the most lightweight exoskeleton for overhead work. At Automatica 2018, Comau, the global leader in advanced industrial automation solutions, launched MATE, its first wearable exoskeleton. Designed to improve work quality in an efficient and highly ergonomic manner, MATE works by providing consistent and advanced movement assistance during repetitive as well as daily tasks. It uses an advanced spring-based passive structure and delivers lightweight, breathable and highly effective postural support without the need for batteries, motors or other failure-prone devices. In December 2020, Comau launched a new version, the MATE-XT, which fully accommodates the specific needs of workers in demanding industrial, non-industrial and open-air environments. Perfect for carpentry, construction, agriculture, assembly, logistics and more, MATE-XT replicates the user’s physiological shoulder movements to provide optimal upper body support and offers 8 different levels of assistance that can be quickly set – or changed – by the worker without interrupting the task at hand. At the 2019 Hannover Messe, German Bionic, a robotics company, presented the first connected robot exoskeleton compatible with IIoT. The Cray X exoskeleton, having undergone many improvements, is said to be the first cloud connected exoskeleton, enabling complete integration into Smart Factory and Industry 4.0 environments. Skelex, a Dutch startup, is another company that has successfully introduced an upper body passive skeleton in the market, primarily for the aerospace and automotive industries. Gaurav Genani, an engineer by day is a guitarist after work, performing in a band and nursing a wrist injury, apart from having gait issues not uncommon with guitar players. While doing his master’s thesis on musculoskeletal disorders amongst musicians at TU Delft in Rotterdam, Gaurav had his Eureka moment that led to exoskeletons and the founding of Skelex. What started as an idea in 2013 finally found its way to the market in 2017 as Skelex 360, with Airbus Industrie among its first customers. The Skelex exoskeleton is powered by the proprietary FlexFrame Technology, the device adapting to the user’s body shape, and supporting biological movement of the shoulder joint, transferring the weight to the lower body. Skelex however does not manufacture these exoskeletons, preferring to concentrate on design and innovation, and has outsourced manufacturing to another Dutch company. Collaboration and outsourced manufacturing is a trend that has caught up in exoskeletons, and even aerospace companies have got into the act. Boeing – one of the largest aerospace manufacturers – has been testing different types of exoskeletons as part of its Working Smart strategy. The company has tested the Ekso Bionics’ EksoVest extensively and found it leads to increased worker strength and speed, as well as reduced fatigue on repetitive tasks, such as overhead drilling. These are now inducted in assembly operations. Lockheed Martin, the well-known global security and aerospace company, manufactures exoskeletons for its own requirements as well as for military

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Ottoblock designs and manufactures the Paexo range of exoskeletons.

Ekso Bionics’ EVO allows full flexibility of the torso and waist.

Hyundai Motor Group’s VEX and CEX exoskeletons. 31 | Industry USA | September 2021

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applications, based on designs of well-known companies like Ekso Bionics and Boston Engineering. While Ekso Bionics has been engaged in developing exoskeleton technology to enhance natural abilities and improve quality of life since 2005, Boston Engineering is a product design company. One of the more interesting exoskeleton products of Lockheed Martin is the FORTIS exoskeleton for handling heavy tools through a spring loaded arm. Held in a gimbal for smooth rotation and flexibility, the FORTIS takes the weight of a heavy tool off the user’s body and directly passes it off into the ground, allowing effortless handling while retaining the controls. Having undergone several revisions since it was first introduced in 2017, the latest version of the FORTIS features a new, redesigned spring arm, which is connected to the exoskeleton at the waist. A set of counterweights at the back keeps the operator steady. Korean company Hyundai Motor Group is also engaged in research and development of exoskeletons as part of its robotics project. Hyundai’s latest exoskeleton wearable robot, Vest Exoskeleton (VEX), has won the Product Design category (Innovative Product field) at the Red Dot Design Awards, the prestigious international design competition. VEX was developed in line with Hyundai Motor Group’s commitment to the health and safety of its industrial workers. It is designed to prevent injuries while advancing the field of robotics. The compact design is achieved using the latest technology that eliminates the need for a battery. VEX, which wears like a backpack, utilises a polycentric axis to provide a maximum force of 5.5 kgf – an astonishing achievement given it weighs only 2.8 kg. In addition to VEX, Hyundai has also designed another lightweight wearable robot, the Chairless Exoskeleton (CEX). With CEX, workers can easily maintain a sitting position without a stool or chair. While all the examples quoted above are of passive exoskeletons which are more common among industrial versions in general, there are also active exoskeletons available for industrial use. ULS Robotics, a Shanghai based startup designs and develops exoskeletons for industrial applications. The company has already in production three types of industrial exoskeletons for upper body, lower body and the lumbar region respectively. MAPS-U is the upper body exoskeleton with four degrees of freedom that provides 10kg of load assistance to the arms for lifting endurance, also reducing shoulder fatigue while preventing work injuries. HEMS-L is a waist that provides 20kg of load assistance, while HEMS-GS is a lower limb exoskeleton with 12 degrees of freedom and 50kg load bearing capacity. All three models are fully electric with battery power for 5 hours of continuous work and quick and easy replacement facility to continue the job beyond. The company says it has many international clients in the automotive and aviation sectors, as well as logistics. No article on exoskeletons can ignore the contribution of Dr Homayoon Kazerooni, academician and entrepreneur. A professor in the Mechanical Engineering Department at the University of California, Berkeley, Dr Kazerooni is also the director of Berkeley Robotics and Human Engineering Laboratory. The laboratory’s mission is to develop fundamental scientific and engineering principles on robotics, control sciences, exoskeletons, and bioengineering. Dr Kazerooni founded Ekso Bionics which became a public

company in 2014, and is the founder and current CEO of US Bionics (DBA suitX), which brings advanced exoskeleton technologies to various markets. Most of the technologies developed in this lab at Berkeley have found their way to market. In fact, suitX offers all three individual exoskeleton modules designed to be able to work in unison to assist the shoulders, back and legs. Each module can be worn individually or in combination to make seven different configurations to cater to customers’ specific needs. The way ahead The exoskeletons have arrived and are in use across various manufacturing sites and assembly operations globally. These are getting better and lighter with new materials like ultralight carbon and soft, super strong technical textiles used in their construction. Once prohibitively expensive, exoskeletons are now within the affordable range of large companies, and with growing popularity and mass production, prices are expected to fall further. But it is still early days and the jury is out on the safety and efficacy of the exoskeleton. In the absence of empirical evidence based on detailed studies as well as absence of standards, there are concerns expressed about the health and safety aspects. For example, the US Consumer Product Safety Commission (CPSC) has warned that muscle strain could occur if a powered exoskeleton moves beyond the normal range of motion of a user’s joint. There is also the risk of skin irritation or chemical burns if an exoskeleton battery leaks corrosive materials. A study has pointed out that some upper body exoskeletons do not reduce the total load on the worker, merely shift it from the shoulders to the lower back and legs. Other risks include pressure wounds or compressed nerves from prolonged use. When such wearable devices are used by multiple users, poor hygiene could spread infectious diseases. In 2017, ASTM International, the international standards organisation, proposed a guide to provide standardised tools to assess and improve the usability and usefulness of exoskeletons. Accordingly the ASTM Committee F48 was formed to develop voluntary consensus standards for exoskeletons and exosuits. It is currently working on the proposed standard, WK68719, working through six subcommittees that include about 150 members, including startups, government agencies, and enterprises such as Boeing and BMW. The F48 committee has already published the first two standards regarding terminology and Standard Practice for Labelling and Information for Exoskeletons, many others are under development. In February 2021, the committee approved a new standard to help establish ergonomic parameters and test metrics. According to ASTM International board member Christopher Reid, the new standard can be used during the iterative design process of exoskeleton creation as well as for comparisons between commercially off-the-shelf ready systems. It is a work in progress and the standards are still evolving. But the exoskeleton has arrived.

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CO R P O R AT E

ALEXANDER LEWINSKY EXPANDS THE MANAGEMENT OF IDS IMAGING DEVELOPMENT SYSTEMS GMBH

On 1 August, the shareholders of IDS Imaging Development Systems GmbH appointed Alexander Lewinsky to the management board. The engineer (BEng, MSc) will take over the operational management of the Obersulm-based industrial camera manufacturer together with Jan Hartmann. Managing partner and company founder Jürgen Hartmann remains responsible for development and product management.

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he company thus relies on internal staff: Alexander Lewinsky has been part of the IDS team since 2012, first as product manager, then as purchasing manager and division manager for production/logistics and quality assurance. In Obersulm, he will continue to be mainly responsible for purchasing, production, logistics, quality assurance and infrastructure. “With Alexander Lewinsky, IDS is getting an experienced employee in the industry as Managing Director, who has accompanied the development of the company for 9 years and has had a significant influence on the entire Operations division, not least through structuring and optimization measures,” says Jürgen Hartmann. His son Jan Hartmann is responsible for administration, sales, system consulting and marketing.

“I am very pleased about the appointment and look forward to working even more closely with Jürgen and Jan Hartmann,” explains Lewinsky, who has been part of the extended management team as an authorized signatory since March last year. Early preparation for a generational change in one’s own family business is close to the heart of founder Jürgen Hartmann: “Continuity and reliability are particularly important to us in relation to our partners and customers. With the rejuvenation of the IDS management, we are very optimistic about the future”. The positive order situation and the strong development of foreign business give the camera manufacturer every reason to do so, despite the challenging procurement situation. Since its foundation in 1997 as a two-man company, IDS has developed into an independent, ISO-certified family business with more than 330 employees. The headquarters

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Alexander Lewinsky joins the management of IDS Imaging Development Systems GmbH as of 1.8.21 IDS Imaging Development Systems GmbH Management: f.l.t.r.: Alexander Lewinsky, Jan Hartmann, Jürgen Hartmann

in Obersulm, Baden-Württemberg, is both a development and production site. With branches in the USA, Japan, South Korea and UK as well as offices in Europe, IDS is represented internationally. https://en.ids-imaging.com/

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CO R P O R AT E

PDES, INC. AND DMSC, INC. SIGN MEMORANDUM OF UNDERSTANDING

PDES, Inc. is pleased to announce the signing of a Memorandum of Understanding (MoU) with the Digital Metrology Standards Consortium (DMSCTM, Inc.). Both organizations seek to improve the ways tools work together to improve standards development, analysis, and define applications of industry standards.

DES, Inc. and DMSC seek to improve the quality and manufacturability of product information through standardization by promoting the Quality Information Framework (QIF), and STEP/QIF Integration, as part of the ISO/TC 184/SC 4 portfolio. The two organizations plan to support joint projects to reach that goal. Dr. Michael R. Jahadi, President of the PDES, Inc. Board, stated, “This new MoU will enhance the interoperability of standards by leveraging the expertise within both organizations through collaborative projects. By supporting the integration of STEP/QIF, we can reduce cycle time and operational cost while improve the quality of data required for the downstream consumption of Model Based Enterprise (MBE). As a result, both organizations could achieve their business goals and objectives.”

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Curtis Brown, President of DMSC, commented “We’re excited about working with PDES Inc. to continue supporting harmonization of QIF and STEP. A key benefit of collaboration between our two organizations will be enhanced industry availability and implementation of QIF/STEP tools in a MBE environment. Better utilization of connected Quality information will enhance design and manufacturing processes, resulting in faster time to market and lower production costs for companies with a vision of Industry 4.0.”

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The Digital Metrology Standards Consortium (DMSC, Inc.), founded in 2005, is a non-profit consortium organization with the responsibility of developing and maintaining the QIF standard. The broader mission is to promote, foster, and develop interoperability standards and quality data frameworks for the manufacturing field of digital metrology. The purpose of these digital metrology standards is to positively impact the digital thread for the Model-Based Enterprise. The DMSC is an ANSI Accredited Standards Developing Organization, as well as an A-Liaison to ISO. The consortium invites participation within the consortium of other standards groups and activities that seek to resolve the technology and other issues of automated (digital) metrology. For more information: https://qifstandards.org PDES, Inc. is a participation-based consortium focused on the development and implementation of model-based standards to support the digital enterprise. Founded in 1988, the organization includes members from Industry, Government and Academia. More information can be found at https://pdesinc.org/

CO R P O R AT E

AWARD FOR EXCEPTIONAL QUALITY IN PRODUCT AND SERVICE

Schneider Electric presented Neugart with this year’s “Schneider Electric Supplier Award” in the “Quality” category. The two Managing Directors, Bernd Neugart (right) and Thomas Herr, accepted the award at a virtual event. (Source: Neugart GmbH)

Neugart is currently the only company to have received this year’s “Schneider Electric Supplier Award” in the “Quality” category. With this award, the French electrical engineering group, Schneider Electric, recognizes outstanding achievements from among its approximately 15,000 suppliers worldwide.

he jury based its decision in favor of Neugart particularly on the “ability of this supplier to deliver high-quality products day after day” and also highlighted the excellent service level.

https://www.neugart.com/fr-fr/

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The two Managing Directors, Bernd Neugart and Thomas Herr, accepted the award on June 3 at a virtual event - on behalf of all employees, as they emphasized: “This award shows once again how important the work and commitment of each individual is. The professionalism of Neugart and the flexibility provided to this internationally positioned company with our products and warehousing close to production makes a significant contribution to Schneider Electric achieving the highest customer satisfaction ratings continually, allowing it to remain competitive in the long term.”

As a gearbox manufacturer, Neugart has been one of Schneider Electric’s preferred suppliers for many years. The reasons for this longstanding relationship are: first, the expertise gained from over 90 years of experience and more than 400,000 planetary gearboxes delivered worldwide annually. And, secondly, a comprehensive overall package of gearbox hardware, tools, supply chain and services.

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ELECTRONICS

PORTESCAP LAUNCHES ONLINE TOOLS FOR SEAMLESS PRODUCT EVALUATION AND ORDERING

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Portescap has unveiled two new online tools to streamline the process of evaluating and buying miniature motors. MotionCompass delivers product recommendations for brush and brushless DC motors based on user criteria, and the eStore lets users quickly and easily find, configure and order Portescap miniature motors. Here’s how they work MotionCompass. This dynamic tool allows users to input operating points such as torque, speed and voltage, along with key application parameters and gearbox and position feedback requirements. MotionCompass will generate a list of motor recommendations that users can prioritize in ascending or descending order according to their speed, efficiency, power or current needs. It also immediately displays prices and availability so users can proceed to the eStore, confirm the order quantity and complete their purchase.

gearheads and encoders. And checkouts are even faster with an e-store account.

eStore. Portescap customers can browse or search for off-the-shelf products to suit their desired configuration, environment or envelope. When a customer selects a motor, they can easily download its specifications as well as 2D drawings and 3D CAD models, check its availability and, if the product is not available for immediate shipment, request a quote. In addition, users can customize a motor for a hard-to-satisfy application by reviewing options for

https://www.portescap.com/en/motioncompass https://shop.portescap.com www.portescap.com

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Taken together, these online tools offer designers a convenient and comprehensive resource to guide their motor selection decisions throughout product development, allowing them to iterate their design and implement any changes based on their off-the-shelf motor options. Customers will also be able to test their designs in a virtual setting, which saves time and helps get end products to market faster.

ELECTRONICS

STANDARD SELF-LATCHING MULTIPOLE CONNECTORS WITH ALIGNMENT KEY

The LEMO B Series offers a modular, ergonomic, rugged and reliable circular multipole connector for applications needing quick and secure Push-Pull latching. Making it an ideal choice for test and measurement, instrumentation, medical devices, research and audio/video applications.

he modular insert configurations include a wide range of high-density multi-pole or hybrid electrical contacts. Contacts can be of solder type, crimp, PCB straight or PCB elbow, fiber, coaxial, thermocouple, pneumatic, fluidic or even high voltage type of contact.

The LEMO B-Series ranges from 00 to 5B size, and features the LEMO “chocolate design” pattern. LEMO’s keying system allows for a higher contact density while preventing mismating. These high quality LEMO connectors are UL listed and cable assembly can be provided. https://www.lemo.com

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ELECTRONICS

THE HIGHEST LEVEL OF PHYSICAL PROTECTION FOR POS TERMINALS – WITH THE HELP OF 3D-MID

POS terminals are considered a popular target for data theft. Attackers use mini-drills to gain access to credit card numbers and PIN codes.

Point-of-sale terminals (POS) are not sufficiently protected against physical attacks. Attackers can access sensitive data (such as credit card number and PIN codes) using probes or mini-drills. An additional security element in the security caps of the terminals can reliably prevent such attacks.

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ccording to a survey by the Bitkom digital association, cyber attacks have caused damages of 102.9 billion euros throughout 70 percent of companies in Germany in recent years. According to the survey, the scope and quality of the attacks have increased dramatically. “The recreational hackers of the past have evolved into wellequipped and technologically savvy cyber gangs,” Bitkom reports. POS terminals count among the targets. Sensitive data such as credit card numbers and PIN codes are temporarily stored on POS terminals to prevent data loss in the event that the payment process is interrupted. This data can be read by attackers if they gain access to the hardware using probes or mini-drills. An additional security element can be used which reliably prevents data loss.

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3D-MID security caps increase the safety classification Electrical paths (traces) on the inside of the protective cap provide a very reliable additional security mechanism that protects against physical attacks. These traces form a closed circuit. They are so close together that it is practically impossible for an attacker to gain access. Any attempt to attack would either damage a trace and break the circuit or short out two traces. This causes the POS terminal to shut down immediately, resulting in the loss of cached data and rendering the device unusable. The electrical traces are applied directly to the plastic parts of the security caps using the 3D-MID process. HARTING is the largest supplier of 3D-MID components (Mechatronic Integrated Devices) outside of Asia and offers all steps in the 3D-MID process under one roof. The injection-moulded circuit carriers replace conventional solutions that use a plastic carrier and printed circuit board. They do this by integrating the function of both parts into one MID. This reduces weight, reduces the number of components and lowers production costs, while at the same time improving

3D-MID caps from HARTING protect the electronics mechanically and electronically from unauthorized access. A high-precision meandering structure detects even the smallest intrusion – thus preventing data theft.

HARTING’s security caps offer outstanding protection thanks to minimum trace spacing of 70 to 150 µm, more traces, and a higher packing density.

security. This 3D-MID solution is particularly useful for POS terminals to improve security standards and to defend against hacker attacks. Very small trace gaps improve security Thanks to HARTING’s 3D-MID technological edge, customers benefit from compliance with the strictest PCI-DSS (Payment Card Industry Data Security Standard) requirements. This solution differs from other suppliers of safety enclosures in that it has smaller trace widths. The closer the distances between the individual traces, the more difficult it is to manipulate the circuit from the outside. While most suppliers today can implement trace widths and spacings of around 300 to 500 µm, Harting offers 70 to 150 µm.

the same component so that a higher packing density can be achieved. 3D-MID technology also allows for improved versatility in the shaping by creating flexible geometric contours in injection moulding and processing them with a laser for the electrical traces. Thus, rounded edges, elevations and transitions can also be produced. https://www.harting.com

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Lower costs thanks to automated production HARTING’s 3D-MID solutions are more secure. Moreover, thanks to the extensive automation of the entire supply chain, they are also more cost-effective than solutions from many other suppliers. All production steps are carried out at HARTING’s own factory. This speeds up the process, increases the production yield and saves transportation costs. Even for products that are technologically less demanding, HARTING has been able to prevail over competitors from Asia. HARTING is the only 3D-MID manufacturer in the world that has a laser system with three fine-focus optics of 50 μm. The fine-focus laser can achieve even smaller trace spacing of only 70 to 80 µm. This enables many traces to be created on 31 | Industry USA | September 2021

ELECTRONICS

SERIAL PRODUCTION OF HEXADRONE’S TUNDRA MODULAR TOOL-CARRIER DRONE WITH FISCHER CONNECTORS’ RUGGED, MINIATURE CONNECTIVITY SOLUTIONS

The Tundra in flight.

Hexadrone unveiled its first serial drone, the Tundra, a ruggedized, multi-functional, modular drone that will be industrially manufactured in a factory under construction in France. The Tundra uses ultra-rugged, miniature Fischer UltiMate™ and Fischer MiniMax™ connectivity solutions, able to withstand the harsh environments the drone may need to operate in.

esulting from more than three years of development, the Tundra is the first French modular, multi-rotor drone. Designed in Hexadrone’s workshops in the Haute-Loire in an open innovation logic, this collaborative tool carrier, in its beta version, won the prestigious Red Dot Design Award in 2018.

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Unveiled on April 30, 2021 in its serial version, the Tundra is a unique 100% modular, multifunctional unmanned aerial vehicle (UAV), designed and manufactured as a development hub for integrators. The body is equipped with numerous interfaces that allow the integration of accessories, sensors and other modules already available on the market, or the development of new ones. This enables the Tundra to adapt to custom features and rapid changes in the state of the art, which also helps it combat obsolescence. The drone’s arms are interchangeable and easy to remove. The user can choose from three different types, depending on the various missions and flight scenarios planned. With the most durable arms, the Tundra can carry a payload 31 | Industry USA | September 2021

of up to four kilos for a flight time of 30 minutes – a high performance in the world of multirotor drones. The serial production of the Tundra, made possible thanks to the construction of an industrial building underway in Saint Ferréol d’Auroure in the Haute-Loire, is the logical next step in this drone’s development that meets the market needs analyzed by Alexandre Labesse, Hexadrone’s Chairman and Founder: “With this multifunctional, modular tool carrier, our customers are opening up the field of possibilities in their collaborative projects and lowering their development costs when they adapt the drone to users’ new needs and new technologies on the market. This is not possible with most of today’s drones, which are designed for a single type of use and quickly become obsolete due to rapid technological advances. In response to obsolescence, we’ve opted for adaptability and durability.” The Tundra’s durability is ensured through a robust design that allows for intensive use in the field. The drone is waterproof and can cope with harsh conditions. Moreover,

The Fischer UltiMate™ Series interface on the Tundra’s body.

The Tundra with Yellowscan’s Mapper, equipped with three Fischer MiniMaxTM Series connectors.

The standard interface module can be adapted with Fischer MiniMaxTM connections.

transportation and assembly in the field are easy, as the landing gear can be fitted and the arms screwed on in less than a minute. Two types of robust, miniature connector for intensive, durable use To fulfill the drone’s technical requirements for modularity, reliability, durability, ruggedness and ease of use, Hexadrone chose Fischer Connectors’ high-performance, ultra-robust, push-pull connectivity solutions. The Tundra comes equipped with a rugged Fischer UltiMate™ USB 2.0 connector that is waterproof and reliable in all conditions. The standard interfaces can accommodate external modules linked, among others, by Fischer MiniMax™ connectors and cabling, which optimize the high-density miniaturization of on-board electronics, such as a companion computer, a storage module, a security key or a lidar that the Tundra can be fitted with for certain aerial remote-sensing missions using lasers.

technical requirements in terms of robustness and reliability, miniaturization, sealing up to IP68, and data transmission”. • Tundra: www.tundra.hexadrone.fr • Shop for Hexadrone’s drone: https://hexadrone.fr/ • Fischer UltiMate™ Series: www.fischerconnectors.com/ global/en/fischer-ultimatetm-series • Fischer MiniMax™ Series: www.fischerconnectors.com/ global/en/fischer-minimaxtm-series • F ischer Connectors’ solutions for UAVs: www. fischerconnectors.com/global/en/applications/roboticsunmanned-vehicles

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Guy Lacroix, Director of Fischer Connectors France, is very happy with the technological partnership established throughout this rugged drone’s development: “We’ve been supporting the Tundra’s innovations from the outset. Our experts are gratified to have been able to see the project through to serial production with suitable connectivity solutions. Since connectivity lies at the heart of this rugged UAV, our high-performance solutions proposed in this modular offering cover the whole range of integrators’ 31 | Industry USA | September 2021

ELECTRONICS

DEEP INSIGHT WITH LIGHT REVOLUTION

How do you make a car rim glow without melting the tyre? Patrick Llewelyn-Davies does it with light, and thereby creates an unusually enlightening picture of this everyday object. His Light Revolution System redefines the contrast of light and shadow, as it uniformly irradiates the object from a complete circular path. A precision motor from FAULHABER ensures the uniform movement of the lamps and exact adherence to 360 degrees.

ost photographs have the snapshot noise in common: whether a smartphone selfie or an artistic professional photograph – the shutter allows the light to pass through the aperture for just a fraction of a second. Fittingly, the analog shutter noise is even simulated by fully digital cameras to acoustically mark the brief moment in which the image is captured.

But there is also a long tradition of light painting, in which the aperture remains open for an extended period of time and moving lights leave their trace on the negative or image sensor. Fascinating images and views can be created using this technique. A familiar example is the red and white streaks of light from headlights and tail lights that can be seen on long-exposure images of motorways at night. Unlike with “normal” photography, movement is not stopped, but rather captured.

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Plastic glow British photographer Patrick Llewelyn-Davies bridges the gap between “moving” light painting and still life. In his images, the resting object is at the centre, and he uses the moving light like a pen for colouring in. Only that he adds no additional colour to his images. Instead, he causes the objects to glow and illuminate. His use of light also allows for the creation of new and sometimes X-ray-like glimpses into the photographed objects. They take on a quasi three 31 | Industry USA | September 2021

dimensional plasticity even though they never optically leave the 2D world.

or less than 360 degrees. And they should accomplish this in precisely the specified amount of time.”

The secret to the light-painted still lives is a seemingly simple apparatus called “Light Revolution System”, which has two meanings. Revolution here means both rotation as well as a fundamental renewal. Two intensely bright LED lights complete a cycle around a round table on which the object of the photographic efforts has been placed. It generally takes six seconds for them to complete their rotation. The time can be varied, however, depending on the desired light effect. The system does not just travel a round path but rather opens completely new possibilities for photographic image composition – there has never before been anything like it on the market.

The inventor/photographer reports of earlier attempts with simpler components that were not able to meet these requirements. The greatest challenge was in moving the central axis of the system both very precisely as well as jerkfree. At the same time, the portable device needed to be as light as possible. When making the selection of the right drive, the experts of the British FAULHABER sales partner EMS provided assistance. “The support from EMS was great,” explains Patrick Llewelyn-Davies. “They provided the necessary technical expertise for the drive and the controller. It is decisive for the high quality of the product. Moreover, motors from FAULHABER have proven themselves in highly critical areas such as aerospace. That’s how I knew that they would have the accuracy and reliability required by the Light Revolution System.” The experts from EMS identified the brushless motors of the BX4 series as the optimum solution. They were able to ensure the desired precision and repeatability of the sequence. “Once we selected a motor family, we could try different sizes without intervening in the programming”, explains Dave Walsha, Commercial Development Officer at EMS, with regard to the joint development work. “As a result, we were able to respond very flexibly to changes to the system.” Thanks to the compact and lightweight design of the BX4 motors, the “ideal weight” was also maintained.

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Maximum precision during rotary motion The lights are fastened to two arms and can be adjusted in height to achieve different angles of incidence. The arms are firmly attached to the rotating central axis. At first glance, this arrangement does not call for any spectacular technology, but in detail, maximum precision and extremely smooth operation are decisive. “Any pause or jerk in the rotation, regardless of how short, would result in uneven illumination,” explains Patrick Llewelyn-Davies. “There would be brighter and darker patches that would affect or destroy the intended effect. The same applies for travelling the complete circle. The arms must not move one degree more

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NEWS

Detailed 3D models of museum objects Of course, the photographer thoroughly tested his Light Revolution System himself. In his online gallery, you can admire examples of the unique light effects that he has achieved with his system. The “glow” that he elicits from unassuming everyday objects like a chicken egg or a fishhook is created by placing the circling LED lamps very low above the table. Because part of the light is laterally reflected by the objects onto the base, a glowing aura is created that appears to emanate from within the objects.

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The system is currently being tested in various application areas. Instead of the lights, a camera can also be attached to one of the arms. If it is attached to an arc-shaped arm, the object can be photographed at a uniform distance from various angles. This method is used, e.g., by museums to calculate high-resolution 3D models of their valuable objects from image data. Researchers can then exchange this data worldwide and use it for their studies. Furthermore, precise replicas can be created using 3D printing. “Up to now, a considerable amount of hand work was associated with the creation of such images,” says Patrick LlewelynDavies. “With the Light Revolution System, the process can be largely automated and greatly accelerated.” https://www.faulhaber.com/en/home/

31 | Industry USA | September 2021

ELECTRONICS

DUNKERMOTOREN IS FIRST DRIVE TECHNOLOGY MANUFACTURER TO INTEGRATE CERTIFIED PROFINET WITH PROFIDRIVE IN SERVO MOTOR

Since the end of February 2021, Dunkermotoren’s fully integrated PROFINET solution has been officially certified by the PROFIBUS user organization.

his means another important feature is fully integrated into the motor, which is a milestone in terms of cabling, commissioning and IIoT capability. Dunkermotoren, the world leader in brushless DC motors with integrated electronics from 1 to 4000 watts, is the first drive technology manufacturer to fully integrate its certified PROFINET solution with PROFIdrive into a motor. The certification assures Dunkermotoren that the high standards of stability, even under extreme bus conditions, are always maintained. Currently the products BG 95 dPro, BG 75 dPro, BG 66 dPro and the BGE 5510 dPro are available with PROFINET interface, covering the output power from 1 to 4000 W. https://www.dunkermotoren.com/en/ MORE INFORMATION

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MEASUREMENT

MONTH’S PRODUCT

OGP INTRODUCES EXCLUSIVE TECHNOLOGICAL ADVANCEMENT IN VIDEO COMPARATOR SYSTEMS

Optical Gaging Products (OGP®), a world-leading manufacturer of precision multisensor metrology systems for industrial quality control, announces a technological breakthrough in value-class video comparator systems: The Automatic Three-Position Lens Changer, available on c-vision™ Lite Video Contour Projectors®.

his CNC lens turret allows for nine automatic, programmable magnification changes – 3 optical and 6 digital – within a CNC program. The system is both parfocal and parcentral – parts on the stage stay in focus and stay centered when magnification and focal length is changed. Three internal lenses offer 2-inch, 1-inch, and half-inch fields of view – permanently mounted in a shop-hardened motorized turret.

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“Before this innovation, operators were required to manually unscrew a lens, attempt to safely store the lens, screw in a new lens, and recalibrate – a very timely task that could never be done in the middle of a program” said Tim Fantauzzo, OGP Vice President of North American Sales. “The innovative c-vision Lite lens turret system allows for these changes automatically, and as part of a CNC program, resulting in far faster, and more accurate measurement results – tying together small part feature details with larger overall part measurements.”

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c-vision Lite systems are a part of the c-vision family of Video Contour Projectors from OGP – the value-class c-vision Lite, the capable c-vision Benchtop, and the heavy-duty c-vision Floor Model. c-vision systems combine the speed and accuracy of a video measurement system with the rugged capacity of an optical comparator, to create the world’s best shop-floor measuring tools for 2D measurement. https://youtu.be/5JKRh84IzHE www.ogpnet.com

MEASUREMENT

PRECISION TOOL TECHNOLOGIES DESIGNS AND DELIVERS RELIABLE GAS INFLATION COMPONENTS

Precision Tool Technologies, Inc., a solutions provider focused on specific industries, has introduced a full line of gas inflation components and systems. These products get the job done on land, sea and in the air when rapid deployment is not only expected—but necessary.

recision Tool Technologies’ gas inflation products integrate proven design, manufacturing and testing concepts with durable materials that boost component reliability, successfully resist corrosion and achieve long service life in saltwater environments. All inflation control components meet the highest quality standards while also conforming to the most current ISO 15738:2019 standards for maritime safety with many components independently tested.

In addition to providing standards units, Precision Tool Technologies can customize its valves and flanges to fit your unique needs in applications ranging from life rafts and slides, to inflatable shelters and venting systems. www.precisiontooltech.com MORE INFORMATION

Products include: • Relief valves that maintain the working pressure of the inflatable structure and provide protection against overpressurization. They also feature very efficient venting of the excess inflation gas. • Top off valves that incorporate an aggressive pitched threaded inlet, allowing users to easily attach integral hand pumps even in cold temperatures. • Inlet check valves that disperse high-pressure, highvelocity gases into the inflatable structure. These units also prevent backflow pressure loss from the inflatable structure following inflation.

• Flanges with a cementable design for simple, efficient installation. Units feature durable materials and achieve an extended service life in demanding environmental conditions. • Inflation valves with durable, plated and coated components that boost their performance and corrosion resistance.

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With a proven process set for more than 200 active customers, we can adapt to all specific client needs with the highest reliability. We have developed in house the most advanced PR dedicated ERP, enabling transparency and real-time full online reporting. International media management is then made easy, fast, and efficient for optimal results.

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MEASUREMENT

EXXELIA’S COMPONENTS ONBOARD PERSEVERANCE ROVER

Exxelia, a leading manufacturer of complex passive components and sub-systems dedicated to harsh environments, is back on Mars onboard the Perseverance rover serving 3 key high-precision measuring and sampling instruments. Where are Exxelia’s components? Prior to answering this question, one has to know that the robot is equipped with seven highly complex measuring and sampling instruments. These tools will be acquiring information about Martian geology, atmosphere, environmental conditions, and potential bio signatures. Three of these tools, SuperCam, MEDA and PIXL, are served by Exxelia’s components:

A key mission requiring a perfect understanding of space missions Strong of its 40+ years’ experience in space applications, Exxelia offers the most complete space qualified passive components product portfolio showing no less than 50 product series qualified to the stringent European Space Agency qualification procedures. Why? Because “we all know that when a product is in space, it can't be fixed! It has to work, and it has to work for 20 years! Our products are tested for 3 to 4 months, to be sure they will work perfectly. In total, the whole process from start to finish takes at least 16 to 20 weeks”, explains a senior VP at Exxelia

• SuperCam is the laser-eye of Perseverance. Its objective is to characterize the rocks present on Martian soil by remote analysis. • The Mars Environmental Dynamics Analyzer (MEDA): It makes weather measurements including wind speed and direction temperature and humidity. • PIXL is an X-Ray fluorescence spectrometer that detects and analyses chemical elements within the rocks and soil.

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Exxelia is back on the Red Planet After the InSight probe that landed on the Red Planet on November 26, 2018 with the high reliability specialist‘s film capacitors onboard, it is with the Perseverance robot that Exxelia proudly makes its return to Mars! At the end of a seven-month journey, NASA’s Perseverance robot landed on Mars on Feb 18 at 3:55pm EST with one mission: search for traces of ancient primitive life on the Red Planet.

https://youtu.be/ARY8WkbQndg https://exxelia.com/en/

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MEASUREMENT

ROHDE & SCHWARZ AND COLBY INSTRUMENTS COLLABORATE TO OFFER ACCURATE TEST SOLUTION FOR UWB DEVICE LOCALIZATION

Ultra-wideband (UWB) technology relies on the ability of devices to determine their location based on distance, moving direction and relative position to other devices. To meet the UWB ecosystem’s testing needs, Rohde & Schwarz and Colby Instruments have collaborated to offer a concerted test solution that accurately simulates the moving direction of UWB devices.

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ohde & Schwarz, a leading provider of wireless device testing solutions, and Colby Instruments, a leading manufacturer of high-precision programmable delay lines, have joined forces to provide the UWB ecosystem with an extremely accurate test solution for angle of arrival (AoA) and phase difference of arrival (PDoA) characterization.

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Engineers testing UWB devices now can combine the R&S CMP200 radio communication tester and WMT software service to implement automated wireless manufacturing testing from Rohde & Schwarz with the high-precision delay lines XT-200 from Colby Instruments to perform measurements in conducted mode including calibration and verification. In UWB technology, the distance between two devices is calculated by accurately measuring the time a UWB signal needs to travel from a transmitter to a receiver (time of flight). By measuring the time or phase difference of a signal received at both UWB receive antennas, it is possible to calculate the angle of arrival. The delay lines let users characterize the DUT with a delay range from 0 to 625 ps and a resolution of 0.50 ps, making it possible to simulate even granular angles and distances. The R&S CMP200 combines the capabilities of a signal analyzer and generator in a single instrument and offers a complete solution for transmitter and receiver measurements in conducted and radiated environments.

Christoph Pointner, Senior Vice President for Mobile Radio Testers at Rohde & Schwarz, says: “With the three core UWB services – hands-free access control, location based services and device-to-device services – determining the location and direction of a device is key for UWB technology. We are happy to have pooled our competencies with those of Colby Instruments to provide the UWB ecosystem with a perfectly matched, highly accurate test solution to master this crucial challenge in UWB device characterization.” Victor Chinn, President at Colby Instruments, says: “We are excited to partner with Rohde & Schwarz to offer innovative products incorporating our industry-leading precision delay line instruments, fully integrated into a single test system solution. Our X Series instruments offer unparalleled precision and performance to meet the challenging UWB market requirements.” https://www.rohde-schwarz.com/uwb

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MECHANICS

ROBOTUNITS’ MODULAR LINEAR MOTION UNITS REDUCE MANUFACTURING ASSEMBLY TIME

The Robotunits Linear Motion System is designed to connect easily with the company’s other systems, components and accessories to allow the easy creation of complete modular automation systems while reducing assembly time. This addresses the demands of plant operators for production systems that can be built, rebuilt and rearranged quickly to respond to changing needs.

he standard Linear Motion Unit includes 50-millimeter aluminum extrusions and a common 14-millimeter T-slot, making it compatible with other Robotunits systems. These key elements — along with the company’s proprietary fastening technology — enable the Linear Motion System to work in combination with Robotunits’ conveyors, material handling components, safety fencing and machine frames.

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The unit is available with a single or double carriage, and the system allows the energy chain to attach directly to the carriage without the need for additional components. For advanced applications, the Omega Linear Motion Unit can be used as an individual device or x-y-z gantry to move and position parts with precision.

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The Robotunits Linear Motion System also features • An integrated belt return inside the extrusion. Three sides of the extrusion can accommodate additional attachments. • The use of single or double idlers, depending on the load. The idler extrusion features a special captive design for high strength. • Durable construction, including large rollers. • Single and multiple guide rails available. • Limitless combinations and complexity. www.robotunits.com

MECHANICS

ACE CONTROLS’ MC75 MINIATURE SHOCK ABSORBERS PROVIDE HIGH-ENERGY DAMPING IN TIGHT SPACES

ACE Controls Inc., a leading manufacturer of industrial motion and vibration control technology, announces its MC75 Family of miniature shock absorbers. Thanks to their small size, these units can provide highenergy damping in tight installation spaces in industrial manufacturing, material handling, packaging, medical, electronics and robotics applications.

achine designers across these and other industries are often tasked with decelerating loads quickly and without recoil in their machines. However, machine designs don’t always allow for a full-size damper. And, the damper must be easy to install. The MC75, which addresses these challenges, features an energy capacity of 75 inch-pounds per cycle and 250,000 inch-pounds per hour. Available in weight ranges from 0.5 to 2.5 pounds through 55 to 160 pounds, units have a very short length of 2.77 inches. They also feature a 0.40-inch stroke length and deliver low return forces.

ACE miniature shock absorbers include a robust construction and one-piece outer body filled with temperature-stable oil. They’re also self-compensating — able to react to changing energy conditions without adjustment. Additional features of the MC75 include: • Continuous outer body thread with lock nut • Integrated positive stop • Maintenance-free • Ready to install

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ACE customers can access our online Calculation Tool to ensure they receive the right shock absorber for their application, as well as our Configurator Tool to select the appropriate accessories for the MC75. www.acecontrols.com

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MECHANICS

COVAL ANNOUNCES A NEW SERIES OF MINI VACUUM PUMPS WITH IO-LINK COMMUNICATION

Coval’s new LEMAX IO series of mini vacuum pumps with IO LINK communication integrate all the required functions for optimized vacuum management in a compact package. Via their IO-Link communications interface, the mini vacuum pumps communicate permanently with the environment and thanks to ASC (Air Saving Control) technology, combine productivity with energy savings, adapting to a multitude of applications in packaging, robotics or plastics processing. Without needing extra peripherals, these all-inone mini pumps are fully compatible with Industry 4.0 automation.

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IIO-Link, simplified communication The IO-Link interface ensures efficient real-time communication between LEMAX IO vacuum pumps and all the higher-level protocols (Ethernet/IP, PROFINET, EtherCAT, etc.) used for supervising the production line. IO-Link enables continuous diagnostics, centralized programming and pump control. The availability of real-time diagnostic status data makes it possible to optimize production. In addition to fast and cost-effective installation, preventive maintenance is easier and the replacement of vacuum pumps does not require reconfiguration.

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Energy savings ASC technology, which ensures intelligent vacuum control by stopping air consumption when the set vacuum level is reached, generates energy savings of between 75 and 99% depending on the application. In addition, ASC analyses the application and adapts to either impermeable or porous parts to optimize operation and energy consumption. Compact size and light weight Compact in size, the LEMAX IO pumps have all the principal functions integrated in a single module: pressure regulation, solenoid valves, anti-clogging open silencer, electronic vacuum switch, M8 connector (direct Plug & Play connection) and adjustable blowing. Their reduced size and weight (130 g) allow the suction cups to be positioned at minimum distance to achieve the shortest possible grip time without load loss.

Modularity The LEMAX IO can be adjusted to the needs of integrators and users. They are available in three nozzle diameters (1, 1.2, 1.4 mm) allowing a suction flow rate from 1.02 to 2.47 SCFM (max. vacuum 85%). They are optionally equipped with a normally closed (NC) or normally open (NO) solenoid valve. This variant is recommended for applications where gripping the workpiece must be guaranteed in case of an unexpected power failure, or even if leakage occurs (positive safety). Several LEMAX IOs can be combined in an island with a single pressure supply. www.coval-inc.com

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MECHANICS

SECO HELPS CUSTOMERS REDUCE THEIR CARBON FOOTPRINT

Seco already has well-established methods for life cycle analysis of its own products and for mapping of production processes as part of its aim to reduce the company’s climate impact. The next step is to also offer to help reduce customers’ carbon footprint.

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ustainability is one of the strategic focus areas for Seco, and the company has ambitious targets and well-developed plans for how to contribute to a better climate in accordance with the UN Global Goals. The company uses established calculation methods to report greenhouse gas emissions from its own production. As the next step, Seco is developing systems that will enable its customers to optimize use of Seco products and thereby reducing their climate impact. “When companies analyze their climate impact, they generally base this on traditional life cycle analyzes of their own manufacturing and products. However, 70% of the climate impact of our tools occurs in the user phase. Significant gains can be achieved by helping our customers optimize the use of our tools,” says Ted Forslund, Global Sustainability Coordinator at Seco.

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Seco and its R&D department are now developing data models which can be used to calculate customers’ carbon footprint in the user phase. The model takes the entire life cycle of a tool into account, including energy consumption and the use of coolant in the customers’ production processes. This in turn helps customers to optimize their processes and reduce their climate impact. “By making the right choices, using the correct cutting data and avoiding suboptimizations when producing individual parts, customers are able to reduce their carbon footprint by at least 20%. The idea is to find the optimal way to produce a part by changing different parameters,” said Sören Hägglund, PhD and R&D Expert Cutting Data at Seco. To help with this, the R&D department at Seco has developed software that can be used to simulate various production processes and try out different alternatives for producing an item, such as choice of processing method, machine, strategy and tool. “For example, it is possible to see if you are using a machine or tool to its full potential during a particular production process. If you can see that the full potential of a machine or tool is not being used, it might be worth selecting other options in order to minimize the

Bar chart showing the potential for reducing CO2 emissions in processing operations. The model includes the carbon footprints of the machine, tools, coolant and electricity consumption.

carbon footprint,” says Daniel Johansson, PhD and Senior R&D Professional at Seco. The huge advantage is of course that customers can easily see how to reduce their carbon footprint. This is also something a lot of customers have been asking for, according to Daniel Johansson. “There is a lot of demand for sustainable manufacturing, but this solution may not have occurred to many in the machining industry,” he says. “What is unique about our solution is that in addition to being able to see our own products, we can also include customers’ processes and offer them the opportunity to minimize the carbon footprint of their production. To use a term borrowed from the automotive industry, we offer a so-called Eco button.”

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Aside from sustainability issues, this work is also in line with the ambition Seco has to stay at the forefront of digital solutions. “In the R&D department we focus a lot on developing technology that can be used in the future and which can be used as a cornerstone for other digital solutions. Currently, our solution is not available for public application, but in the long term we could envisage offering an interface for external use,” concludes Sören Hägglund. https://www.secotools.com

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MECHANICS

RINGFEDER ANNOUNCES GWE 5113 SERVO-INSERT COUPLING WITH NEW HUB DESIGN

RINGFEDER has recently released its GWE 5113 series of elastomer jaw servo-couplings, featuring a new hub design. This design eliminates radial loads and achieves uniform power transmission with an even clamp force and symmetrical arrangement of clamp and screw positions.

WE 5113 couplings precisely transmit torques from 3 to 560 Nm. The hub is slit partially through and located directly under the jaws to minimize pressure on the shaft. Units come with an elastomer spider with 98 Shore A hardness, minimizing movement and achieving longer life cycles. They also come in seven sizes from 12 to 42, with diameters ranging from 4 to 56 millimeters. Equipped with shorter couplings, the GWE 5113 prevents premature wear and system failure. Units also comply with ATEX, providing maximum operational safety.

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www.ringfeder.com

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MECHANICS

WIDIA EXPANDS TOP DRILL™ MODULAR X (TDMX) DRILL PLATFORM TO MACHINE STAINLESS STEEL AND SUPER ALLOYS

The TDMX modular drill features a double angle pocket seat design and a flanged shank that provides outstanding flexibility and stability.

The MS geometry insert for the TDMX modular drill platform provides increased stability when drilling stainless steels and super alloys.

New MS geometry delivers stable modular drilling for general engineering and energy applications.

IDIA announced today the release of a new MS geometry insert for the brand’s best-selling TOP DRILL Modular X (TDMX) drill. With the MS geometry expansion, the TDMX platform now offers three material-specific inserts, broadening the platform’s application capabilities to include inclined entry and exit, stacked plates and cross-hole drilling in stainless steel, super alloys, steel and cast iron materials.

The drill’s “X”-shaped pocket, and tapered seat provide stability in challenging applications while making it easy to change out the insert without disassembling the body from the holder. These key design features reduce unstable cutting conditions experienced with other drills commonly available in the market today, while enabling higher penetration rates and reducing overall machine set up times and costs.

“The launch of the MS geometry insert for our TDMX portfolio gives customers a versatile tool for multiple workpiece materials and applications,” said Ashokkumar D., WIDIA Global Portfolio Manager. “This new MS geometry is designed to perform in different types of stainless steels and super alloys making it an ideal choice for customers looking for excellent stability and reliability in general engineering and energy machining operations.”

All three inserts can be reground to extend the life of the tool. TDMX is available in both imperial and metric sizes in 1.5xD, 3xD, 5xD, 8xD, 12xD and diameter ranges 16 to 40 mm. Orders for the TDMX and MS geometry insert as well as other WIDIA metal cutting tooling can be placed through WIDIA authorized distribution partners.

In a recent customer test, the TDMX body, paired with the new MS geometry insert, achieved a 60 percent increase in tool life versus competing solutions while machining a 13-8 Hyper Chrome 110 KSI workpiece material at 3XD with a cutting speed of 75m/min.

https://www.widia.com

https://youtu.be/v_AK6w3OHfE MORE INFORMATION

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MECHANICS

KENNAMETAL INTRODUCES FIRST STELLITE POWDER FOR LASER POWDER BED ADDITIVE MANUFACTURING

Kennametal’s new Stellite 21 AM metal powder (shown here) unlocks the superior wear and corrosion resistance of the Stellite alloy family for laser powder bed additive applications in oil and gas and power generation.

Stellite 21 AM™ powder unlocks the superior wear and corrosion resistance of the Stellite™ alloy family for additive applications in oil and gas, power generation and beyond.

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ennametal Inc. (NYSE: KMT) announced the launch of Stellite 21 AM powder, the first Stellite powder qualified for laser powder bed additive manufacturing, and the latest addition to Kennametal Additive Manufacturing’s portfolio of high-performance metal powders optimized for 3D printing. With Stellite 21 AM powder, the unique corrosion and wear-resistant properties of the Stellite alloy family are now available for laser powder bed additive platforms to produce high-performance wear components for the oil and gas and power generation industries. Kennametal Additive Manufacturing is the Company’s 3D printing and production business unit within its Infrastructure segment.

“Kennametal Additive Manufacturing is drawing on our longstanding expertise in metal powder production to help our customers leverage the advantages of 3D printing and make better parts, faster and more efficiently,” said Sam Lomasney, Marketing Portfolio Manager, Kennametal. “The addition of Stellite 21 AM powder to our portfolio of highperformance cobalt, nickel and iron powders is another proof point of how we continue to innovate in materials for additive manufacturing.” The business drew on deep expertise in metal powder production for hard facing and thermal spray applications to develop Stellite 21 AM powder. It is available direct to customers for use in their own 3D printing applications or in combination with Kennametal’s end-to-end additive production capabilities to make fully finished components. Valued for its superior wear and corrosion resistance, the Stellite 21 alloy has a long history of success in traditional manufacturing applications in the oil and gas, power generation and aerospace industries. Stellite 21 AM powder enables customers to achieve similar wear and corrosion resistance properties in additively manufactured parts. It

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is ideally suited for flow control applications and can be integrated into complex designs to mitigate cavitation, erosion, or corrosion failures.

https://www.kennametal.com

The new powder’s composition features a Cobalt Chrome Molybdenum alloy matrix, containing dispersed hard carbides which strengthen the alloy and increase its hardness while decreasing the material’s ductility. It also has excellent corrosion and thermal shock and mechanical shock resistance.

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Kennametal Additive Manufacturing offers comprehensive 3D printing solutions, from raw material to finished part. It utilizes gas atomization powder production capabilities to supply cobalt, nickel and iron powders optimized for specific additive manufacturing processes. In addition to the new Stellite 21 AM powder, the business also recently added Delcrome 17-4 AM and Delcrome 316L AM powders for direct metal laser sintering (DMLS) systems to its portfolio of additive powders. At its research and development, prototyping and production center in Latrobe, Pennsylvania, Kennametal Additive Manufacturing utilizes laser powder bed and binder jet printing technologies, combined with post-print processing capabilities, including sintering, hot isostatic pressing and machining, to produce fully finished wear components. These include parts printed with powders specifically designed for 3D printing, including Kennametal KAC89 tungsten carbide and Stellite 6 AM, a wear resistant cobalt-chrome alloy. 31 | Industry USA | September 2021

MECHANICS

KENNAMETAL INTRODUCES THE FBX DRILL FOR FASTER AEROSPACE MACHINING

The FBX drill is part of a tooling concept specifically developed to maximize metal removal rates and decrease cycle times when machining aerospace structural components.

New modular drill delivers maximum metal removal rates for structural components.

ennametal has introduced the FBX drill for flat-bottom drilling of structural aerospace parts. The patented FBX drill delivers superior stability and up to 200 percent higher metal removal rates when machining high temperature alloys, stainless steel, and other materials. The new modular drill is the critical first step in a three-part tooling concept—including the HARVI Ultra 8X and the HARVI end mill series—specifically designed by Kennametal to decrease cycle time for these types of applications.

Quickly removing large amounts of material remains a challenge for these types of components. Traditionally, the first process step is to enter the material by using ramping techniques. This is a time-consuming process and low metal removal rates are the norm. “The FBX drill dramatically speeds up the machining process by combining the advantages of a flat bottom drill and a z-axis plunge mill. The flat bottom design eliminates radial forces while four effective cutting edges provide increased feed and speed rates, leading to up to 200 percent higher metal removal rates than traditional ramping techniques and freeing up capacity for aerospace manufacturers,” says Georg Roth, Product Manager, Kennametal.

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Once the drill has shaped the basic structure of the component, roughing and finishing with indexable and solid end mills are the next process steps. Unique Design Features Four effective cutting edges provide stability in challenging applications like chain hole drilling, while large chip flutes ensure a hassle-free chip evacuation. Supported by a series of exchangeable coolant nozzles to help eliminate heat 31 | Industry USA | September 2021

The unique design of the FBX flat bottom drill directs cutting forces into the machine spindle, minimizing deflection while increasing tool life and metal removal rates.

buildup, the drill point is characterized by a center insert with two effective cutting edges and chip splitters for maximum feed capabilities. The drill bodies are available in diameters 60, 75, and 90mm, and come in a long and short version (150mm and 95mm). This modular drill connects to Kennametal’s bolt taper flange (BTF) mount adapters, available in various spindle connection styles. Versatility and Performance in One Tool The FBX is ideally suited for drilling into solid, chain hole drilling and plunging in a variety of materials such as high temperature alloys, stainless steel, and steels and cast irons. It is equally as versatile and high performing in similar applications for the general engineering and power generation markets. https://www.kennametal.com

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31 | Industry USA | September 2021

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METRIOS. MEASUREMENT SYSTEM AND MECHANICAL PRECISION INSTRUMENTS

High quality injection molding. “A contactless measuring machine was the ideal solution for measuring rubber”. Not just a number. Every machine has its own name “Our employees aren’t just numbers, and neither are our machines. Here, every machine has its own name, even a nickname!”. Technology as your best partner Metrios could allow you to increase the efficiency of your production processes and, at the same time, it will also offer objective results and customized solutions.

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Paolo Marchetti – General Manager DEMA ITALY: “Technology helps you avoid mistakes as you’re not obliged to remember the intricate details of a given process. Data from the previous operation is saved in the PLC or software’s memory, so all you need to do is press a few buttons, making everything easy.”

What is common between injection molding and cooking? “Injection molding is like cooking. If you rush a cake, it’s either going to be undercooked or overcooked. The same applies to rubber. The rubber is injected and then baked in the molding machine. So, it takes patience, time and the right temperature.” “We produce about 40 million parts a year, with about 300 molding machines and consume about 50 tons of raw material.” Why choosing metrios? “This is a part that we’ve been working on for a few years now. We had a dispute about size, and I didn’t have the right instrument to measure the tight dimensions. So, I researched contactless optical measuring instruments and found just what we were looking for METRIOS.” “The quality-price ratio was ideal, so I put my trust in the machine and bought it”. Discover more about Metrios Measuring Machines

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“This is a 40-shore platinum silicone, so if we measure it with calipers, you could flatten it too much or too little, and end up with different measurements.

“Metrios is a quality guarantee, and it gives us peace of mind because all the dimensions that we detect, we save and all that data can be shown to the customer if necessary.”

Instead, if I use Metrios, I simply place the part on the bed and any operator can pull up the program and carry out the measurement without the risk of mistakes.”

Learn more about Metrios Company

“It has to look good too. Cleaning is important as are the mold fastening finishings.

“I think that flexibility is one of our strong points. All our processes are in-house, so there’s no risk of delays or nonconforming materials. We follow the entire process from start to finish.”

It’s subject to very delicate cryogenic finishing processes to prevent it from being damaged.”

https://youtu.be/PuI6urt1cZM

Are you a rubber gaskets manufacturer? Check out the solution that best suits you! “Having such a high-tech machine means that we can configure it with Industry 4.0 regulations, so it’s connected to our management system and all the statistics are imported from the system and are accessible from any computer at any time.”

https://www.metrios.com

http://www.demaitalia.it/en/

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“9 pieces in 37 seconds, inspecting 1,2,3,4,5 dimensions.” Metrios gives you the possibility to gather data about multiple dimensions and to keep them over the time, in order to analyze all these information or even to show them to clients. 31 | Industry USA | September 2021

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VISION RESEARCH LAUNCHES PHANTOM T3610 AND TMX 5010 ULTRAHIGH-SPEED CAMERAS WITH BACK SIDE ILLUMINATION

Vision Research, a leading manufacturer of digital high-speed imaging systems, introduces two models in its Ultrahigh-speed performance line of Phantom® cameras. Featuring a breakthrough CMOS sensor with back side illumination (BSI), the new T3610 and TMX 5010 cameras sustain their image throughput with optimized light sensitivity for high frame rates and sub-microsecond exposures.

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oining the T-Series platform, the Phantom T3610 achieves significantly higher frame rates of 38,040 frames per second (fps) at 1280 x 800 resolution and up to 875,000 fps at reduced resolution. T-Series benefits include a compact form factor and lower power requirements, enabling greater portability and flexibility with tripods and other support.

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The TMX 5010 joins the TMX 6410 and 7510 cameras as the entry point to the TMX family. Benefits include a higher RAM capacity up to 512 gigabytes (GB), a higher partition offering of 511 segments, standard 10Gb Ethernet with a rugged RJ45 port, and the ability to upgrade to higher throughput models at a later date. Both the T3610 and TMX 5010 camera models include features designed to maximize image capture and workflow flexibility, including a 2x2 binned mode for higher vertical resolution at the camera’s top frame rates. Their BSI sensor technology also provides greater sensitivity and sustained throughput by placing the photoactive surface above the circuitry. This design provides a direct route for photons and improves signal efficiency. Extreme Dynamic Range (EDR) is also included to capture detail in flashes and saturated highlights.

T3610 Key Specifications Maximum resolution: 1280 x 800 Frame rate at maximum resolution: 38,040 fps Maximum frame rate (standard mode): 875,000 at 1280 x 32* Maximum frame rate (binned mode): 875,000 at 640 x 64* Minimum exposure: 1 microsecond (standard); 190 nanoseconds* Native ISO: 40,000D (mono), 12,500D (color) Maximum available RAM memory: 256 GB 10Gb Ethernet: Optional CineMag compatibility: Optional Size and weight: 5 x 5 x 8 inches; 10 pounds *with export-controlled FAST option

TMX 5010 Key Specifications Maximum resolution: 1280 x 800 Frame rate at maximum resolution: 50,725 fps Maximum frame rate (standard mode): 583,330 at 1280 x 64; 1.16 million fps at 1280 x 32* Maximum frame rate (binned mode): 583,330 at 640 x 128; 1.16 million fps at 640 x 64* Minimum exposure: 1 microsecond (standard); 95 nanoseconds* Native ISO: 40,000D (mono), 12,500D (color) Maximum available RAM memory: 512 GB 10Gb Ethernet: Standard CineMag compatibility: Optional Size and weight: 7 x 7 x 11.7 inches; 20 pounds *with export-controlled FAST option www.phantomhighspeed.com

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31 | Industry USA | September 2021

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EMERSON’S ULTRASONIC SYSTEMS REDUCE MOLD CLEANING TIME FROM HOURS TO MINUTES

New Branson MCX Series of mold cleaners increases workforce productivity, improves cleaning effectiveness and reduces risk of damage to costly molds.

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merson has announced its new Branson MCX Series ultrasonic mold cleaning systems, which feature side-mounted immersible transducers and powerful immersion heaters that can provide more effective, fast and efficient cleaning than other systems on the market. Compared to manual cleaning of plastics injection molds, which may take up to three hours or more, the Branson MCX Series actually does a better job in 15 to 20 minutes, depending on mold design and level of residue, dramatically increasing productivity and avoiding potential mold damage.

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Unlike many competitive systems, the Branson cleaners are purpose-built for cleaning injection molds, which is why the side-mounted transducers represent such an important innovation compared to transducers mounted on the bottom of the tank. Since most plastic injection molds are rectangular, with a lot of the design details on the surface facing the side of the tank, side-mounted transducers result in a more intense and focused cavitation as compared to bottom-mounted transducers. Cleaning is more effective and takes less time. “Manual scrubbing is still the most commonly used method for cleaning plastic injection molds, but it is highly labor intensive and can take two or three hours,” said Nitin Phadnis, director of Emerson’s welding and assembly business. “Even then, the end result may not be as good or predictable as ultrasonic cleaning, which that takes just 15 to 20 minutes and dramatically reduces the risk of damaging intricate mold design details that can be very expensive and time consuming to repair. No other process cleans mold components faster, safer or more thoroughly than Branson ultrasonic technology.”

Branson MCX Series ultrasonic mold cleaning systems feature side-mounted immersible transducers and powerful immersion heaters, cutting cleaning from hours to just minutes.

In contrast to traditional manual cleaning, which requires high concentrations of often-toxic cleaning solutions, brushes and other tools, Branson ultrasonic cleaning systems use ultrasonic technology to produce fluid cavitation, a non-contact cleaning process. Mold halves are placed between the transducers mounted on opposite sides of the tank, which is filled with cleaning solution. The system emits ultrasonic waves into the solution, creating minute bubbles (or cavities) that eventually implode, releasing tremendous amounts of energy. The resulting turbulence dislodges contaminants from the mold surfaces and even blind holes and tiny crevices, where brushes cannot reach. The cavitation turbulence enhances the effectiveness of the cleaning chemicals and results in better release, improved productivity, less maintenance, longer mold life and reduced chemical waste.

Emerson experts are available to support customers in determining optimum cleaning system size and configuration, as well as other details. They can be reached via this link: https://go.emersonautomation.com/branson-consult-anexpert https://www.emerson.com/en-us

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The MCX Series cleaners are pre-configured in three stock tank sizes to accommodate small molds up to 24 x 24 x 10 inches, medium-sized molds up to 38 x 38 x 14 inches and molds as large as 52 x 48 x 17 inches. The side-mounted immersible transducers can deliver cavitation in 25 and 40 kilohertz frequencies. In addition, the MCX Series can be configured to include one or more rinse stations to remove latent chemistries and add rust inhibiting chemistries to improve mold life and performance.

31 | Industry USA | September 2021

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SOFTING EXPANDS ITS WIREXPERT PRODUCT LINE WITH WIREXPERT 500 CABLE CERTIFIER

The new WireXpert 500 certifier, which offers the same powerful features as Softing’s flagship WireXpert 4500, targets copper cabling up to Cat 6A standards.

ofting Inc., an industry leader in industrial communications technology, has expanded its WireXpert cable tester series to include the WireXpert 500, a cable certifier that targets copper cables up to Cat 6A. With its modular concept and unique licensing system, the WireXpert 500 is a versatile, cost-effective tool for cable system certification in office environments, industrial settings, laboratories and data centers.

Softing has found that the overwhelming majority of cable contractors require Ethernet copper cable certification up to Cat 6A and has developed its WireXpert 500 to target these contractors. By enabling cable certification up to Cat 6A only, the WireXpert 500 fits over 95 percent of contractor requirements. Contractors can also easily upgrade WireXpert 500 units to certify copper cabling through Cat 8 or fiber optic cabling.

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The WireXpert 500 is not a stripped-down version of the flagship WireXpert 4500; besides the fact that WireXpert 4500 certifies cables up to Cat 8, both certifiers are identical. Both feature the unique Dual Control System (DCS), which equips both local and remote devices with a main processor and color LCD screen. These features reduce the amount of walking a single user must do during troubleshooting, improving the testing efficiency for smaller, one-person testing projects. WireXpert 500 devices also feature Softing’s “3 around 1” mode when users purchase two kits with four total testers. The 3 around 1 mode lets users reassign three testers as remotes while one tester remains in the main distribution frame (MDF). Now, three technicians can take to the field 31 | Industry USA | September 2021

can immediately take advantage of 3 around 1 mode or operate the testers independently to handle separate concurrent jobs if needed. WireXpert 500 units are ready to ship now.

Additional WireXpert 500 features and benefits include: • Intuitive navigation, thanks to on-screen menus. • Professional report generation via eXport PC software. • Proven accuracy — WireXpert 500 is based on a measurement system independently verified by Electrical Testing Laboratories (ETL). • Regular firmware updates, enabling users to stay current. • Tests MPTL links using optional MPTL adapters. • Various measurement modules — WireXpert 500 can identify and record copper patch cord performance with kits available for Cat 5e, 6 and 6A tests. Industrial Ethernet cable test kits include M12 adapter kits with both channel and permanent link configurations. Kits that support X-Coded M12 interfaces are also available, enabling 10-GB Ethernet tests. Units also support coaxial cable tests for attenuation, length, resistance, delay and return loss with optional coax test adapters.

https://itnetworks.softing.com/us

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while one local remains in the MDF, improving the testing efficiency for larger projects. Using only two WireXpert 500 kits, all three remotes can certify cables back to one local certifier.

In addition to the new WireXpert 500 series, Softing announces its two-for-one deal as part of its Summer Promo, enabling users to purchase two WireXpert 500 certifier kits — equipped with the DCS — for the price of one competitor kit. Since the two-for-one promo includes four testers, users 31 | Industry USA | September 2021

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SIGMA-NETICS ANNOUNCES UL-RATED PRESSURE SWITCHES FOR EXPLOSIVE ENVIRONMENTS

– Sigma-Netics, a global manufacturer of pressure switches, pressure transducers, metal bellows and metal bellows assemblies, announces its 703-U and 703-UJ Series of UL-rated, explosion-proof pressure switches. These components are suitable for gaseous or liquid fluid systems in hazardous applications, including offshore exploration, petrochemical processing and oil and gas pipelines.

he 703-U and 703-UJ Series have a corrosionresistant stainless steel construction and UL ratings for hazardous locations, including Class 1: Division 1, Groups A, B, C, D, as well as Class 2: Groups E, F, G. Units also feature high overpressure capabilities, a NEMA Type 7 explosion-proof rating and rugged piston design, enabling these switches to withstand high pressure spikes, shock and vibration.

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The 703-U Series features factory-set fixed pressure, while the 703-UJ features field-adjustable pressure. Designed for easy field adjustment, the 703-UJ also incorporates a tamper-resistant locking mechanism to maintain set point integrity. Additional features and specifications of the 703U/UJ Series include: • Pressure range: 6 to 5,000 PSI • Temperature range: -40 to +180 °F • Pressure connection: 1/4"–18 NPT (male) and 1/2"–14 NPT (male) • Single pole double throw (SPDT) option • Double pole double throw (DPDT) option 31 | Industry USA | September 2021

• 1/2-inch NPT electrical connection with five full threads for conduit engagement • Factory-sealed lead wires — Type UL 1015 AWG #18, 24 inches long • Hydraulic and electric modules AISI 316 stainless steel Thanks to their durable construction, 703-U/UJ pressure switches boast exceptional accuracy and repeatability even in explosive environments. They also guarantee a long service life, thanks to a snap-action electrical switch tested to 1 million cycles. www.sigmanetics.com

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NEW IKO CAM FOLLOWERS ADDRESS AXIAL LOADING AND PROVIDE MAINTENANCE-FREE OPERATION

IKO International has introduced the CR...BSE Series of imperial cam followers, offering machine designers a versatile, reliable way to convert rotary motion to linear motion.

esigned to resolve the main factors that can cause bearing failure, these heavy-duty cam followers feature two IKO innovations:

• A ThrustDisk seal. This special seal slides into the outer ring’s contact areas and handles axial loads caused by misalignment. It also resists heat and contamination to improve bearing life. • C -Lube. CR...BSE bearings are lubricated with a thermosetting solid-type lubricant which fills the inner space of the bearing. This lubricant helps provide longterm, maintenance-free operation.

The cam followers’ ability to handle thrust loads allows them to handle higher loads, while their sealing technology ensures the high performance that heavy-duty applications demand. CR...BSE cam followers — part of IKO’s Inch Series — also offer a low coefficient of friction, good rotational performance and easy mounting. Stud diameters range from 0.19 to 0.375 inches. www.ikont.com

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31 | Industry USA | September 2021

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SOFTING INTRODUCES SOFTWARE MODULE FOR CONNECTING MODBUS TCP CONTROLLERS TO IIOT APPLICATIONS

edgeConnector Modbus supports innovative industrial edge solutions. (Source: Softing Industrial)

Softing adds to its Docker technology-based edgeConnector product family. The new edgeConnector Modbus is a flexible Docker container application for Modbus TCP controllers.

fter edgeConnector Siemens for connecting SIMATIC S7 controllers and edgeConnector 840D for accessing data from SINUMERIK 840D controllers, Softing introduces edgeConnector Modbus. This Docker Container is suitable for connecting Modbus TCP controllers e.g., from Schneider Electric, Wago, Beckhoff or Phoenix Contact, to industrial IoT applications. edgeConnector Modbus can also be used to collect energy data or other process variables from Modbus-compatible sensors. An integrated OPC UA server enables simple and secure data connection to higherlevel management systems, such as ERP, MES or process visualization systems. As a further communication protocol, MQTT makes it possible to integrate control data directly into private or public IoT cloud applications.

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“By using container technology, our edgeConnector products are very quickly started up and running. They are operated on standard hardware and can be managed easily from a central platform. In this way, we offer our customers a simple and secure option for integrating data from production into innovative and flexible Industrial IoT solutions,” says Sebastian Schenk, Product Manager at Softing Industrial. 31 | Industry USA | September 2021

All edgeConnector products support state-of-the-art security standards such as SSL/TLS, X.509 certificates, authentication, and data encryption. They are easy to configure locally via an integrated web interface or can be managed remotely via a REST API. For the future, Softing plans to further expand the edgeConnector product family to enable Ethernet/IP connectivity for Rockwell and Omron controllers. There are also plans to expand the configuration options from the cloud. edgeConnector Modbus can be downloaded from online directories such as Docker Hub or Microsoft Azure Marketplace and tested for free. https://industrial.softing.com

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CMP PRODUCTS LAUNCHES TECHNICAL “KNOWLEDGE BASE”

Leading manufacturer of cable glands, cable cleats and accessories, CMP Products has today launched a comprehensive “Knowledge Base” to support customers and users of cable glands in a variety of industry sectors.

nowledge Base is a compilation of technical expertise and advice, gathered over CMP’s 60+ years’ experience in the art of terminating cable glands.

The easy-to-use guide provides users with useful technical knowledge and application recommendations to aid in the selection and installation of cable glands, as well as providing advice on best practices for ordinary, wet and hazardous locations. The platform aims to present comprehensive information relating to key industry topics in a clear and straightforward way. Topics such as compliance testing, compatibility with different cable types, selection of barrier type cable glands, and corrosion prevention are all covered in the guide, and illustrative diagrams and examples support explanations.

Key industry codes and standards are broken down into easy-to-read sections covering the likes of Articles 500 & 505 of NFPA 70, C22.1-18, UL 514B, UL 2225, NEMA 250 as well as other important elements of IEC and the National Electric Code / Canadian Electric Code, interpreting key points to consider when selecting cable glands for various applications.” Lee Frizzell, Technical Director, said: “Our new platform was developed to create a ‘Knowledge Base’ for appropriate technical information relating to global cable gland requirements. We regularly engage with clients across a range of applications and our Knowledge Base draws from these various experiences, to provide advice and best practice to installers and engineers alike.” MORE INFORMATION

https://www.cmp-products.com/

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ANYBUS WIRELESS BOLT CAN — CAN COMMUNICATION VIA WI-FI OR BLUETOOTH

Since its launch five years ago, the Anybus® Wireless Bolt™ has provided thousands of industrial applications with wireless Ethernet access. With a rugged and unique form factor for bolt-on-machine mounting, it is today proven and trusted in the most demanding industrial applications. Use cases vary from warehouse installations and AGVs to manufacturing of food, underground mining or rough outdoor applications. Building on the success, HMS now launches the Anybus Wireless Bolt CAN, featuring CANbased communication to the host equipment.

Industrial CAN goes wireless The new Anybus Wireless Bolt for CAN enables CAN-based, heavy-duty machinery and applications to transfer CAN data over a robust wireless link. Wireless communication is established either over a fast Wi-Fi connection or a reliable Bluetooth link. The CAN data is transported over a TCP/IP link which enables other standard Wi-Fi infrastructure to also connect to the wireless link if desired.

Wireless access to J1939 CAN-based vehicle data A typical use case is wireless access to CAN data from an industrial vehicle, such as a bulk material transport truck. For example, with the Anybus Wireless Bolt CAN, J1939 CAN data is easily communicated to a handheld tablet which gives the operator full control and visibility of the ongoing bulk material filling process.

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Wireless CANopen use case in manufacturing Anybus Wireless Bolt CAN is fully transparent when it comes to transporting CAN data, meaning that it works with any CAN-based protocol, including CANopen. This opens the possibility to create mobile automation islands in any manufacturing process – the Anybus Wireless Bolt CAN will bridge the CANopen line wirelessly.

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A wide range of wireless connectivity options for industrial networks and IoT applications In addition to the new Anybus Wireless Bolt CAN, the Wireless Bolt product family includes other versions which can connect to the host equipment using serial and industrial Ethernet connectivity. On the wireless side of the Wireless Bolt, the Wi-Fi and Bluetooth options were recently complemented with a version that supports the new LTE standards NB-IoT and CAT-M1, targeting IoT applications. https://www.anybus.com

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31 | Industry USA | September 2021

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DABURN’S NEW RJ45 MAGNETIC MODULES MEET ETHERNET REQUIREMENTS

Daburn Electronics and its Polytron Devices division have announced a family of RJ45 magnetic integrated connector modules that can accommodate a variety of Ethernet-enabled devices.

hese RJ45 jack and connector modules integrate magnetics to protect against electromagnetic interference (EMI) and common mode signals, satisfying various data transmission requirements such as Power over Ethernet (PoE) networks, PHY IC 10Base, 10/100Base, 1000Base (1G) and 10G. This product family is comprised of three series:

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• 12F/14F-1X Series. This 10BASE-T RJ45 jack and magnetic module’s integrated filter is the same size as the RJ45 connector, saving PCB space while reducing EMI radiation and improving EMI performance. • 13F/6X Series. Designed for 100BASE-T transmission over UTP-5 cable, this RJ45 jack and magnetic module series offers designs to support every PHY, and it meets or exceeds IEEE 802.3 and ANSI X.3263 standards. • 13F-67 Series (PoE and PoE+). This version of the 13F/6X Series is designed to provide the higher current and isolation required for PoE applications.

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By using an RJ45 connector with integrated magnetics, engineers can lower component count, create a simpler PCB layout, save board space and reduce power consumption. Applications for Daburn RJ45 integrated connector modules include routers, switches, VDSL digital equipment, network set-top boxes and other home and commercial devices. For more information about Daburn-Polytron RJ45 jacks with integrated modules: https://www.daburn.com https://polytrondevices.com/

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WEAV3D AWARDED NSF FUNDING TO FURTHER DEVELOP NEXT-GENERATION COMPOSITE FORMING MACHINE

WEAV3D Inc., an innovator in composite materials, manufacturing processes and processing equipment, has been awarded a $999,943 National Science Foundation (NSF) Small Business Innovation Research (SBIR) Phase II grant. This two-year award will fund the design, fabrication and testing of a continuous composite forming machine that uses ultrasonic welding to increase the production throughput of WEAV3D’s patent-pending continuous composite forming process.

his SBIR Phase II project addresses the traditional challenges of composite manufacturing. While these processes can produce lightweight, stiff and strong components, they suffer from high part cost and low production throughput. The WEAV3D process combines weaving and composite consolidation into an automated, continuous process that reduces waste, cycle times and material handling costs. WEAV3D’s Rebar for Plastics® approach improves part stiffness and strength while minimizing weight, enabling new innovations in the automotive and construction markets at a fraction of the cost and cycle time associated with traditional composite manufacturing.

“During Phase I, we demonstrated that replacing infrared heating with ultrasonic welding for thermoplastic consolidation yields an 85-percent reduction in embodied energy, all while matching or exceeding the production speed of the infrared system,” explains Chris Oberste, Ph.D., Founder and CEO of WEAV3D. “Our proposed research activities for Phase II will translate these embodied energy reductions into production speed improvements through the fabrication and testing of our next-generation composite forming machine.” MORE INFORMATION

Traditional composite manufacturing methods also rely on energy-intensive curing processes, which translate to high embodied energy, or energy per unit mass, and contribute to the overall CO2 footprint of the finished part. WEAV3D was previously awarded a $224,718 NSF SBIR Phase I grant to investigate alternative thermal consolidation methods, with the goal of reducing embodied energy by at least 60 percent relative to the current infrared consolidation baseline. Of all

the consolidation techniques evaluated, ultrasonic welding showed the best combination of speed, efficiency and weld quality.

WEAV3D’s next-generation system will be built with automotive production speed and quality standards in mind, with a target production capacity of 200,000 to 300,000 automotive door panel size parts per year. https://weav3d.com/ 31 | Industry USA | September 2021

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INNODISK RELEASES CAN BUS MODULES FOR UNMANNED SMART SYSTEMS

Innodisk recently released their latest CAN Bus modules. With a complete line of form factors and strict industrial quality, these products have proven themselves indispensable in the success of unmanned systems.

he demand for unmanned systems has seen marked growth since 2020, with a report from Fortune Business Insights estimating a CAGR of 12.23% for the UAV segment. Many industry verticals have felt the impact of unmanned systems, such as agriculture, logistics, transportation, and aerospace, which have all begun to leverage the benefits of unmanned vehicle technologies.

Unmanned aircraft are at the heart of all unmanned systems, but at the heart of all unmanned systems is the CAN Bus. With this continued expansion, rising complexity, and the increased efficiency requirements of new applications, it is critical that the CAN Bus module can operate in harsh conditions, like extreme temperatures and electromagnetic interference. Innodisk CAN Bus modules all support wide temperature, 2.5KV isolation protection, and the highlayer protocols SAE J1939 and CANopen needed to ensure optimal performance in extreme conditions without degrading.

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Amongst the latest popular adopters are unmanned flight application, which has utilized Innodisk CAN Bus modules in the latest aircrafts. Innodisk’s USB to CAN module has successfully built into autonomous commercial drones, as well as agriculture machine, robot operating system (ROS), Automated Guided Vehicle (AGV) that for all kinds of smart applications. CAN Bus is enabled to control the system, interact with the onboard computer and various CAN devices, and diagnose issues in ground stations. “We think it’s pretty cool that Innodisk’s CAN modules are successfully supporting our customers’ projects of different 31 | Industry USA | September 2021

smart applications,” said Johnny Wu, Senior Manager of Innodisk’s Intelligent Peripheral Application Department. He further added, “Using Innodisk products for their unmanned devices reaffirms our commitment to providing the most durable products on the market. We’re proud to have played a small but crucial part in their developments.”

it is tantamount that their hardware solution will meet the rigors of these industrial environments. https://www.innodisk.com

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CAN Bus solutions sufficiently capable of handling the strain of these harsh environments have, until now, been a major roadblock for reliable systems development. Innodisk CAN Bus modules provide complete hardware and software integration and offer different form factors to fit diverse demands. For integrators and engineers looking to introduce their products into the unmanned systems space, 31 | Industry USA | September 2021

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WEAV3D AND GLOBAL ALLIANCE AUTOMOTIVE AG PARTNER TO EXPAND STRUCTURAL COMPOSITE OPPORTUNITIES IN AUTOMOTIVE SECTOR

WEAV3D® has partnered with Global Alliance Automotive (GAA) AG to promote the use of WEAV3D’s lightweight, locally tunable structural composites in the automotive industry. These materials are a cost-effective alternative to traditional composites, steel and aluminum, and can increase vehicle fuel economy and electric vehicle range.

EAV3D’s patent-pending composite forming process, which can support automotive volumes of hundreds of thousands of units per year, produces a woven composite lattice structure from unidirectional fiber-reinforced composite tapes. These composite lattices are then overmolded into finished structural components using traditional molding processes—a design concept known as Rebar For Plastics®.

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“Our locally tunable reinforcement materials enable automotive manufacturers to lightweight automotive interior and exterior components without reinventing production lines,” says Chris Oberste, Ph.D., WEAV3D founder and CEO. “European GHG emission requirements are worldleading, so European automakers are ahead of the rest of the world when it comes to implementing lightweight materials. This partnership allows us to leverage GAA’s close relationship with European OEMs to drive the adoption of our innovative solution.”

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“WEAV3D’s process is a game-changer for the automotive industry,” adds Ralf Mueller, GAA Managing Director. “Not only does the WEAV3D lattice increase the strength and stiffness of automotive components, but it also promises significant cost reductions compared to existing composite designs and production methods.” www.weav3d.com

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31 | Industry USA | September 2021

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DIGITALISATION IN PROCESS TEMPERATURE CONTROL

Remote monitoring, support and digital process-optimisation in the temperature control of food processes.

ockdowns and pandemic-related employee absences are making it difficult for many food producers to maintain their usual production capacity. You don’t send a machine or plant operator to work from home lightly. Production of dairy products, pasta, pastries, confectionery, food additives, even new types of foods such as plant-based meat replacements must continue, even when everything around is at a standstill.

The food industry therefore made advances in digitalisation last year which would otherwise have taken many years. And this development has had a major impact on temperature control. Systems which operate for 24 hours per day must record the core parameters over the entire production process to comply with the regulations of hygiene and traceability e.g.: the temperature of grinders for chocolate production, the bath or screw temperatures of extrusion plants for pasta or confectionery, temperatures in doublewalled vessels (often with agitators) for tempering fluids, temperatures in pipe lines for transporting various semifinished or finished products, and increasingly also large reactors which can be used for everything from sugar production to the production of natural flavourings for foodstuffs.

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Any deviations from the standard, temperature deviations, alarms etc. must trigger the necessary remedial actions immediately, especially at those times when there is no-one standing by the system. There are also the needs for remote support by the plant manufacturers’ service technicians and the ongoing optimisation of the whole production plant.

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Feeder-mixer-kneader-conche, throughput 400 kg/h, temperature controlled up to 90 °C.

To provide even better support to its customers during this development, Regloplas AG offers a range of solutions for its temperature control units and cooling systems (-20 °C to 350 °C and 3 to 80 kW heating capacity) which drive forward the digitalisation of temperature control in the food industry. Regloplas AG’s new RT200 control system with integrated OPC UA server now offers maximum flexibility for digitalisation within the production process. The central concept of digitalisation is data exchange of all the process and machine data across the network and to higher-level IT systems such as MES, ERP and PPS. All peripheral machines, devices and systems involved in the production process communicate with one another. This enables real-time process optimisations leading to higher productivity, reduced downtime, optimised machine capacity and improved product quality. (fig1)

• Technical improvement and increased reliability due to the use of a temperature control unit by a manufacturer specialising in temperature control With less outlay on the integration of high performance and flexible temperature control solutions, is equally attractive to plant manufacturers and to processing operations. Regloplas AG is continuously developing its offers and technical expertise for these users. The motivation, in addition to economic considerations is being able to contribute to a healthier, tastier and sustainable food supply. https://www.regloplas.com/en/products/

The use of temperature control units from Regloplas AG’s modular toolbox offers a series of additional advantages: MORE INFORMATION

• Cost reductions compared to plant manufacturer’s own solutions (produced in small quantities) • Problem-free continued use of the temperature control unit in a new or upgraded system

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S M A R T FA C TO R Y

MITSUBISHI ELECTRIC AUTOMATION INTRODUCES LOADMATE PLUS™ ROBOT CELL FOR FLEXIBLE MACHINE TOOL TENDING

LoadMate Plus aims to increase production in high-mix, low-volume machine shops and free up operators through automation.

itsubishi Electric Automation, Inc. is announcing the release of its LoadMate Plus engineered solution. LoadMate Plus is a robot cell which can be easily moved for efficient use, and is targeted towards manufacturers in CNC machine tool applications that find themselves facing a labor crunch, while needing to be more efficient and improve their production. The robot cell provides flexible solutions for traditionally high-mix, lowvolume facilities to introduce automation, and is designed with mobility and flexibility in mind.

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LoadMate Plus automates the task of loading and removing parts from a machine tool through the use of robotics, and can be mounted next to one machine, between two machines, and otherwise moved around a facility as jobs require. When this cell is paired with Mitsubishi Electric M8 Series CNC, operators can use the Direct Robot Control (DRC) feature within the CNC controls to also control and program the robot with menus and G-code from the same screen used for the machine tool. No robot programming experience or teach pendant is required, allowing manufacturers to use existing staff to automate and make adjustments.

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“Most automation solutions for machine tending rely on either cobots for flexibility, or industrial robots for performance and larger parts,” said Rob Brodecki, services product manager at Mitsubishi Electric Automation. “With LoadMate Plus, users don’t have to sacrifice one for the other. The cell is flexible, regardless of the robot, and users can choose from a number of robots to match a shop’s specific needs. Plus, with an available 3-year robot warranty, and Mitsubishi Electric technicians who can service LoadMate Plus, users can ensure that their production will continue uninterrupted.” LoadMate Plus can be used with a variety of machine tools, including mill, lathe, and drilling/tapping. To learn more about LoadMate Plus, visit this link. https://us.mitsubishielectric.com/fa/en

S M A R T FA C TO R Y

CURTISS-WRIGHT LAUNCHES NEWEST INTEGRATED MOTOR / ACTUATOR MODEL IN THE EXLAR® GTX SERIES

Curtiss-Wright’s Actuation Division today announced the release of its newest integrated motor / actuator, the Exlar® GTX060. The GTX060 is the third frame size in the GTX integrated motor / actuator series of industrial electromechanical actuators.

he GTX Series actuators offer force, precision, and repeatability while eliminating or minimizing the maintenance and inefficiencies typical of fluid power alternatives. With continuous force ratings up to 2,668N (600 lbf) and speeds to 1,016 mm/sec (40 in/sec) in both VAC and VDC power options, the GTX060’s compact form can be applied across a wide range of automation applications. In addition, new feedback and splined rod options, available throughout the entire GTX Series, offer even more versatility.

With the addition of the GTX060, our offering expands to 60 mm, 80 mm, and 100 mm frame sizes spanning forces from 2,668N (600 lbf) to 15,392N (3,460 lbf). Exlar is a business unit of Curtiss-Wright’s Actuation Division. https://www.cw-actuation.com/

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The GTX Series features include: • High capacity planetary roller screws offering up to 15X the life and significantly higher shock load resistance than a comparably sized ball screw • New splined rod option eliminating the need for an external anti-rotational device • IP66S environmental protection • Connects with most leading motion / motor controllers • Removable front seal bushings to simplify maintenance and re-greasing of nut assembly to maximize actuator life • Bolt-on mounting accessories for simplified installation and ease of field replacement

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S M A R T FA C TO R Y

MORE SAFETY IN HARSH ENVIRONMENTS

The LBK safety radar system enables reliable 3D area monitoring in hash environments.

3D safety systems are a good option for reliably monitoring danger zones. They present a safe alternative, even in harsh environments where e.g. sparks, dirt and dust occur. They are therefore also a solution for applications where previous optical sensors were unable to provide a reliable answer.

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3D system with radar technology For over 50 years, Leuze as a high tech company and pioneer in the field of optical sensors has repeatedly set new technological milestones and standards on the market. Particularly in the area of safety technology, Leuze’s optical safety components, services and solutions can be used for a wide variety of different applications. With the LBK safety radar system, Leuze has now added a new, innovative sensor system to its product range. This system implements an operating principle new to safety technology. As a result, it is also able to provide a solution for applications that previously could not be solved reliably using optical sensors. Even in harsh environments where e.g. sparks, dirt and dust occur. The manufacturer of the new 3D safety system is the Italy based company Inxpect S.p.A. The LBK safeguards danger zones close to machinery and systems. To do this, it uses a radar technology that is also used e.g. for locating aircraft or ships.

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Detection of objects using radar waves The LBK system operates in a frequency range of 24 GHz. This means that the electromagnetic waves are much shorter than sound waves. Unlike light, the radar waves can penetrate non metallic objects. The compact sensors with their integrated antennas emit electromagnetic waves. These waves are reflected off objects. The sensors receive these reflections and then evaluate them. The electromagnetic waves of the LBK radar system are completely harmless to personnel. New applications solved using LBK Utilizing the properties of the radar frequency electromagnetic waves in sensors provides a solution for applications where optical sensors have so far proven unreliable. Even non metallic objects such as dust, welding sparks or chips are penetrated without the sensor being influenced. As a result, the LBK system is particularly suitable for applications in harsh environments. For example in wood or plastic processing. Such applications typically produce a large quantity of particles that are then suspended in the

LBK reliably differentiates between static and dynamic objects.

sensor is able to determine the speed at which the person is moving.

air. However, these particles do not prevent the LBK from performing its task of reliably detecting and protecting persons. Even if radar waves penetrate the particles, the latter still reflect a small proportion of the waves. As the quantity of radar waves reflected by a person is significantly different to that reflected by wood chips or moisture, the LBK can detect whether the reflection comes from a person or from non metallic particles. In other words, particles in the air are not detected whereas a person is. The LBK therefore switches off reliably when a person is located in the danger zone. The LBK sensor emits its radar waves in three dimensional space so that not only the surface area but also the volume of this space is monitored. This allows the LBK to detect persons who enter a hazardous area or who are located in this area, regardless of whether they are standing, kneeling or lying.

Flexible in use, easy to install In addition to use in harsh environments, the LBK safety radar system is used primarily for preventing unwanted restarts and for monitoring hidden areas. Users can adapt it to their individual requirements. The system consists of a controller to which up to 6 radar sensors can be connected. The positioning of the sensors, the adjustable operating range and the selectable opening angle allow flexible adaptation of the monitored area to the danger zone. This also allows areas on steps or pedestals to be monitored reliably. The user can define the system parameters using the easy to operate configuration software. Should the customer desire, certified safety experts from Leuze can perform configuration and commissioning. www.leuze.com

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Detecting human movements The LBK 3D radar system not only operates in a wavelength range new to safety technology. It also uses FMCW, an operating principle which is also new to safety technology. FMCW stands for Frequency Modulated Continuous Wave. Here, the transmission frequency changes within a defined bandwidth. Starting at a fundamental frequency, it increases continuously up to a maximum frequency and then returns to the fundamental frequency again. If a person reflects this signal, it reaches the receiver with a time delay. Subtraction of the reception signal from the transmission signal produces a difference frequency. If the distance between the LBK sensor and the person remains constant, the difference frequency also retains its value. However, if the person moves, the time delay between the transmitted and received signal changes, and therefore also the difference frequency. The faster the person moves, the greater the change in difference frequency will be. In this way, the LBK

Precise determination of movements This method is also referred to as radar Doppler. It allows movements to be determined with a very high degree of accuracy. The LBK sensor therefore detects not only a moving person, but also a person who is currently standing still, even if the movement is extremely slight. Even if a person is standing still, they are never absolutely motionless – there is always some movement, e.g. from their pulse or heartbeat, etc. The LBK sensor utilizes this to reliably distinguish a person in a danger zone from a static object, e.g. a pallet or material container. The slight movements of a person are sufficient to generate a reliable switch off signal for the machine. As a result, the LBK system interrupts the operating process only if somebody is actually located inside the danger zone. For example, completely static, motionless material containers can be left inside the protected area without them leading to interruption of the operating process. In this way, the LBK system prevents unnecessary downtimes and thereby increases the availability and cost effectiveness of the system. On the other hand, it ensures that the machine only starts to run again when all persons have left the danger zone, and therefore contributes to reliable personnel protection.

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S M A R T FA C TO R Y

NORD MEETS THE DEMAND FOR SPECIALIZED FOOD PROCESSING SOLUTIONS

NORD DRIVESYSTEMS is a global leader in complete drive solutions for food and beverage industries worldwide. This includes processing to packaging and every step in between. NORD is dedicated to serving a wide array of food industries including bakery, dairy, meat, poultry, and many more.

ORD DRIVESYSTEMS provides highly configurable, flexible, and reliable solutions for food processing applications, including expansive product ranges that are ideal for mixing, agitating, kneading, pumping, packaging, and other food and beverage applications.

For mixing, agitating, and kneading processes, NORD offers heavy-duty gear units including our Helical Bevel and CLINCHER Parallel Shaft units that can be configured for mixers and agitators of any scale. These units feature high capacity output shaft bearings for heavy duty loads, temperature sensors for overheating protection, programmable inverters for STO and reverse operation, and optional twin gearboxes with shafts turning in opposite directions. NORD’s MAXXDRIVE® industrial gear units for mixing and agitating processes are also available for applications that require even more torque, anywhere from 130,000 to 2,250,000 lb-in.

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For cutting, slicing, and dosing, NORD provides systems for CIP area installation and machine integration. These drives have smooth washdown surfaces, FDA-compliant sealed aluminum surfaces that can tolerate anywhere from pH 2-12, stainless-steel fittings, and are available with IP66 or IP69K ingress protection. NORD also has a wide variety of paint options for food processing. The NORD Severe Food Duty 3 paint system is ideal as it focuses on contamination protection, is food-safe, and fulfills the NSF/ ANSI 51-2009e test criteria. For further protection, products can be treated 31 | Industry USA | September 2021

NORD DRIVESYSTEMS powers equipment that is used to process food and refine simple ingredients.

with NORD’s nsd tupH sealed surface conversion system for extreme ambient conditions and hygiene requirements. It provides unique protection against corrosion as it is a conversion of the unit’s surface, not a paint layer which can detach or flake off. Globally, NORD offers three inline product lines available in single-stage (high speed), two- or three-stage versions to cover a wide variety of pumping applications. These units feature cast iron or aluminum housings with high capacity output bearings for long, trouble-free operation. The pump drives include high starting torques and soft starts, wall or motor mounted inverters, H1 food-grade oil, and the ability to provide cost-effective custom application specific mounting solutions and special shafting - special shaft dimensions, cross drilled shafts, and stainless-steel shafts.

help reduce CO2 emissions while still being service and maintenance-friendly, reducing downtimes and contributing to greater efficiency. Contact NORD to help you find the right solution for your drive system. https://www.nord.com

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For heating, cooling, and freezing processes, NORD provides drive solutions adapted to extreme temperatures. Composed of various fan/fan-less configurations, H1 low/ high-temperature food-grade oils and hydrophobic bearing lubricants, and an extensive offering of environmental protection features for both the motor, gearbox, and VFD. Every food processing solution from NORD is guaranteed to be efficient and reliable. With comprehensive application knowledge and technical support, NORD has already installed thousands versatile, reliable units in the food industry. These units are environmentally friendly and 31 | Industry USA | September 2021

S M A R T FA C TO R Y

CONTACTLESS ENERGY AND DATA TRANSFER FOR HANDLING TASKS

No cables here either – real-time communication takes place via an optical connection using EtherCAT®.

Although robotic systems are sometimes limited by constraints in automation and drive technology, this issue can be easily minimized. Application-specific automation from a single source enable machine builders to develop new, commercially beneficial solutions for customers. To demonstrate, consider the case of a gantry robot that uses contactless energy and data transfer instead of fixed wiring runs and cable carriers

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antry robots are a tried-and-tested solution for intralogistics material flows within a machine or application. They are commonly used to detect products automatically, grip them securely and quickly, and take them to their destination. This type of robot is useful in many industries, and can be used for a wide range of product sizes and weights, and distances to be covered. Oftentimes, the lengths of power and communication cables and cable carriers limit the flexibility and adaptability of an existing machine to a new production scenario. Adding contactless energy and data transfer opens up new production scenarios, and has largely consigned cables to the past.

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Less noise, enhanced dynamics, greater flexibility The illustrated solution demonstrates contactless energy and data transfer combined with intelligent software and reliable mechatronics to create a fully integrated solution. What immediately catches the eye about this gantry is the drive concept used to move the gantry robots on the rail: contactless energy transfer. As a result, multiple robots can move freely on the same horizontal stretch, greatly increasing the flexibility of this gantry robot application. This regularly leads to overlapping sections between robots– ultimately offering a great deal of freedom in terms of machine design and operations. Logistics processes of this kind would not be as easy to implement with cable carriers, because of the additional area that carriers use along the entire distance of the system. In addition, cable carriers generate noise, are subject to wear, increase inertia, and have an overall negative impact on both dynamics and energy efficiency due to the friction they generate. Another benefit of contactless energy and communication transfer is that there are no longer any

Besides saving space, the use of single-cable technology reduces cabling outlay and the weight of the overall solution. In the MOVI‑C® automation controller, data from the FSoE (Fail Safe over EtherCAT) master is routed and mapped to the relevant robot axes.

MAXOLUTION® machine automation forms part of SEW‑EURODRIVE’s strategy to implement applications tailored precisely to the requirements of specific sectors.

restrictions regarding installation space, cable breakage or limited cycle rates – issues all associated with cable carriers and moving cables. The clever innovation is made possible by a contactless inductive energy transfer system, including a decentralized power supply module. Depending on the design, this module delivers a transmission power of between 5 and 11 Hp.

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What is exciting about this logistics solution is that throughout the entire load cycle, the robot consumes less than 0.7 Hp via the pick-up – even though the horizontal axis alone requires more than 5 Hp of acceleration power during acceleration. The short-term energy requirements are met by the energy storage unit, a double-layer capacitor package that takes care of the primary energy supply to the robot with a DC link voltage of 100 V. The typical travel profiles of a gantry robot, which involve alternating acceleration and braking phases, led to the idea of retaining the regenerative energy generated during braking within the process instead of dissipating it via resistors. The energy storage unit absorbs this braking energy and additionally functions as a booster when the gantry’s drives accelerate at 20 ft/s2. The design is so effective that the contactless energy transfer and storage solution only has to compensate for the system’s mechanical efficiency losses, which amount to around 0.7 Hp. Unlike the familiar DC link connection of multi-axis applications, which is located in the central control cabinet, each unit is enabled to store energy independently. This makes it easy and convenient to scale this type of system.

Cable-free communication The robot gantry’s contactless energy transfer system, which eliminates the need for restrictive cables, also extends to the communication processes. In this context, an EtherCAT® data light barrier transfers the interpolated position setpoints from the central motion controller to the four servo inverters in the moving housing box at 1 ms intervals. A motion controller calculates the complex robot motion control – and can do so for up to four robots at once. Motion control involves performing calculations to prevent collisions and coordinating the robots to achieve a productive overall system. If a machine in a production network requires double the material flow output, the gantry system gives users the option to move a robot from another section on a flexible basis. Handling units that draw their power with cables, in contrast, are tied to their section. As a result, the associated resources become movable and systems as a whole are more flexible and productive. Entirely new machine concepts can be created based on this approach. The demands placed on communication are correspondingly high as well. Optical real-time communication The automation provider opted to use the real-time Ethernet protocol EtherCAT® in the gantry – once again dispensing with cables by implementing an optical connection to the mobile units. The drive data can be delivered to the robots via data light barriers. Having separate motion controllers in each robot is a thing of the past: one does the job for 31 | Industry USA | September 2021

SEW-EURODRIVE’s MAXOLUTION® machine automation portfolio aims to provide system solutions – for example, for handling gantries.

running the whole robotic system. With each cycle taking 1 ms, the optical system has practically no latency periods when transmitting the interpolated position setpoints to the inverters or feeding back the relevant actual values. Communication for the functional safety technology works in the same way. For this application, a central safety controller for all robots and the machine as a whole was selected. This safety controller communicates directly with the MOVI‑C® automation controller via EtherCAT® using the EtherCAT®FSoE (Fail Safe over EtherCAT) protocol. This setup enables both controllers to share data with ease, simplifies programming considerably, and offers excellent conditions for diagnostics and debugging thanks to its high information density.

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Solutions in a nutshell The seamless integration of the FSoE safety master and the EtherCAT® data light barrier are integrated into a comprehensive automation solution including motors, electronics and visualization. Clearly, working with a skilled automation provider can streamline the development process and the newest drive technology innovations and trends can be considered. In this context, standardized interfaces play just as important a role as prepared software modules or application-specific function modules. https://www.seweurodrive.com/home.html 31 | Industry USA | September 2021

Current supply from a socket – the intelligent energy supply with the DC link buffer via double-layer capacitor packages ensures the robots can be hooked up to a 230 volt connection.

SEW‑EURODRIVE uses a portable touch panel to operate the system on site.

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TRACEABILIT Y

TO PREVENT COUNTERFEITING, THE BEARING GIANTS ARE ADOPTING SIC MARKING TRACEABILITY SOLUTIONS

The bearing market has been facing a scourge of counterfeiting for many years leading to huge consequences. No less than 5.4 million jobs are at stake, as well as a loss of 36 billion euros for the global economy (figures from the World Bearing Association).

hese alarming figures are prompting major bearing manufacturers around the world to mark their components. On the one hand to facilitate internal traceability and maintenance actions, but above all to improve their corporate identity, by offering distinctive and aesthetic signs.

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Various marking requirements. Every year, millions of bearings are manufactured for numerous sectors such as the automotive and aerospace industries, but also for the energy and medical sectors. Obviously, this large demand generates a wide variety of products, in terms of used materials (steel, ceramic or other treated metals) but also in terms of dimensions (larger or smaller diameters or widths). As a result, marking solutions must easily adapt to these differences.

The marking type is also different. The bearings are marked with a variety of information, ranging from alphanumeric production codes or product data (site or date of manufacture) to Datamatrix codes or logos. The inscriptions must be clear, readable and unalterable. This last point is especially true if the bearings are subject to significant mechanical or thermal stress. In addition to their great modularity, the marking solutions used must be able to adapt to the different parts’ shapes. Consisting, among other things, of an outer and inner ring, it is common to engrave both. This involves flat, circular, concave and convex markings. All of this while considering cycle times that can sometimes be in the order of a second. Laser marking, a cutting-edge technology 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 of industry. Its experience has enabled the French group to offer a technically superior range of laser marking machines as well as a large number of automatic reading solutions (Datamatrix). SIC MARKING’s integrated lasers are particularly well suited to marking ball bearings, providing clean and permanent results on all materials, from plastics to ceramics to hard

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metals. The various options available, including the 3D function and Autofocus, ensure perfect marking on all bearing surfaces (outer or inner ring). The range is completed by 3 workstations (L-BOX, XL-BOX and XXL-BOX) allowing a dedicated marking station. This can be integrated into a production line or used as a stand-alone marking station. The production of small, medium and even large series is 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. Personalized support around the world What makes the strength of the 300 employees’ company, apart from its product quality, is its ability to adapt to the different needs of its customers, perfectly illustrating its knowledge of tailor-made solutions.

With its many years of experience, SIC MARKING was able to offer a customised station, equipped with an IPG 50W laser, marking on the bearing face and an IPG 3D laser, automatically controlled on 2 axes, capable of marking on the part radius. A proofreading system was also integrated in order to proofread the marking directly, as well as a conveyor belt, allowing the machine to be integrated into the production line. In addition to a solution that perfectly met the specifications, SIC MARKING was able to convince the customer thanks to its dedicated organisation, local support via its German subsidiary and a major marking test campaign that mobilised its Laser experts. www.sic-marking.com

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SIC MARKING has 3 competence centres in Europe, America and Asia, enabling it to offer specific solutions, developed and studied locally. Thus, the team dedicated to the customer’s needs is perfectly capable of adapting to the various contacts, whether they are multi-site, process, workshop or line managers. The particulars of the different sites are carefully studied whether it’s the surface area available, the technologies for conveying parts or the environmental constraints. This ability to provide multisite support is highly appreciated by the ETIs and large international groups that place their trust in SIC MARKING.

bearings with diameters ranging from 150 to 600mm. In addition to adapting to the different part sizes, the solution had to be integrated directly into the production line and be able to mark the bearings in two places at the same time, while ensuring that the Datamatrix was read back.

The laser marking specialist had the opportunity to prove the qualities of its solutions by taking up the challenges proposed by a major Swedish ball bearing manufacturer with a presence in Germany. The manufacturer wanted to mark an alphanumeric and Datamatrix code on steel 31 | Industry USA | September 2021

Industry USA | 31 - September 2021

Articles inside

SIC MARKING

NORD DRIVESYSTEMS

LEUZE

CURTISS - WRIGHT

MITSUBISHI ELECTRIC

SEW

INNODISK

WEAV3D

REGLOPLAS