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THE CASE FOR HYDROGEN AS CLEAN FUEL

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MARKET OVERVIEW English version

THE CASE FOR HYDROGEN AS CLEAN FUEL The long term solution for clean energy is decarbonisation, decentralisation and digitalisation. Hydrogen, being an energy carrier rather than a source, fits in this pattern.

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by Milton D’SILVA

he world is in the grip of severe climatic events for some time now, but 2021 has brought home the severity like never before. Sample these developments:

• The month of July 2021 witnessed unprecedented flood situations in Germany and Belgium in Europe, the Henan province of China, and the Indian State of Maharashtra, besides other places. A few weeks earlier, parts of Canada witnessed an unprecedented heat wave, with temperatures soaring to almost 50-degree Centigrade, in what is described as a once-in-a-1000-year event.

• During the same period, dozens of wildfires raged across western United States, a region experiencing an unrelenting drought. The largest of these fires, termed the Bootleg Fire, consumed more than 400,000 acres of forest, the dry weather making the efforts to put them out difficult.

Last heard, these fires are still raging at various places. In addition, California is witnessing an unprecedented water crisis.

• Hurricane Ida, which struck Louisiana, USA, on August 29, 2021 is believed to have intensified due to the effects of climate change, killing scores of people and plunging millions into darkness. The after effects spread to four states causing unprecedented flooding in New York and New Jersey.

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MARKET OVERVIEW

Toyota 2nd generation hydrogen truck.

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MARKET OVERVIEW

Damaged power lines in the aftermath of Hurricane Ida. Image source: Entergy Corp.

The World Meteorological Organization’s State of the Global Climate 2020 report has documented various indicators of the climate system. These include greenhouse gas concentrations, increasing land and ocean temperatures, sea level rise, melting ice and glacier retreat and extreme weather. Consequently, the number of weather-related disasters to hit the world has increased five-fold over the past 50 years. While the world has woken up to the disastrous consequences of climate change, the efforts to battle these are woefully inadequate. There are positive developments like the adoption of the Paris Agreement in 2015, and the movement towards renewable energy and electrification of the automobile. There is also the growing realisation and commitment by several countries led by the European Union, and over a thousand big global companies, to cut emissions and become carbon neutral by 2050 or earlier.

China has pledged to do so by 2060.

So where does Hydrogen – the lightest element and under standard conditions a colourless, odourless, non-toxic and highly combustible gas – figure in this? To understand that, one must look at fossil fuels, the leading cause of rapid climate change in recent years. According to the US Environmental & Energy Study Institute (EESI), fossil fuels 32 | Industry USA | November 2021

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currently supply about 80 per cent of the world’s energy.

Burning of fossil fuels releases large amounts of carbon dioxide (CO2), which is a greenhouse gas, which in turn leads to build-up of heat in the atmosphere, causing global warming. The use of fossil fuels in automobiles and power plants also releases nitrogen into the atmosphere, which being already present in the air in abundant measure, is causing a surplus that contributes to the formation of smog and acid rain. The solution to this crisis is clean and green energy from renewables like wind and solar power. While hydroelectric power is considered clean and renewable it contributes just over 16 per cent of total global electricity production. Hydrogen is the other clean source of energy with great potential.

According to a McKinsey study for the Hydrogen Council, hydrogen could become a major asset in the fight against climate change, cutting CO2 emissions by 20% between now and 2050. The Hydrogen Council is a global CEOled initiative of leading companies with a united vision and long-term ambition: for hydrogen to foster the clean energy transition for a better, more resilient future. The study indicates hydrogen as an energy source is a highly credible alternative to fossil fuels and a substantial addition

MARKET OVERVIEW

to existing renewables: in less than 25 years, hydrogen could account for 18% of global energy consumption and reduce CO2 emissions from current levels by some 6 gigatonnes.

Hydrogen in industry Hydrogen was first produced in a laboratory by Robert Boyle in 1671 but recognised as an element only in 1766

by Henry Cavendish. It took another 125 years to find its various chemical applications. Since then hydrogen has been widely used in various industrial applications, mainly in refineries for hydro-desulfurisation and hydrocracking operations, and in production of ammonia, the raw material for fertilizers. These two industries account for almost 80% of hydrogen consumption today, with another 10% going for Methanol production. That means only 10% hydrogen is presently used in all other applications covering food, metal working, welding, flat glass production and electronics industries; medical uses, and fuel cell applications in the automotive sector. This indicates the scope and potential for use of hydrogen in the battle against climate change.

The steel industry is the latest to contemplate the use of hydrogen as a source of energy in order to reduce its carbon footprint. After power generation, the steel industry is the largest producer of carbon dioxide, accounting for up to 9%

of total fossil fuel emissions (Source: World Steel Association).

In July 2021, Swedish steelmaker SSAB announced that it has rolled the first steel produced using Hydrogen Breakthrough Ironmaking Technology (HYBRIT), i.e., produced by 100% fossil-free hydrogen instead of coal and coke, with good results. “The first fossil-free steel in the world is not only a breakthrough for SSAB, it represents proof that it’s possible to make the transition and significantly reduce the global carbon footprint of the steel industry. We hope that this will inspire others to also want to speed up the green transition,” said Martin Lindqvist, President and CEO of SSAB, on the occasion. SSAB aims to cut its CO2 emissions in Sweden by 25% by as early as 2025, and by 2040, the plan is to eliminate most of the remaining CO2 emissions. Other global steel makers like ArcelorMittal and Thyssenkrupp in Europe and China’s Baosteel Group, are also pursuing similar measures for carbon reduction. ArcelorMittal is planning to convert its Hamburg plant to climate-neutral steel production by 2030. According to the International Energy Agency, to meet the global climate and energy goals, steel industry emissions must fall by at least half by 2050. Cement industry is another energy intensive industry and could follow the steel example.

Wildfires raged across western United States. Image source: Marcus Kauffman, Unsplash

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MARKET OVERVIEW

Hydrogen as automotive fuel Elon Musk famously declared in 2019 that the idea of hydrogen fuel cell (he called it fool cell) car is ‘mindbogglingly stupid,’ but that is not necessarily true as innovators tend to dismiss rival technologies. Transportation accounts for approximately 28% of global energy demand, and approximately 24% of global CO2 emissions. That is too huge a window of opportunity to miss for any technology that shows promise.

At the moment, battery electric vehicles (BEV) are having the edge, but there are companies betting on fuel cell electric vehicles (FCEV) as a more sustainable option in future. Presently there are only three companies – Toyota, Honda and Hyundai – offering FCEVs in the passenger car segment while almost every major automaker has at least one model of BEV on offer. The major advantage of a FCEV, which runs on hydrogen, is the long range it offers apart from the refuelling time of a regular gasoline vehicle, the disadvantage at the moment being the higher cost as well as the limited number of refuelling stations. But there are other considerations as well. Overall, it appears that BEVs are more suited to short commutes while FCEVs make better sense for travelling long distances, with distinct advantages for long haul trucks on account of large onboard storage capacity.

A recent whitepaper jointly published by Deloitte and Ballard Power Systems, a global provider of clean energy solutions, examines the issue of FCEV viability at some length. The Total Cost of Ownership (TCO) analysis of this study shows consistent and highly encouraging results. Even when ignoring qualitative benefits of hydrogen, i.e., zeroemission at the use end, among others, FCEVs are forecast to become cheaper from a TCO perspective compared to BEVs and internal combustion engines in commercial vehicles over the next 10 year period in all use cases.

The focus then – from governments across the world as well as major manufacturers – is on the commercial vehicles segment where hydrogen is seen as having a greater potential. For example, in April 2021, Daimler Truck AG and Volvo Group, major players in the CV industry, officially outlined their pioneering roadmap for the new fuel-cell joint venture cellcentric, as part of an industryfirst commitment to accelerate the use of hydrogen-based fuel cells for long-haul trucks and beyond. “Hydrogenpowered fuel-cell electric trucks will be key for enabling CO2-neutral transportation in the future. In combination with pure battery-electric drives, it enables us to offer our customers the best genuinely locally CO2-neutral vehicle options, depending on the application,” says Martin Daum, Chairman of the Board of Management of Daimler Truck AG and Member of the Board of Management of Daimler AG. Daimler Truck and Volvo Group are not the only companies working on hydrogen powered commercial vehicles. Toyota has begun testing its new generation of hydrogen fuel cell technology for heavy goods vehicles in the US, based on the same system used in its hydrogen-powered passenger car Mirai, but with a flexible design that could be used by different truck manufacturers. Even Hyundai plans to offer

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The 2021 Mirai Hydro Blue, exclusive to the Limited grade,

by Toyota Motors.

Swedish steel company SSAB produced the first fossil-free steel in the world.

MARKET OVERVIEW

hydrogen fuel cell versions of all its commercial vehicles by 2028 – the company has already commercialised an all-fuelcell truck model, the Hyundai XCIENT launched in 2020. The BMW Group has clear goals for effective climate protection and sustainable mobility up to the year 2030. It recently hosted the Central German Hydrogen Summit, which took place at BMW Group Plant Leipzig in May 2021. As a first step, hydrogen is already being used in logistics to power tractors and forklifts carrying required parts to the assembly lines.

The Bosch Group is also working with Qingling Motors, the Chinese truck manufacturer through a joint venture in China. “We are now literally picking up speed in the industrialisation of the fuel cell. Innovative technologies and strategic partnerships are the ideal fuel for rapidly achieving the goal of making road traffic as climate-neutral as possible,” says Stefan Hartung, Bosch board of management member and chairman of the Mobility Solutions business sector. For years now, Bosch has been working with Qingling in China in the areas of fuel injection and the exhaust-gas treatment.

Bosch also has an existing alliance with Powercell Sweden AB, the Swedish manufacturer of fuel-cell stacks, to make the polymer-electrolyte membrane (PEM) fuel cells for the global automotive market.

Ballard Power Systems, mentioned earlier in connection with the study with Deloitte, has also joined the FCEV bandwagon by announcing a strategic partnership with Quantron AG for the development of hydrogen fuel cell electric trucks in early September 2021. The partnership is expected to accelerate deployment and market adoption of FCEVs in the truck segment by leveraging Ballard’s domination in fuel cell technologies and Quantron’s expertise in electric vehicle integration. About the partnership, Robert Campbell, Chief Customer Officer of Ballard Power Systems, says: “Ballard is looking forward to collaborating with Quantron to accelerate the adoption of fuel cell technology for truck applications. The combination of both companies’ expertise will deliver high performance hydrogen trucks to respond to the growing demand for zero emission vehicles from fleet operators and unlock new business opportunities for medium and heavy-duty fuel cell trucks in Germany.”

Production, storage and distribution Going forward, much depends on how clean is the hydrogen, which though available abundantly in compounds, must be extracted in pure form for use as fuel. There are many different ways to produce hydrogen for use as a fuel, but the two most common methods are steam-methane reforming used widely in refineries and ammonia production, and electrolysis, which is how it is produced for use in fuel cells and other applications. In the electrolysis method, electric current is used to split water into hydrogen and oxygen. So if the electricity used is produced by renewable sources, such as solar or wind, the resultant hydrogen is termed Green, and is the most desirable option. Hydrogen produced by electricity generated by fossil fuels with Carbon Capture & Storage (CCS) is not considered as clean and is termed Blue.

On the other hand, most hydrogen in use today in refineries is termed Grey, because it is generated by fossil fuels without CCS.

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Hydrogen refuelling stations across the world. Source: Ludwig-Bölkow-Systemtechnik.

The Hyundai XCIENT launched in 2020.

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MARKET OVERVIEW

Hydrogen fuelcell stack by Bosch-Powercell alliance. Image source: Bosch Presse

The logistics fleet power by hydrogen at BMW. Image source: BMW Group

Globally there are many initiatives to scale up production of hydrogen on mega scale never attempted before. In Germany, major industry players like Mitsubishi Heavy Industries, Shell, ArcelorMittal and Airbus, have joined forces to form the Hamburg Hydrogen Network to reduce emissions. As part of this initiative, a 100-megawatt electrolysis plant for the production of green hydrogen from renewable energy has been announced recently. In recent months, India has announced two megaprojects, as part of its National Hydrogen Mission. The first is led by the Indian subsidiary of US-based renewable energy startup Ohmium International, to launch India’s first Green Hydrogen Electrolyzer Gigafactory at Bengaluru. The second is a giga project announced by Reliance Industries, India’s largest industrial conglomerate. This is a multi-pronged initiative that includes a fuel-cell factory, an integrated solar photovoltaic module factory, an advanced energy storage battery factory and an electrolyser factory for production of green hydrogen. Down Under, the Australian government is working on a National Hydrogen Strategy for production and export of commercial renewable hydrogen, over the next few years.

consulting company for energy supply, hydrogen, mobility and sustainability. The same report also mentions concrete plans already in place for 225 additional refuelling station locations. Europe had 200 hydrogen stations at the end of the last year, 100 of which are in Germany. France is still second in Europe with 34 operating stations, and with 38 planned hydrogen stations it currently shows the strongest growth in Europe. However, while the other European countries focus on publicly accessible passenger car refuelling stations, most of the French stations aim at the refuelling of buses and delivery vehicle fleets. A significantly increasing number is also projected in the Netherlands, where the number of planned stations has increased to 23. In line with plans, the ninth refuelling station was recently opened in Switzerland.

Storage – bulk as well as on-board – is another area that poses various challenges as hydrogen is highly combustible.

Pure hydrogen can be stored either as a gas or in liquid form.

Storage of hydrogen as a gas requires high-pressure tanks that can withstand 350-700 bar (5,000-10,000 psi) tank pressure. Storage of hydrogen as a liquid requires cryogenic temperatures because the boiling point of hydrogen at one atmosphere pressure is -252.8°C. This means the requirements of storage tanks either at production site or distribution point, are very stringent. Storage options today include insulated liquid tanks and gaseous storage tanks.

Tanks are made in three broad types: all-metal cylinder, continuous filament with metal liner or composite materials.

Most tanks used at present are of metal, which makes them expensive, but those made of composites are even more so.

Better and improved production processes of carbon fibre and other composite materials are likely to bring the costs down in future. The hydrogen tank of the Toyota Mirai, for example, has a three-layer structure made of carbon fibrereinforced plastic consisting of nylon 6 to store hydrogen at 700 bar (10,000 psi).

Conclusion The road to a cleaner, greener planet minus the climate excesses is going to be a long one. A beginning has been made. A lot depends on ongoing R&D and government regulations for hydrogen to play a meaningful role in this endeavour, and there are sceptics galore. BloombergNEF, the leading strategic research provider covering global commodity markets and the disruptive technologies driving the transition to a low-carbon economy, was initially sceptical about green hydrogen. But based on the optimistic electrolyzer cost scenario, it now believes renewable hydrogen could be cheaper by 2030 in all countries, including the US which has traditionally enjoyed cheaper rates in fossil fuels.

At the end of 2020, there were 275 hydrogen stations in Asia, 142 of them in Japan, and 60 in Korea. The 69 Chinese hydrogen stations in the database are used almost exclusively for the refuelling of buses or truck fleets. The majority of the 75 hydrogen stations in North America continue to be located in California with 49 operating stations.

The long term solution for clean energy is decarbonisation, decentralisation and digitalisation. Hydrogen, being an energy carrier rather than a source, fits in this pattern. By using renewable energy to produce hydrogen for storage, it can act as a battery and solve the problem of grid overload on a sunny or windy day.

The third part, distribution is also being addressed as the movement to use hydrogen as automotive fuel gathers momentum. Globally, 553 hydrogen refuelling stations are in operation worldwide as of 2020, according to an assessment made by H2stations.org, an information service of Ludwig-Bölkow-Systemtechnik (LBST), a German 32 | Industry USA | November 2021

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CO R P O R AT E

FPT INDUSTRIAL NORTH AMERICA SIGNS NEW DISTRIBUTION PARTNER FOR ATLANTIC PROVINCES OF CANADA

FPT Industrial announced today a new strategic partnership that allows Madsen Power Systems, a leading distributor of marine engines, to represent FPT Industrial in the Atlantic Provinces of Canada including parts of Quebec.

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FPT Industrial is pleased to welcome Madsen Power Systems to our marine distribution network in North America,” said Braden Cammauf, Head of Commercial Operations for FPT Industrial North America. “Madsen Power Systems has a long history with FPT Industrial. Their commitment to the customer, and to providing high quality service and support makes them an excellent choice to represent FPT Industrial as a distribution partner.”

FPT Industrial’s lineup stands out because of benefits such as compactness, wide range of options for flexibility, reduced fuel consumption and long maintenance intervals for reduced costs, and high performance guaranteed in all conditions. The Brand’s portfolio comprises power generation engines for both unregulated and regulated markets. For North America, FPT Industrial’s Tier 4 Final engines are focused on the latest and most strict emissions regulation, FPT Industrial’s Tier 4 Final engines are equipped with the renowned and patented HI-eSCR aftertreatment system. Besides ensuring compliance with the emissions standards, this technology is the result of the Brand’s experience of more than 25 years in SCR solutions development – FPT has already sold more than one million SCR units worldwide.

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Based out of Newfoundland, with locations in Alberta, Ontario and Nova Scotia, Madsen Power Systems traces its roots back to 1963 when E. W. Madsen started a small fuel injection shop in St John’s, NL. Madsen’s focus on quality workmanship and customer satisfaction earned the company a reputation as a leading expert in specialized components for marine and industrial engines. The Power Systems division was created in 2003 to provide customers with the whole system, extending beyond specialized components to whole propulsion engines and power generation products.

“Madsen Power Systems has partnered with FPT Industrial and its engine offerings since our beginning. We are very excited about the opportunity to grow that relationship at the distributor level”, said Cameron Spracklin-Reid, General Manager at Madsen Power Systems.

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AU TO M OT I V E

SYSTEMS-LEVEL THINKING KEY TO LOWERING COST OF EVS, SAYS ESI AUTOMOTIVE

A systems-level approach to electric vehicle (EV) development is essential to calculating potential gains in vehicle efficiency and build costs required to bring the total cost of the EV powertrain down. That’s the message from ESI Automotive at a time when the US is pushing for half of new cars sold in the country to be battery-powered by the end of the decade.

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he Biden administration recently stated its intent to invest billions of dollars into charging stations for EVs and introduce point-of-sale rebates for consumers purchasing EVs to alleviate cost pressures. Automakers have backed the move, committing to end internal combustion engine (ICE) vehicle production and kickstart EV manufacturing. However, the country remains in a precarious state: three percent of new cars sold in the United States in the first half of 2021 were electric1 - a far lower rate than China and Europe - which offer more generous incentives and have stricter auto-regulations.

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A major barrier to EV adoption in the States is the cost of EVs. At the high end of the EV market, a Tesla Model S starts at more than $80,000, and at the low end, a Chevrolet Bolt starts at $31,000 — nearly $10,000 more than a larger gasoline-powered sedan like the Chevy Malibu. Reaching price parity with ICE cars is key to ensuring greater adoption of EVs. Chris Klok, director of vehicle electrification at ESI Automotive believes that it is possible for OEMs to make both cost savings and vehicle efficiency improvements by viewing the entire design and production process at a systems-level.

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“By viewing vehicle manufacturing at a systems-level, it is possible to understand where significant savings can be made, which can contribute to lowering the overall resale price of EVs, making them more competitive.”

“For example, silver sintering technology delivers proven benefits to the inverter in terms of increasing overall vehicle range and performance by boosting thermal and electrical conductivity. As part of the powertrain system, sintering contributes to a decrease in bottom line expenditure.”

“Furthermore, sintering has been proven to improve powerdensity to the inverter, increasing range and eliminating the need – and cost – of additional battery content.”

According to Klok, key to automakers being able to identify these efficiency and cost improvements is a more collaborative approach to working with the vehicle supply chain. The formation of technology partnerships can enable OEMs to improve powertrain efficiencies with the assistance, experience and support of more established technology partners. https://esiauto.com 1 Electric vehicle sales surge in 2021 (power-technology.com)

ELECTRONICS

CURTISS-WRIGHT LAUNCHES NEWEST SENSE AND CONTROL ACTUATOR MODEL IN THE EXLAR® SMART ACTUATOR (SA) SERIES

Curtiss-Wright’s Actuation Division today announced the release of its newest motor/actuators with integral controls, the Exlar® SA-R080 rotary and SA-L080 linear actuator. The SA-080 is the first frame size (80 mm) in the harsh environment control and sense family of industrial electromechanical actuators from Curtiss-Wright.

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he SA series actuators offer force, precision, energy efficiency, and control while minimizing the additional cabling, external servo controls, and integration necessary with more traditional actuation solutions. The SA-L080 is capable of continuous force ratings up to 2330 lb-f (linear) and the SA-R080 is capable of torque up to 24.7l-in (rotary). Utilizing 18-32VDC input voltage, the SA series actuators’ compact form can be applied across a wide range of automation applications. In addition to integral controls, the SA series offers a corrosion resistant and sealed housing, a stainless-steel output shaft, and a wide operating temperature range, ensuring long life in rugged environments.

- SIL 3, Category 3 Safe Torque Off - Control I/O available to work in a variety of applications

The SA-080 series’ features include: - Integral power and control electronics optimized for high performance - Standard rear manual drive for emergency operation - Magnetic absolute encoder for closed loop feedback - Corrosion resistant epoxy housing - High pressure seal and rod scraper for ingress protection - Tested to MIL-STD-810G for environmental protection, corrosion resistance, vibration, and dust/sand ingress - RS-232 and CANopen communication protocol

https://www.cw-actuation.com

The SA series actuators are suited for a variety of defense, industrial, and commercial applications where distributed precision motion control and the need to operate in harsh environments is required, such as in mobile equipment and other outdoor installations. In addition, electromechanical actuation offers better energy efficiency and less environmental impacts and maintenance compared to traditional fluid power alternatives.

Exlar is a business unit of Curtiss-Wright’s Actuation Division.

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ELECTRONICS

LANNER ACCREDITED WITH ISO 26262 CERTIFICATION IN COMMITMENT OF EXPANDING EDGE COMPUTE PLATFORMS TO AUTONOMOUS DRIVING

Lanner Electronics Inc. today announced that it has attained ISO 26262 certification for automotive functional safety, and reinforcing its initiative in developing edge compute platforms for autonomous driving systems. As one of the first industrial computer companies to be certified for ISO 26262, Lanner commits to bringing their AI-accelerated edge computing hardware solutions that enhance the performance of perception, prediction algorithms for autonomous driving systems.

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SO 26262 is an international standard intended to ensure safety throughout the lifecycle of automotive equipment and systems, covering all the functional safety aspects of the entire development process. In 2021, over 50 Lanner product managers and engineers have received the ISO 26262 Functional Safety Certification Programme (FSCP) certification and understand the latest functional safety knowledge and best practices. Moving forward, Lanner aims to acquire IATF 16949, a technical specification on quality management system development in the automotive industry supply chain and assembly process.

As Lanner continues to expand in functional safety compliance verification, the company is currently involved in offering edge computing hardware solutions for several autonomous driving projects, including traditional car vendors as factory-installed solutions, and startup companies as innovative self-driving solutions. Powered

by Intel Xeon Scalable Processor, Lanner edge compute systems provide workload-optimized platforms with builtin AI acceleration, performing as the central brain for level 4 autonomous vehicles, processing the extensive amounts of data from car sensors, cameras, and LiDAR.

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“As a 30-year leading hardware solution provider for enterprise network security, Lanner leverages our strengths in developing highly customizable, high availability compute platforms for self-driving sectors,” said Jeans Tseng, CTO of Lanner Electronics. “Lanner is extremely proud to be entrusted with ISO 26262 functional safety verification to develop next-gen edge compute platforms for 5G and AI markets, in addition to further accelerating deployments of autonomous driving applications.” https://www.lannerinc.com

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ELECTRONICS

LANNER AND ADVA DELIVER TURNKEY OFFERING FOR INTEL SELECT SOLUTIONS FOR UCPE

Lanner Electronics and ADVA announced that the Lanner’s NCA-4025 is now verified as an Intel Select Solution for uCPE with ADVA Ensemble Connector, giving communication service providers (CSPs) and enterprises a simple and cost-efficient route to virtualization at the network edge.

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The partnership between ADVA and Lanner gives businesses and CSPs an open and flexible solution guaranteed to meet the performance needs of the most demanding uCPE applications. It delivers improved networking through the Ensemble Connector operating system and virtual network function hosting environment. This features advanced applications at Layer 2 and 3, including LTE access and Carrier Ethernet 2.0 functionality, as well as zero-touch provisioning for ultimate simplicity and scale. The uCPE offering also enables access to the Ensemble Harmony Ecosystem, the industry’s largest set of onboarded virtualized applications and supported servers.

“We’re excited that Lanner’s NCA-4025 is now a verified Intel Select Solution for uCPE preinstalled with Ensemble Connector. The new plug-and-play offering delivers the highest levels of performance while running multiple virtual network functions. It reduces the effort and complexity of testing and validation and accelerates time-to-market for new services,” said Mike Heffner, GM, Edge Cloud, ADVA. “The carrier-class capabilities of our Ensemble Connecter combined with Lanner’s high-performance network appliances provide customers with a choice of highly scalable and secure hardware-software solutions that are pre-integrated and ready to deploy.”

“Together with ADVA, we’re setting a new benchmark for performance, scale and security. Our platform powered by the Intel Xeon D2100 multi-core processor and running ADVA’s carrier-grade software gives network operators a highly versatile uCPE solution that supports agile service provisioning straight out of the box,” commented Sven Freudenfeld, CTO, Lanner Telecom Business Unit at Lanner.

“Not only does our NCA-4025 remove the headache of hardware and software integration, but it also accelerates time-to-market for SD-WAN, SD-Security and other NFV applications. Now our customers can be free to innovate and respond in an instant to new business opportunities.”

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anner Electronics and ADVA and today announced that the Lanner’s NCA-4025 is now verified as an Intel Select Solution for uCPE with ADVA Ensemble Connector, giving communication service providers (CSPs) and enterprises a simple and cost-efficient route to virtualization at the network edge. In addition, ADVA’s Ensemble Connector is available preinstalled on a variety of Lanner’s leading network appliances, so customers can select from a range of workload-optimized solutions that deliver the full benefits of network functions virtualization (NFV). Lanner’s NCA-4025 and ADVA’s Ensemble Connector will power uCPE deployments with advanced encryption performance, secure SD-WAN services and robust network protection for operators rolling out uCPE at scale.

https://www.lannerinc.com

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ELECTRONICS

DUNKERMOTOREN PRESENTS NEW IIOT BRAND “NEXOFOX” ON THE MARKET AND THUS GOES BEYOND THE BOUNDARIES OF DRIVE TECHNOLOGY

On October 11, 2021, Dunkermotoren announces the market launch of the new IIoT brand “nexofox”.

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nder nexofox, Dunkermotoren will offer its customers a holistic solution portfolio covering all aspects of the use and connectivity of its smart motors. Holistic means, on the one hand, from the initial consultation and joint concept development to project implementation in partnership. On the other hand, holistic also means from the field level to the cloud from a single source, i.e. from the implementation of the control logic with MotionCode to condition monitoring & predictive maintenance using cloud services.

With nexofox, the drive technology manufacturer is breaking new ground and moving from a pure product supplier to a full-service provider. With nexofox, Dunkermotoren is launching its own brand, which fully addresses the topic of the Industrial Internet of Things and its unlimited possibilities as well as the connectivity and programmability of smart motors. In the field of integrated smart BLDC motors, Dunkermotoren has been considered a pioneer in the industry for years and is now once again taking on a pioneering role with nexofox.

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https://www.dunkermotoren.com/

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ELECTRONICS

PORTESCAP’S VOICE OF THE CUSTOMER PROGRAM PRODUCES MOTION INNOVATIONS

Portescap, a recognized leader in miniature motors and motion control solutions, is unveiling the latest motion innovations to come from its Voice of the Customer product development process.

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oice of the Customer harnesses our customers’ technical insights and turns them into innovative motion products that solve complex problems for their critical applications. Customer collaborations have sparked various different Portescap product platforms, and all of them are 100 percent customizable. We are pleased to announce these innovative new products inspired by customer feedback: Quick Response Digital Linear Actuators These actuators incorporate our low inertia Disc Magnet motor technology to enable quick linear acceleration and deceleration within the same low-profile package, saving process time.

Dual Motion Can Stack Actuator This innovative actuator provides linear and rotary motion simultaneously by stacking two permanent stepper motors into one lightweight, compact package.

The Voice of the Customer process strives to identify the technological possibilities in the next three to five years that will drive our motor innovations, solve customer problems and influence their product development.

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SMART Motor An extra terminal between the power source and the brushed motor sends electrical signals to the cloud so users can monitor motor wear and battery life, and receive warnings via software or a smartphone app.

High Speed Coreless Brush DC Motors These coreless motors surpass 10,000 rpm and can even reach 40,000 rpm for several minutes. Thanks to modifications to the brush material and ball bearings, this is the first time we’re offering such high speed in brush DC motors with small cycle time.

https://www.portescap.com/

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ELECTRONICS

MATCHING DC-MICRODRIVES AND MOTION CONTROLLERS

Perfectly Paired for Size and performance. Small and powerful DC-motors are critical to the development of ever more highly integrated systems. These motors are driving technology in many different sectors, from medical and laboratory technology to aerospace, robotics, optics and photonics, as well as industrial machinery and equipment in general. But the small motors only mature to an application-relevant drive or positioning system when combined with other components, such as gearheads, encoders and motion controllers. Making the right choice is fundamental for reliable operation.

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ll components must be compatible with the motor and meet its requirements. In the worst case, selecting the wrong controller can destroy a motor in no time. When selecting a suitable motion controller for a drive system, it is important to answer a few questions first.

For example, the movements that are to be carried out must be established, and it must be defined what this means in terms of motor control requirements. Is the drive working continuously or in start-stop mode? Is precise positioning required? What type of load will the drive be moving? What are the load cycles? Is a gearhead required? Which motor is best suited for the application? The motion controller is then selected based on the answers. And it may get interesting, because not every motion controller suits every motor. DCmicromotors in particular have unique requirements due to their design.

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Risk of overheating At the heart of the DC miniature and micromotors from FAULHABER is the patented, self-supporting, coreless rotor coil with skew-wound design and brush commutation, which rotates around a fixed magnet. This motor is also often referred to as a bell-type armature motor due to its look. Its design not only has many practical benefits, it also influences the selection of the motion controller.

No cogging torque forms due to the symmetrical air gap, which enables precise positioning and excellent speed control. The ratio of load to speed, current to torque, and voltage to speed is linear. And as almost the entire motor diameter can be used for the winding, the motors achieve higher power and torques for their size and weight compared with conventional designs. The rotor’s low inertia also guarantees an extremely low electrical time constant. The motors can thus be operated very dynamically and heavily overloaded. Triple continuous torque in overload mode is quite common and easily possible for servo applications, as long as the temperature of the motor winding is monitored.

But motors with a diameter of only 22 mm or less don’t have an integrated temperature sensor. There simply isn’t enough space. So if just any controller is connected to a microdrive,

in the worst case the coil may be completely burnt up before any heat is even noticed on the outside.

Problems like these can be avoided with motion controllers from FAULHABER, which were developed for the requirements of mini and micro drives and tested under real operating conditions. They “estimate” the winding temperature for the respective motor type using models of varying complexity. This means that the full dynamic range of the motor can be exploited, for example for fast positioning processes. The current is also limited before the winding overheats. The parameters required are conveniently transmitted to the drive controller with the “Motor selection dialogue” of the FAULHABER Motion Manager.

Due to the low electrical time constant, which benefits dynamic processes, additional losses may occur due to

Powerful and extremely miniaturised The motion controllers of the MC V3.0 family, which have been tried and tested for years, have limited usability for the micromotors from FAULHABER due to their size and the resolution of the integrated motor current measurement.

This is where the new MC 3001 B/P comes in: The first motion controller that is perfectly suited to smaller servo drives, both in terms of its size and the resolution of the current measurement. With a maximum supply voltage of 30 V, the motion controller sized 16 x 27 x 2.6 mm (W x L x H) achieves a continuous current of 1 A and a peak current of 5 A. At lower supply voltages, such as in 12 V systems, continuous currents of up to 2 A can also be easily achieved.

At the same time, they do not compromise on function compared with their large family members. The I/O options and encoder interface are the same as the rest of the product family. USB, RS232, and CANopen are available as communication interfaces. A compact EtherCAT interface can then also be provided via a customer-specific carrier board (motherboard).

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Additional information about thermal integration in the application can be used in the models that are stored in the controllers for further improvement. How well is the motor cooled? Is it necessary to limit power due to high ambient temperatures? Is a gearhead and encoder used? With additional information like this, maximum motor power can also be used with, e.g. a drive that works cyclically in a climatic chamber, in that the motor controller keeps track of the ambient temperature parameters from the climatic chamber control within the models stored. The same applies if the load cycles are known. The motor can then often be smaller in design, which is an advantage especially when used in mobile devices.

the pulse width modulation (PWM) that is common in drive controllers. The typical electrical time constants of FAULHABER cbell-type armature motors are about 10 µs.

For PWM frequencies below 50 kHz, the continuous torque specified in the data sheet is no longer achievable in many cases, or the motor may overheat. That is why it is important that the PWM frequency is sufficiently high when selecting a motor controller. For FAULHABER motion controllers, this is between 78–100 kHz, depending on the type. Due to the type of modulation, up to 200 kHz act on the motor, which suits the requirements of the small motors.

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The controllers are available in two variants: The model with flat board-to-board connectors (MC 3001 B) is ideal when several drive controllers are combined on one carrier card.

The MC 3001 P variant features a plug connector with a 2.54-mm grid over three sides. It is easy to integrate into your own configuration, e.g. for multi-axis applications in laboratory automation. Now, there are finally powerful motion controllers for even the smallest DC drives from FAULHABER, perfectly matched to the motors both in terms of size and function.

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https://www.faulhaber.com

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CO R P O R AT E

DMSC AND MTCONNECT INSTITUTE UPDATE MEMORANDUM OF UNDERSTANDING

The Digital Metrology Standards Consortium (DMSC™, Inc.) is pleased to announce an update to the Memorandum of Understanding (MoU) with the MTConnect® Institute.

The original MoU was signed in 2011. As technology has evolved, both organizations recognize an even greater need to optimize the way industrial software and machines work together, to encourage manufacturing standards development, and to use data modeling to enable information interoperability by specifying the content of specific information and where it is stored – all with the goal of improving manufacturing efficiency.

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MSC and MTConnect are leading modern industrial standards development by crafting a common, standardized, machine-readable information schema. This makes it easier for software developers, quality managers, engineering, and manufacturing to use quality and manufacturing data together. By promoting the Quality Information Framework (QIF) and MTConnect integration, manufacturers will have access to a wider variety of world class manufacturing machine and software solutions. The two organizations plan to support and promote joint projects that will encourage integration and use of standardized information frameworks for parts and processes.

Curtis Brown, President of DMSC, commented “We’re enthused about collaborating with MTConnect in an effort to support and expand the use of QIF for manufacturing applications. A key benefit of collaboration between our two organizations will be expanded industry availability and enhanced implementation of QIF where an information schema for Quality data is needed. We look forward to integrating our data models with the promise of better connectivity between quality-related information and manufacturing process information in a more reliable and secure manner.”

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Doug Woods, President of the MTConnect Institute, said “Manufacturers looking to rapidly digitize their operations want integration across all departments. MTConnect breaks down silos, but harmonization with other standards is absolutely necessary to stay relevant. Working with DMSC on functional, technical interoperability is a big milestone for MTConnect and for smarter manufacturing.” https://qifstandards.org/about-dmsc/

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ELECTRONICS

ROUND CABLE ENTRIES FOR DIAMETER COMBINATIONS UP TO 22.5 MM

The tight-fitting, easy-to-mount cable entries hold up to 35 cables or conduits of different diameters.

CONTA-CLIP further expands its KES-E cable entry program for screwless mounting, adding metric 50 mm variants.

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he new KES-E-R cable entries allow for quick and secure feeding of cables into control cabinets or machine housings. The plates are simply manually pressed into the machined openings. The inner, elastic sealing lip of the profile seal bulges on the inside of the panel, ensuring secure and vibration-proof hold. In order to feed cables or hoses into a housing, users simply pierce the surface membrane at one of the marked center points and push the conduit through.

The new KES-E-R cable entries are available in seven A and seven B versions for cables and pneumatic hoses with diameters from 1 mm to 22.5 mm. The A versions are suitable for wall thicknesses from 1.5 mm to 2.5 mm, the B versions for 2.5 mm to 4 mm. Different versions hold up to 35 cables or conduits, thus allowing for extraordinarily high packing densities. The cable entries provide IP54 protection against dust and splash water. They are made of TPE and are free of halogen and silicone. The material is suitable for ambient temperatures from -40°C to 90°C.

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https://conta-clip.fr/

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ELECTRONICS

ORBEX INTRODUCES NEW LINE OF BRUSHLESS DC FLAT MOTORS

The Orbex Group, a leading manufacturer of high-performance electric motors and slip rings, is pleased to announce a new line of flat brushless DC motors.

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hese compact motors, available with or without encoders, are useful for applications that require high-torque density and have space limitations — including robotics, packaging, security, medical and more.

These high-performance motors feature a range of sizes, voltages and speeds to give you the best performance in space-limited installations. Motor diameters range from 43 mm to 90 mm and lengths range from 9 to 38 millimeters to give many options for efficient use in compact spaces.

Available power levels span from 12 to 220 watts with winding options for different supply voltages.

To learn more about our flat brushless DC motors, visit: www.orbexgroup.com MORE INFORMATION

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IT

MONITORING THE CHARGING STATIONS OF THE E-BUS FLEET OF THE CITY OF JENA

The charging infrastructure always in view.

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ow Jena’s public transport system monitors its charging columns for the e-bus fleet and uses advanced diagnostic features to increase availability and optimize maintenance activities.

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In the city of Jena, electromobility has been present in the form of a tramway in service for 120 years. Supplemented by a fleet of diesel-powered buses, an efficient public transport system has been created over time. Last year saw the introduction of e-mobility in the operation of city buses as well. Three first vehicles started regular service in 2020 to contribute to CO2 savings (53,000kg per bus and year), but also to reduce particulate matter and noise emissions in the urban area.

The attractiveness of public transport is essentially promoted and maintained by smooth and punctual operation. In this context, operations of tramways in particular require a reliable and uninterrupted power supply, which is the responsibility of the power supply department at Jenaer Nahverkehr, operator of the city’s public transport. Nevertheless, malfunctions of the system technology can occur in rare cases. In order to minimize the effects of malfunctions on the operational process as well as on the passengers, it is necessary to keep downtimes as low as possible. This is supported by a reliable control and telecontrol system implemented on the basis of the PcVue SCADA software.

For many years, Actemium Germany’s Automation Frankfurt business unit has been the partner of Jena’s public transport system for the implementation and further development of the control and telecontrol technology for the power supply, but also for the monitoring of signaling and safety systems.

Maintenance of the newly introduced charging infrastructure for the electric buses fell under the responsibility of the Power Supply department, and the desire arose to integrate

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the chargers into the control system. Actemium Automation Frankfurt was commissioned to do this.

The primary goal of this expansion is remote monitoring of the charging infrastructure by the power supply department so that any faults that occur can be detected and eliminated as quickly as possible. And to do so while reducing travel times for service personnel as much as possible, especially in a city that, due to its topography and its location within the Saale Valley, has a high traffic density on a small number of routes.

With the existing control system, the possibility of processing the data for visualization, archiving and data exchange with external systems via various industrial communication protocols, as well as remote alarming, is already provided as standard.

With its latest PcVue version, the manufacturer ARC Informatique provides a communication driver for the OCPP protocol that supports the current protocol versions 1.6-

Integrated operating functionality A newly added entry point into the user interface that is seamlessly integrated with the existing system, is a map display that shows the charging stations distributed throughout the city area as symbol markers. The newly added part of the visualization benefits from a very short learning curve for users who have been familiar with the existing functions and operating philosophy of the control system for years, and which is also reflected in the charging station monitoring area.

Data analysis and monitoring The central function of the implementation by Actemium is alarm and log data management, which allows precise fault analysis in live operation as well as in the evaluation of historical data. The alarm system enables the on-call service to diagnose the fault in advance via the secure remote access of the public utility company and then to rectify it or initiate appropriate measures.

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OCPP- Driver for communication with charging stations Typically, the open standard protocol OCPP (Open Charge Point Protocol) is used for monitoring e-charging stations, which ensures the interoperability of products from different manufacturers.

J and 2.0.1 as well as the security profiles 1 and 2. The software also overcomes a typical OCPP problem, which is that a charging station can only communicate with one Charging Station Management System (CSMS). Using a proxy function, the charger’s OCPP messages can also be passed on to third-party systems. This represents a typical feature of the open PcVue system, which inherently has a wide range of data exchange options.

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In addition, the traffic control center benefits from the connection to the charging infrastructure. The dispatcher workstation there shows the whereabouts of a bus at the corresponding charging points in real time and points out faults that affect operation. This means that adjustments can be made quickly in vehicle deployment planning to avoid cancellations or delays in the route schedule. Afterwards, the maintenance personnel can determine the actual cause.

The users of the system can monitor active charging processes via a trend data display, whereby all measured values, such as currents, voltages and power values of a transaction, can be visually compared. Likewise, already completed charging processes can be called up from the transaction history and viewed in retrospect, as well as compared with each other. The respective vehicle is identified and its current state of charge is documented.

Practical benefits proven after just a few weeks Christian Zeh, a testing and maintenance engineer at Jena’s public transportation system, is enthusiastic about the solution: “By integrating the monitoring and control system for e-charging stations, all operating states are now visible in the control system, which opens up immediate intervention options for us. The charging infrastructure is thus fully integrated into the operational workflows of the power supply department. The usefulness of the system was proven after just a few weeks in daily operation, especially with regard to controlling temperature fluctuations in the charging stations.”

The transaction history is exported at the push of a button or automatically and stored as a weekly and monthly report.

Of particular interest is the respective energy consumption per vehicle and charging process, but also the number of incorrect transactions.

With the implementation of the charging infrastructure in its control and telecontrol system, the power supply team is thus well prepared for the already planned increase in the electric bus fleet and the associated expansion of the charging infrastructure.

Alarms of particularly high priority are sent as remote messages to the mobile terminals of the on-call service.

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The implemented user interface of the system further enables: • An access management system for charging stations • Lock or unlock charging stations for use • Remotely activate or cancel charging processes • Store and retrieve charging station-specific documents

www.pcvuesolutions.com 32 | Industry USA | November 2021

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OPTIMIZE YOUR INTERNATIONAL PR AND ADVERTISING FOR THE INDUSTRIAL MARKET!

International capability

Outstanding results

Optimized process

More than 80 employees in 35 different countries, ensuring a strong relationship with main local media. Mepax distinguishes itself through its extensive media knowledge and ability to select the best international online/print advertising options. PR can be translated into 35 languages.

40,000 published articles in 2020: EMEA: 48% - Asia: 31% - Americas: 21%. Most of the articles are published in the top 1000 media worldwide.

With a proven process set for more than 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.

www.mepax.com info@mepax.com

THE MOST INNOVATIVE PR AGENCY

MEASUREMENT

BLUETEST ADDS OPTION TO INTEGRATE R&S CMX500 5G RADIO COMMUNICATION TESTER INTO ITS RTS REVERBERATION TEST SYSTEMS

Users of Bluetest reverberation test systems (RTS) can now enjoy the benefits of the R&S CMX500 5G NR radio communication tester from Rohde & Schwarz for 5G FR1 MIMO over-the-air (OTA) measurements.

With the R&S CMX500 integrated in the Bluetest Flow control software, the solution provides a stable and reliable environment for measuring throughput as well as receiver sensitivity and output power on multicarrier devices with up to 4x4 MIMO.

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he reverberation chambers from Bluetest in combination with the R&S CMX500 now enable developers and manufacturers of 5G components and devices to perform MIMO stress testing under realistic conditions with high data rates.

Bluetest, based in Gothenburg, Sweden, specializes in reverberation chambers such as the RTS65 for efficient OTA performance evaluation of the device under test (DUT).

Unlike anechoic test chambers, reverberation chambers reflect an RF signal inside the chamber to the greatest possible extent to create a Rayleigh faded multipath RF environment similar to real world indoor and city conditions.

The setup is run by the Bluetest Flow software, an integrated test environment for complex wireless solutions. It features characteristics such as an integrated result database, comprehensive customization options and a full-fledged scientific computing environment, and supports legacy as well as the latest wireless standards such as 5G NR. The R&S CMX500 emulates the network in the test setup. It is a future-proof solution for 5G NR testing, allowing both non-standalone and standalone testing in FR1 and FR2.

Featuring a modular design, the R&S CMX500 adds 5G capabilities to LTE based legacy solutions such as the well-

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NEWS

Users of Bluetest reverberation test systems (RTS) can now enjoy the benefits of the R&S CMX500 5G NR radio communication tester.

established R&S CMW500 wideband radio communication tester or the R&S CMWflexx platform.

Rohde & Schwarz and Bluetest have been cooperating for many years. The two companies worked earlier on integrating the R&S CMW500 tester into the Bluetest Flow software to support LTE, LTE-A and many other cellular and non-cellular wireless standards. This successful cooperation led to the next logical step – the integration of the R&S CMX500 for 5G NR FR1 measurements.

Christoph Pointner, Senior Vice President Mobile Radio Testers at Rohde & Schwarz, says: “We are happy to continue our cooperation with industry-leading partner Bluetest and to provide our valued clients with top-class 5G test solutions.

For Rohde & Schwarz, this integration is a welcome addition that enhances our already comprehensive 5G test and measurement portfolio.”

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Klas Arvidsson, Bluetest Product Manager, comments: “The R&S CMX500 and the popular RTS65, or the larger RTS85/ RTS95 walk-in chambers, together create a user-friendly, yet powerful, test setup for RF R&D of 5G devices of various sizes including larger IoT equipment.” www.rohde-schwarz.com/cmx500

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MECHANICS

HANITA INTRODUCES THE VARIMILL CHIP SPLITTER

High-performance solid carbide end mill improves quality of chip evacuation for dynamic and trochoidal milling operations in steel, stainless steel and superalloy applications.

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anita, a WIDIA brand, today announced its release of the VariMill™ Chip Splitter for dynamic and trochoidal milling operations in steel, stainless steel, and heatresistant superalloys. The VariMill Chip Splitter delivers higher metal removal rate (MRR) by separating long, undesirable stringy chips from deep cavities and dynamic milling paths by cutting material into shorter, more manageable sections.

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This high-performance end mill is designed with nonoverlapping chip splitters along the flute cutting edges. The result is more efficient MRR, while maintaining the ability to make finishing passes. The unequally spaced design feature allows each sequential cutting edge to remove any remaining material left by the chip splitter of the previous flute. The tool’s innovative design reduces breakage and makes it versatile enough for both roughing and finishing passes.

“The Hanita VariMill Chip Splitter helps machinists cut faster and longer by enhancing the ability to flush or blow away stringy chips from deep axial cuts, without forming clumps of intertwined swarf. This is very important to avoid recutting of chips, which could damage the cutting edges and shorten tool life, Additionally, the ability to rough and finish with the same tool provides great benefit in cycle time and inventory management, both in the tool crib and the machine’s carousel” said Steve George, Senior Manager of Hanita Product Engineering.

VariMill™ Chip Splitter End Mills are available in 5 and 7-flute configuration in ½”-1” inch standard dimensions in both WP15E and WS15PE grades. The end mill can cut up to 4.5xD; achieving the highest feed-rate per tooth values, significant reduction in radial forces, and consequential improvements to MRR and overall tool life without compromising surface quality. The 5-flute chip splitter maximizes performance needs when machining steel materials and the 7-flute chip splitter excels in machining stainless steel, and heat-resistant superalloys such as 17-4PH, inconel and titanium. https://www.widia.com

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MECHANICS

NEW SECO HIGH FEED SQUARE CUT SIZE 14 MILLING SYSTEMS TO TACKLE DIFFICULT-TO-MACHINE ISO P, M, AND S MATERIALS

Seco Tools has launched a new High Feed cutter and insert series in size 14. Increase tool life and maximize the value of every edge with this new series in stainless steels, titanium, and superalloys milling applications. The High Feed Square Cut size 14 milling system is ideal for tough materials and comes in a full range of proven Seco Tools grades made to achieve fully secure, and optimized high feed milling.

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he single-sided, straight edge insert geometries allow you to push your high feed milling speeds to new limits. Ensuring high feed per tooth whether ramping, pocketing, plunging, or performing face or copy milling, this new solution creates great chip evacuation and makes it easier than ever or handle difficult machining operations or milling in deep cavities.

Not only does this solution make it easier to machine sticky materials, but it is designed for easy, ergonomic indexing and the pocket and screw designs simplify positioning. The cutters themselves feature a new environmentally friendly coating and their outstanding high feed milling performance reduces the amount of power used in roughing. Yet another step in the right direction for Seco Tools to continue their journey to create more environmentally sustainable manufacturing and machining solutions. https://www.secotools.com/

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MECHANICS

ROLLON ACQUIRES IMS, EXPANDING ITS LINEUP OF LINEAR ACTUATOR MODULES AND ROBOTIC TRANSFER UNITS FOR HEAVY PAYLOADS

Rollon, a leading manufacturer of linear motion guides, actuators and systems, is pleased to announce it has acquired Intelligent Machine Solutions, Inc. (iMS), a Michigan-based designer and manufacturer of standard and custom machinery for the automation industry.

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ith this acquisition, Rollon is expanding its lineup of linear actuator modules and robotic transport units (RTUs), allowing for static loads of over 110,000 pounds and support for industrial robots up to and including the Fanuc M-2000.

In addition to their very high load capacities, these new linear modules and RTUs are easy to implement in automated environments across many industries. They feature a modular design for application-specific configurations and are designed for fast assembly. Additional features include:

“We’re very excited to add iMS to the Rollon team,” said Scott Spangler, Business President Rollon Americas. “With iMS technology and expertise, Rollon is even better positioned to serve the growing market for high-payload linear transfer and seventh-axis robotic systems with our engineered systems and products.”

-Solid steel construction.

-Large servo-reducer driven rack and pinion drive systems for high positioning accuracy.

-Standard multi-axis configurations.

These new linear systems are engineered and manufactured in the USA, providing high-quality solutions with fast lead times to North and South America.

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www.rollon.com

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MECHANICS

PULSE TECHNOLOGIES IMPROVES ELECTRODE PERFORMANCE

Pulse Technologies’ newly patented Hierarchical Surface Restructuring (HSR™) technology enables medical device manufacturers to achieve greater performance, efficiency and longevity in their neural interfacing devices.

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ong-term implantable and diagnostic medical devices such as pacemakers and various types of neurostimulators function via sensing, recording and stimulating between their electrodes and surrounding tissue in the biological environment in order to deliver effective treatment for patients. Generally speaking, higher electrode surface area improves electrochemical performance of the electrode.

HSR is a novel surface restructuring technique that bombards the electrode’s surface with ultra-fast, ultra-short and high-energy laser pulses. This increases the electrode’s available electrochemical surface area, thereby enhancing both charge storage capacity and specific capacitance of the electrode’s surface while reducing impedance.

Additional benefits include: - Surface tunability - Ultra-high surface area - Hierarchical surface structure - Applicable on complex geometries - Suitable for use in a diverse range of sensing, recording and stimulating applications - Scalable and commercially viable - Applicable on finished medical device assemblies - Compatible with individual electrodes, subcomponents and fully assembled leads

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Electrodes and microelectrode arrays treated and optimized

by HSR’s proprietary process can assist device manufacturers in producing higher-performing and more efficient implantable and diagnostic medical devices with enhanced performance and longevity. www.pulsetechnologies.com

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MECHANICS

MICHELL BEARINGS ANNOUNCES THE INCORPORATION OF MICHELL BEARINGS INC. AT SEA, AIR, SPACE EXHIBITION

Michell Bearings, a leading UK Babbitt bearing manufacturer that supplies products to the global industrial and naval industries, has announced the incorporation of a USA business, Michell Bearings Inc.

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he incorporation will allow customers in North America, especially those in the USA naval industry, to collaborate with Michell Bearings in more efficient way.

It will also assist Michell Bearings in providing engineering and manufacturing content on future programs from the United States of America (USA).

Geoff Humble, Sales and Marketing Director at Michell Bearings, said: “We are delighted to announce the incorporation of our USA business at the exhibition this week. The event marks the first time that we have exhibited at a naval show in the USA which is an important milestone for our business.

Located within an 8,500 sq. ft. facility in Sioux Falls, South Dakota, Michell Bearings Inc. will provide a hub for all current and future USA contracts. Plans are also in place to open a sales and engineering head office in Philadelphia, Pennsylvania, during 2022.

The new facility will enhance Michell Bearings’ current service to USA customers, enabling the coordination of USA supply chain activities, manufacture and assembly from the Sioux Falls site for those contracts where in-country content is required. This will expand the company’s offering to its customers in North America and generate USA jobs in both Michell Bearings Inc. and its suppliers.

‘The investment into Michell Bearings Inc. further demonstrates our long term commitment to customers across the Americas, which is a key strategic market for Michell Bearings. It will also allow us to engage with customers in a more efficient manner from a USA base, together with providing local engineering support and incountry manufacturing content on key USA Government programs.’

The announcement, at the Sea, Air, Space exhibition in Maryland, follows many successful contracts for the UK manufacturer from USA customers involving both industrial and naval product applications, with engagement on naval projects dating back almost 50 years.

Last year Michell Bearings announced the celebration of its centenary year following its incorporation in 1920 by Australian engineer, Anthony George Maldon Michell, who invented the hydrodynamic bearing in 1905.

Now a member of the British Engines Group, Michell Bearings employs over 150 people within manufacturing sites in the UK and India, as well as a long established global sales network. https://www.michellbearings.com/

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MECHANICS

NORD’S NEW LINE OF SMALL CLINCHER™ PARALLEL SHAFT GEAR UNITS PROVIDE MORE POWER, FLEXIBILITY, AND RELIABILITY

NORD’s small CLINCHER parallel shaft gear units are now more versatile and are available with our nsd tupH sealed surface conversion.

NORD’s redesigned line of small CLINCHER parallel gear units showcase increased power and torque capacity for a variety of applications. These re-engineered versions will be replacing the existing SK0182NB, 0282NB, and 1382NB units. They are lightweight, have improved heat dissipation, are more cost-effective, and are available with NORD nsd tupHTM sealed surface conversion for wash-down and extreme environments.

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ORD’s CLINCHER parallel shaft gear units are reliable, compact, and powerful. When combined with centralized or decentralized variable frequency drives, CLINCHER units provide ultimate efficiency and economy for a wide range of system solutions along with a rigid UNICASE™ one-piece housing to guarantee long service life, quiet operation, and low maintenance.

Small CLINCHER gear units are quite versatile, providing ratios of 4.85 – 356.89:1 and a power range of 0.16 HP – 5 HP. With torque up to 3,540 lb-in they are the perfect solution for high efficiency operations where low operating costs are essential. With increased torque capacity of up to 33%, CLINCHER specifications match or exceed equivalent competitor units and provide more power in a smaller package.

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Small CLINCHER units include the SK0182.1, 0282.1, and 1282.1/1382.1 and are offered with a standard die-cast aluminum housing. Additionally, the SK1282.1/1382.1 units are also available with a cast-iron housing, which is required for the NORD Screw Conveyor Package and Spread Bearing Designs (VL2/VL3). Additional design flexibility has been made possible by offering two mounting executions: a B14 face flange/foot mounted version and a B5 flange version.

Within each mounting style, there is an execution to match the mounting and shaft dimensions of legacy NORD product and an execution to match common competitor equivalents.

NORD’s new CLINCHER models also come with extensive shaft designs including solid keyed, hollow keyed, shrink disc, GRIPMAXXTM (1282.1/1382.1 only), and screw conveyor (1282.1/1382.1 only). There are also a variety of input options including direct mount motors, universal motor adapters – NEMA or IEC, and solid input shafts. This increases system flexibility and reduces installation space due to the units’ slim design.

https://www.nord.com

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MECHANICS

KENNAMETAL INTRODUCES HIPACS FOR AEROSPACE FASTENER HOLE DRILLING AND COUNTERSINKING IN ONE STEP

HiPACS system utilizes standard PCD-tipped or diamond coated solid carbide drills.

High precision tool achieves tight tolerances in one operation and significantly reduces cost per hole in aerospace applications.

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ennametal has introduced the HiPACS drilling and countersinking system for aerospace fastener holes.

Designed to drill and chamfer holes in one operation, the high-precision tool meets the aerospace industry’s stringent accuracy requirements, while delivering increased tool life in machining composite, titanium and aluminum aircraft skins.

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“Most fastener hole tools used today are complex madeto-order tools with long lead-times,” says Georg Roth, Product Manager, Kennametal. “HiPACS uses standard, offthe-shelf components for quick delivery and low cost per hole, by allowing the drill and chamfer insert to be indexed independently from one another. What’s more, it’s the only indexable drilling and countersinking system on the market that can hold the aerospace industry’s required fastener hole chamfer tolerances in just one operation.”

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Kennametal’s HiPACS is a cost effective and easy to assemble system comprised of three components: a reducer sleeve, countersinking insert and solid caribe drill. The system works with any standard hydraulic chuck.

Three simple components eliminate the need for custom tooling Designed to be clamped in a standard hydraulic chuck, the HiPACS modular system consists of three components that are fast and easy to assemble: - A reducer sleeve with a built-in high-precision pocket seat. In conjunction with a standard hydraulic chuck, this component provides ultra-secure clamping and a runout of no more than 3 µm, significantly increasing tool life and hole quality.

- A PCD countersinking insert. This eliminates the need for expensive custom solution step drills, reducing manufacturing costs while meeting the industry’s accuracy requirements.

- The two series of solid carbide drills —both diamond-coated and PCD-tipped—covering all material combinations found in a typical aerospace assembly. In addition, the straight shanked tools allow for length adjustments in increments of 10mm.

NEWS

Kennametal’s HiPACS is a cost effective and easy to assemble system comprised of three components: a reducer sleeve, countersinking insert and solid caribe drill. The system works with any standard hydraulic chuck.

The new HiPACS drilling and countersinking system can be utilized on all machines typically used for aerospace applications. In less stable conditions such as robot end effectors, the diamond coated carbide drills offer excellent tool life and hole quality. PCD-tipped drills, on the other hand, excel in stable conditions such as gantry machines.

With an industry standard interface, HiPACS can be utilized on any CNC machine, and is suitable for a variety of drilling and countersinking applications. https://www.kennametal.com/us/en/home.html

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MONTH’S PRODUCT

GLOBALMATIX TELEMATICS SOLUTION FOR XTCU TELEMATICS INTERFACE – THE NEW DIMENSION FOR THE FLEET MANAGEMENT OF THE FUTURE

Shared mobility is one of the major trends of future mobility, particularly in urban regions. Large fleet operators, such as rental car and car sharing companies, also see enormous growth potential in this area.

With around 255,000 rental and car sharing vehicles in Germany, “Car to Cloud to Company” will be a critical technology when it comes to efficient and inexpensive fleet deployment. This is why GlobalmatiX AG, a subsidiary of Softing AG, Munich/Haar, has developed an innovative telematics solution, which, with the help of artificial intelligence, offers the greatest amount of available data and transfer security on the market.

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longside standards such as location information and journey approval via app, the outstanding range of services includes continuous technical diagnosis of the entire vehicle, early detection of impending defects, as well as the detection of minor damage and – with the help of artificial intelligence – the reporting thereof in a damage report including a calculation of the cost of the damage.

Thanks to individual data acquisition and reporting tailored to the needs of every particular fleet operator.

Detecting Minor Damage Up to 90% of all minor accidents are not discovered when rental cars are returned as the car bumper has sprung back into its original state and position. This is problematic as this area can be subject to quite considerable damage.

The xTCU interface detects this damage and, using the software developed by GlobalmatiX partner Spearhead AG,

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Zurich, provides an individual damage report based on the vehicle model incl. an estimate of the costs of the damage within seconds. Millions of pieces of historic and recent accident and assessor data from the Stuttgart-based expert organization DEKRA SE provide the basis for this.

Cees van Dijk, CEO of Spearhead AG, Zurich: “GlobalmatiX, with its highly sensitive telematics box, is the first company to be able to deliver the extensive volume of data we need for digital accident analysis to our cloud system in real time.”

The xTCU Gateway is a 4G/LTE/5G CAN data logger and GPS telematics interface specially developed for Car to Cloud to Company use cases. It is smaller than a smartphone and can be installed in any vehicle in just a few minutes, thus enabling the acquisition of OBD data or diagnostic data from the ECUs. The telematics box certified according to CE,

eMark and RED in the EU enables access to a wide range of vehicle data in rich quality – regardless of the vehicle brand.

With it, GlobalmatiX offers a previously unreached level of security against unauthorized access by third parties with its innovative encryption technology and proprietary 4G/ LTE/5G wireless network. In other words, GlobalmatiX xTCU can acquire and analyze virtually all data measured by the vehicle’s ECUs, supplemented by state-of-the-art GPS tracking, and transmit the information to the vehicle operator “over the air” almost in real time. With the help of artificial intelligence in the Big Data Cloud, a qualified analysis of vehicle data, events and changes to the ideal state is now possible for the first time and can be sent to the vehicle management system – in as detailed a form as the fleet operator desires.

The companies see great potential for cost savings in the future, particularly in contactless lessor-lessee management, while at the same time improving customer service. The xTCU telematics interface is the key to achieving these goals.

Successful Premiere with Enterprise/Switzerland: Millions to be Saved Enterprise in Switzerland was the first rental car company to carry out an extensive test run with GlobalmatiX; in June 2021, they concluded a long-term contract on the use of the telematics interface. After an evaluation of the results, the outcome is convincing in several areas: “Our major digital challenge is detecting and settling minor damage,” says Marco Venturini, CEO of Enterprise Switzerland. “Previous solutions based on expert opinions were simply too late, too time-consuming and too expensive. The GlobalmatiX telematics solution, in conjunction with the MSS Holding AG software customized to suit rental car management, is a great help in settling these cases of minor damage and

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The benefits for rental car and car sharing companies are: - digital recording, classification and processing of the damage, - digitalization of the damage report (previously several days were required, now in real time), - correct assignment of the damage to the party responsible and transparent, fair settlement of recovery costs, - millions of euros saved (depending on the size of the fleet) with clear, unambiguous identification of the party responsible, - savings from assessor costs that are not necessary.

The GlobalmatiX telematics solution thus offers a reliable basis for the stationless and contactless use of rental and car sharing vehicles. The detailed recording of the current condition of a particular vehicle before it is next rented out saves the otherwise necessary inspection at a station, and thus additional personnel costs, without jeopardizing the level of quality that customers expect today. At the same time, this helps reduce the idle time of rental cars.

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at the same time implementing vehicle diagnostics for all our brands.”

If you take a look at the statistics, you will see that a rental car has four incidences of minor damage a year on average, with repairs totaling around EUR 6,000. In comparison, the costs for the xTCU Gateway, the installation and the annual telematics costs constitute only around one tenth of the repair costs not chargeable by the company. In the case of the fleet sizes of rental and car sharing companies, this represents millions in saved costs every year.

To make these services possible, GlobalmatiX has not only engaged in a partnership with Spearhead AG, Zurich, for the diagnosis and assessment of minor damage. A further partner is MSS Holding AG, Zurich, a comprehensive mobility provider, as well as the licensees Enterprise, National and Alamo in Switzerland. This is where an extensive “Digital Connected Car” concept was developed as a management platform for vehicle fleets.

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There are currently four telematics applications in use which are of great significance for lessors and operators of passenger car and van fleets: remote vehicle diagnostics and predictive maintenance, accident detection and automatic claims handling, complete résumé file (CarCV) for vehicles and keyless door opening for rental vehicles.

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Andreas Buhl, President of MSS Holding AG: “The multibrand capability, the modular and tailor-made applications for all vehicles over the xTCU interface, the high data resolution as well as the extent of applications over only one box were decisive in our awarding the contract to GlobalmatiX. By using the GlobalmatiX telematics solution, we have established the basis for digitizing our Connected Car concept. This will enable us to simplify complex return processes in a customer-friendly way and make them more cost-effective. Creating a résumé increases the resale value of our vehicles and facilitates marketing before the vehicle is returned. Furthermore, keyless access to the vehicle allows us to put rental on the road.”

Alois Widmann, CEO GlobalmatiX: “We have developed a smart telematics box to be used for several brands in large fleets. It is not only easy and quick to install, but also records diagnostic signals at extremely high sampling rates and combines them with telematics data. From everywhere in the world, the data acquired is transferred to and analyzed in the Big Data Cloud of our partner Spearhead in real time via mobile radio. The fleet manager can act immediately on the basis of these results. This innovative telematics solution with just one box makes sure that the ongoing total costs for large fleets are significantly reduced.” https://automotive.softing.com/index.html

PROCESS

DE DIETRICH PROCESS SYSTEMS PRESENTS ITS NEW DRUM DOCK STATION EQUIPPED WITH THE DIT SOLUTION FOR SAFE HANDLING OF POWDERS

The De Dietrich Process Systems group extends its range of solutions for handling pharmaceutical and chemical powders with a new Drum Iris Technology (DIT) dock station which guarantees a high level of containment.

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he loading, unloading and transfer of powders are a major concern for companies in the pharmaceutical and chemical sectors. Several objectives must be reached: limiting the exposure of operators to highly active or toxic powders while at the same time protecting these same powders from any pollution coming from the environment.

Thanks to the new drum dock station equipped with the DIT (Drum Iris Technology) solution, De Dietrich Process Systems offers an innovative solution consisting of an interface with two elastomer diaphragm valves. The docking principle is based on the successive opening and closing of the diaphragm valves which hold the drum and allow the operator to push it towards the flexible or rigid glove box.

The DIT solution can be used with a powder pump or installed directly on a reactor, filter dryer or any other type of equipment. The station is available in several variants: with a single-chamber (OEB 5) or double-chamber (OEB 6) glove box for a higher level of containment and available in stainless steel (304/316) or Hastelloy, with a flexible glove box (OEB 4) in low density polyethylene or polyurethane.

All variants are compatible with the ATEX zones and can be equipped with integrated cleaning systems. With the new De Dietrich Process Systems drum dock station, equipped with the DIT solution, handling and transferring powders is easier and safer than ever before https://www.dedietrich.com/en/solutions-and-products/ containment/drum-dock-station

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This system allows the contents to be accessed, while guaranteeing total leak-tightness. The station is also equipped with a stacker for lifting the drum and limiting the amount of manual effort. The stacker improves the workplace ergonomics, lowering the risk of operator injuries and optimizing the yield and production cycle times. The modularity of the drum dock station makes it possible for

drums to be docked from below or from the rear, which makes it suitable for a wide range of configurations.

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S M A R T FA C TO R Y

MITSUBISHI ELECTRIC RENEWS SCADA LINEUP

GENESIS64 Basic SCADA

GENESIS64 Advanced Application Server

Supporting the increasing focus on digital manufacturing and IoT, Mitsubishi Electric has renewed its SCADA lineup, now offering two types of software for system monitoring and process control under the series name “GENESIS64”, replacing the existing “MC Works64” SCADA software. The new lineup will meet the diversifying IoT needs, covering a wide variety of purposes from small production line monitoring and control to multi-site monitoring and business intelligence (BI) of plant-wide systems, process automation as well as utility and building automation. The “GENESIS64 Basic SCADA” is an entry-level software with essential functions for small production lines, and the “GENESIS64 Advanced Application Server” is a full SCADA suite for large-scale monitoring of factories, buildings and utilities.

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he “GENESIS64 Basic SCADA” facilitates the visualization of data in small applications but can also be scaled up to medium applications with optional add-ons depending on requirements of the customer.

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For customers with bigger system needs, “GENESIS64 Advanced Application Server” will help to create a serverless system using cloud computing, which will facilitate the construction of redundant, multi-location or other highly secure, large-scale systems. This “top end” software can also connect to wearable devices such as smart glasses and smart watches, supporting customers interested in introducing remote monitoring or giving work instructions remotely. Furthermore, the software can be operated by voice commands with the use of AI smart assistant speakers, which helps operators avoid touching the monitoring screen - another function that supports the “new normal” in the manufacturing world.

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With the renewal of the SCADA lineup, Mitsubishi Electric customers will have a unified one-stop access to SCADA solutions provided by the U.S.-based ICONICS, Inc., a SCADA and IoT analysis software company acquired by Mitsubishi Electric in 2019. Customers will be able to benefit from the combination of ICONICS’ software technology and Mitsubishi Electric’s FA technology spanning expanded software products and services from the edge to the cloud, all targeted at helping customers solve their automation and process control issues. This integration is initially demonstrated in the direct connection of Mitsubishi Electric PLCs to the GENESIS64 SCADA software, achieving automatic detection and smooth startup while eliminating the need for an OPC server. https://us.mitsubishielectric.com/fa/en/products/ visualization/iconics-suite

The “GENESIS64 Advanced Application Server” will facilitate the construction of redundant, multilocation or other highly secure, large-scale systems.

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Touchless monitor and control can be achieved with the use of AR devices; apps for mobile devices and smart watches facilitate remote monitoring.

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VIAL CHECK

Intelligent multi-camera system for quality control of vaccine bottles.

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ombating the Covid-19 pandemic is at the top of the global agenda. Around the world, efforts are being made to supply the population with vaccine as quickly as possible. But providing around 8 billion doses at least one for every person in the world - is no easy task.

Glass vials are a crucial factor in the delivery of the billions of doses of vaccine. About 50 billion of them are produced worldwide every year. Currently the producers of the vials are massively ramping up their production so as not to become the proverbial bottleneck in the supply chain. However, medical-grade vaccine vials are not standard glass tubes.

Whether rolled-rim bottles, threaded bottles or ampoules, they are all made of the special glass borosilicate and require customized production lines. Any interaction between the container and the liquid inside must be prevented, as any chemical interference could affect the vaccine. Even the smallest scratch, crack or fissure can render an entire batch unusable, contaminate the line during the filling process or even lead to a machine standstill.

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The demands on manufacturers are enormous: it is not only a matter of producing large quantities quickly, but also of maintaining particularly high quality standards. At the same time, increasing production capacity is usually time and capital intensive. A cost-effective, quickly integrated, extremely reliable solution for inspecting vaccine vials comes from Bad Königshofen in Germany: Isotronic GmbH, has developed the automatic tubular glass inspection system “VialChecker”. IDS industrial cameras from the uEye CP camera family are used as image processing components for dimensional and surface inspection.

Application Vaccine vials usually hold between 2 ml and 100 ml of liquid. They are on average 45 mm high and 11.5 mm wide.

Manufacturers use borosilicate glass for this purpose to keep the vaccines in the required stable condition during storage and transport - even at extreme temperatures. The small containers for the precious contents are subject to high quality requirements. At the same time, large quantities currently have to be produced in the shortest possible time. What is needed is very fast quality control with high reliability in defect detection - how can that work?

The production of vaccine bottles is subject to particularly strict quality requirements.

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Rolled rim bottles, threaded bottles or ampoules made of borosilicate glass for vaccines are subject to the highest quality requirements.

Take high-performance cameras that have high-resolution sensors while enabling high frame rates and combine the GigE industrial cameras from the IDS uEye CP family with industrial-grade touchscreen monitors, control cabinet, connection to the respective production system and intelligent software. VialChecker is the name of the all-in-one inspection system for automatic dimensional and surface inspection of vaccine vials, available in two versions. Compliance with the dimensions is checked by the “VialChecker Geometry”, while the “VialChecker Cosmetic” checks the surface of each individual bottle for flawlessness.

The latter can optionally be used as part of the geometry inspection or take on more demanding tasks as a separate system.

Testing takes place at various points in the manufacturing process, such as directly after the bottles have been formed or shortly before packaging. A system usually supports between three and eight cameras, so that different measuring stations can be integrated along the production

The cameras capture at least 20 images per rotation, allowing the VialChecker to check up to 120 vials per minute with a very high degree of accuracy. It is up to 0.01 millimeters for dimensional tests and 0.1 square millimeters for cosmetic tests. In addition to real-time, low-latency processing, there is detailed logging of system operation. The high reliability of the software ensures that the products are within the geometric product specification and are error-free, while meeting the quality requirements.

Depending on the requirements and the testing task, different camera models are needed for the measuring station. Currently, Isotronic mainly uses the IDS camera family GigE uEye CP. They offer maximum functionality with extensive pixel pre-processing and are perfect for multi-camera systems such as the VialChecker thanks to the internal 120 MB image memory for buffering image sequences. The cameras deliver data at full GigE speed and, thanks to PoE (“Power over Ethernet”), also allow singlecable operation up to 100 meters.

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The VialChecker Geometry contains more than 50 dimensional checks and performs tests for both standard and non-standard tubular glass products with a measurement accuracy of up to 0.01 millimeters. Defects such as cracks, scratches, chips, inclusions or stains, on the other hand, are detected with an accuracy of 0.1 square millimeters thanks to the powerful cameras. Intelligent software enables accurate fault description analysis and classification.

line. “Depending on customer requirements, the system is specified or supplemented with appropriate sensors or cameras, for example to measure glass thickness,” explains Valentin Mayer-Eichberger, Chief Operating Officer at Isotronic. “If more than eight cameras are needed, several computers are sent into action.” For example, they observe the laterally rotating tube glass or the glass bottom and provide high-resolution images.

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The multi-camera system “VialChecker” enables high-speed processing in the quality control of vaccine bottles.

Modern software that is also intuitive to use. The machine operators appreciate that.

One of the preferred models is the UI-5250CP-M-GL with a 2 megapixel CMOS sensor, one of the most sensitive sensors in the IDS portfolio. It is available in two versions, mono and color, and is characterized by outstanding light sensitivity.

In addition, it offers various switchable shutter modes that enable the image-true capture of moving subjects or the particularly noise-free recording of high contrasts. “This is particularly important for the fast, reliable detection of defects on the glass surface,” says Valentin MayerEichberger, explaining the choice of the uEye+ camera from IDS. This allows either several characteristics to be checked simultaneously or the AOIs to be captured in an exposure series with different parameters.

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This small powerhouse with a frame rate of 52 fps is thus predestined for the various inspection tasks along the production line - at high speed: “The system enables high-speed processing, it manages up to 120 cycles per minute,” Valentin Mayer-Eichberger underlines. Besides the convincing performance of the cameras, however, other factors play a role: “We appreciate the uniformity and durability of the IDS cameras. And the service,” says Gregor Fabritius, Managing Director of Isotronic, explaining the historically grown, long-standing relationship with IDS. Software The IDS cameras are directly connected to the system using C++. A software algorithm developed by Isotronic GmbH detects errors and outputs the error message via 32 | Industry USA | November 2021

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the monitor. “We not only have a measurement system that reports good/bad, but also records the quality of each product and displays statistics over time. The machine adjuster uses this to check that everything is still correct and that the bottle has been adjusted well.”

The Isotronic software has an intuitive, user-friendly interface that has been developed to meet the needs of customers. In addition, the VialChecker is optimized for remote support with continuous updates and software improvements. Valentin Mayer Eichberger is convinced: “This is the basis for a dynamic, sustainable system. We use machine learning for demanding tasks such as error classification. On-site or cloud-based solutions for handling large amounts of data, as well as detailed analytics and process optimization are part of the scope of services. It is possible, for example, to analyze the frequency of faults over time as well as to monitor tool wear and raise alarms. The cloud service for production monitoring is extensive: At the end of production, we calculate charts per quality measure.

Certificates on the accuracy of the measurements can be issued for the acceptance of the measurement system.”

Outlook Experts estimate that global demand for vaccine vials will further increase by one to two billion over the next two years. The head of AstraZeneca, one of the major vaccine producers, also warned early in the pandemic: “There are not enough vials in the world.” Vaccine vial manufacturers

Rough environments in the moulding process place special demands on the protection of the cameras.

worldwide are ramping up production of the glass that is supposed to protect the precious liquid. To ensure that this valuable liquid is protected accordingly, automatic, highperformance testing systems are more in demand than ever to guarantee the immense demand for quality. “In addition, there is a general growth in the industry and in demand from the Asian region - and that even before the pandemic,” notes Valentin Mayer Eichberger. Good prospects for systems like the VialChecker: It helps producers avoid becoming a bottleneck in the vaccine supply chain. https://en.ids-imaging.com/

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MONITORING OF ENERGY NETWORKS – HOW TO MAKE IT EASY AND SECURE

Fig. 1 - By using Smart Grid gateways for monitoring energy networks, existing systems, new devices and control systems can be connected – regardless of the communication technology or the manufacturer brand.

Cloud and cyber security in critical energy applications - Digitalization and IoT (Internet of Things) is a clear trend within power plants and substations, just as it is in industrial automation. The Smart Grid is certainly a driving factor, but there are also other reasons for this change. Operators often find that only having data available in the control room is insufficient. Instead, they want to monitor transformers remotely, implement new maintenance concepts from anywhere, optimize utilization and commissioning, or retrieve environmental data online. This requires a solution with a high level of cybersecurity that guarantee critical control data to be strictly separated from monitoring data. The solution should also be easy to use and have a compact form factor to ensure that it is suitable for retrofitting and that it fits into existing cabinets.

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Cybersecurity of utmost importance Substations which convert high transmission voltage into consumer voltage are an important part of the electrical grid, not only for municipalities but also for the railways and industrial companies to name but a few. They usually consist of power transformers, switchgear and a lot of equipment for measurement and control. Substations are usually managed from a control room, or remotely from control centres. This control path is subject to strict security regulations as a successful hacker attack could have catastrophic consequences. There is also a need for cloudbased monitoring. But how can this be achieved without neglecting the required cybersecurity?

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Two separate data streams In principle, there are two different data streams in substations: the first is the control data with which the control room communicates with the substation or individual devices. Control data means sending commands such as “Turn switch on”, “Measure now” or “Send measured value”.

This critical communication runs in real time according to the protocols used in the energy sector such as IEC61850 or IEC60870-5-104. The security requirements are high and unauthorized data must be excluded.

The second data stream delivers monitoring data from sensors and devices to the control room. Real-time communication is not required here but the data packages are usually more extensive for this IoT data. Of course, the

Fig. 2 - Here is an example to demonstrate how the monitoring works in practice. A gateway collects the data from the various sources via the relevant ports.

data must not be compromised here either, which is why communication is usually handled via TLS or VPN, for example.

There are also event-based alarm notifications that can be transmitted via independent data channels such as MQTT or SMS. Since the data only flows one way towards the control room or the cloud, this data stream and the transmitting device are well protected against attacks.

The data involved can come from various sources. Some data comes directly from the “heart” of the substation – values of the IEDs (Intelligent Electronic Devices), i.e. the control computer for the switchgear or measuring devices in the station. Other data is provided by additional sensors

How to gather and forward the data?

So how is it possible to gather the various data and how is it transmitted to ensure the required level of cybersecurity?

There are readily available gateways for this task (Fig. 1), such as the Ixxat SG gateway from HMS Networks. These gateways combine the functionality of RTUs (Remote Terminal Units), controllers and gateways; opening up possibilities to digitize substations and distribution networks. Existing systems, new devices and control systems can be connected quickly – regardless of the communication technology or manufacturer.

A gateway collects the data from various sources via the relevant ports (Fig. 2). It supports the communication protocols used in the energy sector, including IEC61850 and IEC60870-5-104, and can simultaneously feed in the data from IoT sensors connected via Modbus and analogue interfaces (for example).

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Typical data that is monitored The data typically transmitted along the monitoring path includes, for instance, temperatures of transformers, highvoltage lines and motors, or oil pressure in transformers.

If we take SF6-insulated circuit breakers as an example, it is possible to monitor gas pressure, temperature and gas humidity, and transformers, cables or battery backup systems can provide voltage data. Data from building management can also be made available via the monitoring path. For example, door sensors of the access control system, air conditioning values or even a robot lawn mower can be monitored.

that are commonplace in the industrial environment or in building management.

Monitoring and added value Protocol conversion and, where applicable, media disruption, mean that such a cloud connection is very secure. In addition, the data is only transmitted in one direction; access options are initially not provided but can be defined as exceptions if necessary. Configuration of these 32 | Industry USA | November 2021

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Fig. 3 - The control unit of the UPS communicates with the gateway via Modbus and is connected to the control room via an IEC61850based gateway. The status data of the individual battery cells is sent in parallel via MQTT to the manufacturer’s private cloud.

types of gateways is usually graphical and does not require any programming knowledge or additional software.

There are many use case scenarios. For example, a sensor manufacturer can use a Smart Grid gateway as a platform for communication with its private cloud, for remote monitoring, surveillance and maintenance planning.

Substations can digitize the energy supply in an easy way: The gateway feeds the measured data – either from IEDs or sensors into the control system and can forward it directly to the cloud (MQTT) via an integrated LTE modem where it remains available for continual status monitoring.

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Another example of an application can be found in battery back-up systems for local control networks, for example in converter stations in the railway power supply system (Fig. 3). The control unit of the Uninterruptable Power Supply (UPS) communicates with the gateway via Modbus and is connected to the control room via IEC61850. The status data of the individual battery cells is sent in parallel via MQTT to the manufacturer’s private cloud. This guarantees functional reliability through continuous monitoring and prompt, plannable maintenance. It can even lead to new business models, e.g. renting a UPS system according to usage. And the best part: thanks to the ability to retrofit, older existing facilities can also benefit from the new possibilities of digitalization.

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https://www.ixxat.com/products/energy/sg-gatewayoverview

S M A R T FA C TO R Y

DATACOM SALES GROUP PARTNERS WITH SOFTING TO EXPAND IT NETWORK TECHNOLOGY SUPPORT FOR U.S. CUSTOMER BASE

Datacom Sales Group, LLC, a manufacturers’ representative firm that provides sales and marketing services to the datacom and networking industry, has announced a new partnership with Softing Inc., an industry leader in active network testing and cable testing products.

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his collaboration, which leverages Datacom Sales Group’s sales and marketing expertise, will expand Softing’s ability to support its IT network customers in the Texas, Oklahoma, Louisiana and Arkansas markets.

“Datacom Sales Group is another exciting addition to Softing IT Networks for structured cable testing,” says Jeff Besola, Senior Vice President of Global Sales, Softing Inc. “This partnership is an exciting example of our commitment to provide the best field support to our customers.”

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“Datacom Sales Group is proud to represent Softing,” says Gary Moore, President, Datacom Sales Group. “We represent fiber and copper cable manufacturers, and this partnership will allow us to round out our product offering with Softing’s high-quality test equipment.” https://industrial.softing.com/

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MODULAR DESIGN FOR HIGH-PRECISION AND DYNAMIC MACHINING: MAXXTURN 65 G2

The MAXXTURN 65 G2 has been completely redesigned. With its clever modular design, the machine offers a wide range of options for specific customer requirements. The high drive power of the main and counter spindles, combined with optimum torque characteristics, ensures economic efficiency in the machining of steel as well as in the high-speed machining of aluminium. 12 driven tools and a Y-axis ensure perfect results in complex milling and drilling operations. With numerous automation solutions and the EMCONNECT digital process assistant, the MAXXTURN 65 G2 is state-of-the-art and enables lowmanpower production in operation.

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Machine structure The core of the machine is the 40° inclined bed. Designed as an extremely rigid and compact welded steel construction, it is the basis for a robust and precise lathe. Reinforcements provide additional rigidity in zones exposed to higher stress.

As a further development of the MAXXTURN 65 G1, the machine impresses with its modern and innovative design.

The optimised integration of the chip conveyor ensures compact dimensions. Instead of belt drives, spindle motors are used on the main and counter spindles, which ensures a particularly wide speed range of up to 5000 rpm and extremely good concentricity properties. Three main spindle sizes are available depending on customer requirements: Standard Ø 65mm/BigBore Ø 77mm/SuperBigBore Ø 95mm. A symmetrically designed headstock, together with temperature sensors at the bearing points and liquid cooling, ensure high thermal stability.

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The C-axis is part of the basic machine equipment and allows the positioning of the spindle within a resolution of 0.001 °. Due to the directly flanged encoder, the C-axis is ideally suited for contour-precise milling; a hydraulic holding brake (option) can be additionally activated. The Y-axis is also integrated in the basic machine structure and set at 90° to the X-axis. Extremely short projection lengths form the basis for solid turning and drilling operations as well as contour-free milling operations. Absolute measuring systems are installed in all linear axes - position dispersion as per VDI3441 in X/Y/Z: 0.0035/0.0035/0.004 µm as standard/0.002/0.002/0.002 µm as an option, with glass scales and laser measurement.

Machine configurations

Torretta BMT con azionamento diretto.

NEWS

Controllo con l’assistente di processo digitale EMCONNECT

Lunetta per lavorazione alberi.

The MAXXTRURN 65 G2 has numerous modular options and is available in different versions: • MT65 G2 M: incl. tool drive, C-axis and tailstock • MT65 G2 MY: incl. tool drive, C-axis, Y-axis and tailstock • MT65-G2 SM: incl. counter spindle, tool drive and C-axis • MT65-G2 SMY: incl. counter spindle, tool drive, C-axis and Y-axis On the MT65M-G2 with tailstock, the tailstock is mounted on the roller guide track and can be moved automatically over a length of 500 mm. A drag steady rest with Ø 8-101 mm is optionally available. This ensures even more flexible use of the machine, e.g. for shaft machining. On the MT65S-G2 with counter spindle, the counter spindle head is seated on its own roller guide track and can be moved automatically over a length of 580 mm. The spindle is driven by an integrated spindle motor (ISM) with liquid cooling. A strokemonitored parts ejector, flooded with coolant, ensures safe removal of the finished parts. In addition, a 12-station VDI30 turret (optionally VDI 40) with single-motor technology is available. A servo motor powers the driven tools or the swivel movement - no lift-off and indexing with directional logic are the result. Each station can accommodate driven toolholders; alternatively, a 12-station BMT55 turret with direct drive, with up to 12,000 rpm, or even a 16-station BMT45 turret can be integrated.

work processes are to be made more efficient and the usual high reliability of the machines is to be maintained in all operating modes. EMCONNECT can be easily and quickly updated and configured, and the selection of available apps is constantly being expanded. For example, the Shopfloor Management app serves as an option for machine and production data acquisition, enabling comprehensive monitoring of all machines and organisation of processes in the production area. Apps for minimising downtimes are also available with EMCONNECT. Automation The EMCO SL1200, IRCO ILS-MUK 7012 or 10012, FMB TURBO 5-65 or 8-75 and TOP AUTOMAZIONI X-FILES bar feeders are available for efficient production. The EMCO gantry loader ensures fully automatic loading and unloading of the workpieces and seamless interaction between the machine tool and the loading device. If required, flexible ROBOT automation can also be offered. https://www.emco-world.com/en/products/turning/ cat/10/d/2/p/1000988%2C10/pr/maxxturn-65-g2.html

Control The customer can choose between the SINUMERIK ONE or the FANUC 31i-B control system. The control panel on the MAXXTURN 65 G2 is height-adjustable on the right and can be swivelled, which ensures the best ergonomics. 22" multi-touch screens improve the view of individual control functions.

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The optional digital process assistant EMCONNECT stands for connectivity and networking of the production environment and helps with the comprehensive integration of customer- and system-specific applications around the machine control and the production process. The user and his requirements are the focus of the operating procedures, 32 | Industry USA | November 2021

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S M A R T FA C TO R Y

168 MANUFACTURING OPTIMIZES ITS NEW FULLSHOP™ MODEL FOR COMMON MACHINE SHOP SIZES

168 Manufacturing, a brand of Precision Tool Technologies that designs and develops CNC machine shop automation technologies, announces its new FS40 series of FullShop™ Automated Coolant Management Systems. Optimized for the most common CNC machine shop sizes, the FS40 enables these shops to take their productivity to the next level. Due to its modularity, one FS40 system can automate a few CNC machines or expand to accommodate up to 40 CNC machines.

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ike the flagship FS120 system, the new FS40 series monitors and replenishes all CNC sumps with optimized top-off ratios. This turnkey system is easy to install and consists of a centralized pumping station, controller, distribution manifolds and level sensor that drops into the machine tool sump. Compared to the FS120, which has a footprint of 50 by 60 inches, the new FS40 is even more compact — 30 by 30 inches.

Other features of the FS40 include: - A modular concept that supports five remote fluid nodes - Per CNC concentration control: top-off at 0.5 to 20 percent - Collaborative with our FullShop™ coolant health app - Industry 4.0 features — e.g. remote operation and teleservice - Simple low-cost installation Like the FS120, the new FS40 enables unattended CNC operation, bringing “lights-out” capabilities to machine shops. Now, instead of operating one or two shifts a day with a shop full of operators, these shops can run high-volume jobs unattended overnight, keeping the spindles spinning 24/7 and unlocking greater productivity. www.168mfg.com

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AUTOMATION24 NOW OFFERS ENDRESS+HAUSER PROCESS CONTROL MEASUREMENT DEVICES

Automation24, an online shop for industrial automation technology, is pleased to announce it has added Endress+Hauser process control measurement devices to its growing product offering.

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“We are very excited to add Endress+Hauser products to our online shop,” says Ron Baysinger, Vice President. “The company has been a proven leader in the process industry since 1953, and its comprehensive product lineup means our customers now have a one-stop shop for innovative and precise measurement technologies.”

Highlights from this product offering include: - Cerabar pressure transducers and transmitters - Ceraphant pressure switches - Picomag and Promag flowmeters - Minicap capacitive level detectors - Prosonic ultrasonic level detectors - TH Series thermometers - Ecograph data loggers - RIA 14/15/16 loop-powered process indicators - M easuring devices for hazardous areas and other demanding applications

https://www.automation24.com/

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ndress+Hauser process instruments and components deliver impeccable accuracy, allowing plant operators in industries like food and beverage, water and wastewater, oil and gas and pharmaceutical to reduce operating costs and enhance the quality of their end products.

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EMERSON MARKS 75 YEARS OF INNOVATION IN PRECISION CLEANING AND WELDING TECHNOLOGIES Branson combines breadth of technologies and a problem-solving approach to deliver advanced solutions to automotive, medical, electronics industries worldwide.

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merson (NYSE: EMR) celebrates the 75th anniversary of its Branson™ brand, a name that has become synonymous with ultrasonic technologies for plastics and metal welding, and precision cleaning. The Branson portfolio has led the industry with expanded offerings beyond ultrasonics, developing nine other material joining technologies including laser, vibration and infrared welding.

Emerson marked the anniversary at its new $49 million global headquarters for welding and precision cleaning technologies that opened in January. The new facility bolsters Emerson’s continued innovation in advanced design, engineering and joining technologies that support such complex and fast-growing industries as medical devices, existing and new bio-based plastics packaging, electric cars and next-generation batteries.

“We are extremely proud of our history and how we revolutionized the use of ultrasonics in so many remarkable ways,” said Vernon Murray, president of Emerson’s assembly technologies business. “Our goal has always been to deliver proven performance, unequaled expertise, and the broadest technology portfolio for material joining and precision cleaning applications. We look forward to continuing our stewardship in the field as we make advancements that benefit everyone.”

The Branson brand traces its history to Norman G. Branson, a research engineer who founded a company in Danbury, Connecticut, in 1946 to harness the power of high-frequency ultrasonic energy for cleaning and degreasing applications as well as nondestructive testing and gauging. But it was ultrasonic welding — developed in 1963 at Branson Sonics and Materials, which was acquired by Emerson Electric Co. (Emerson) in 1984 — that represented the real breakthrough for the company and for manufacturing. It set in motion a monumental change in the way plastics, and later metals, were joined.

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Since its beginning, Branson has been driven by the spirit of innovation, and today ultrasonics is just one of many cleaning and joining technologies offered by Emerson’s Branson portfolio. Other welding methods include spin and vibration welding, staking and swaging, and a new patent-pending “dynamic mode” of ultrasonic welding that can automatically adjust itself to part-to-part variabilities and unique materials. “Clean welding” approaches, such as Contoured Laser Technology, Clean Vibration Technology and Contoured Infrared Technology, are being adopted with ever greater frequency.

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Continuing the Commitment Given this depth of technical resources, Emerson application engineers are able to utilize a process-neutral approach to help manufacturers evaluate, select, implement, and optimize the right joining solution, regardless of the application or complexity.

This high level of customer support is enhanced by the technological capabilities available at the new 146,000-square-foot Branson headquarters. The facility includes an expanded research and development lab, increased manufacturing space, a dedicated training workspace for seminars, and training classes, technical services and other resources.

The 75th anniversary represents a milestone that Emerson will recognize throughout the next several months as the company continues its path of inventiveness, delivering advanced Branson products to solve critical industry challenges. https://www.emerson.com/en-us/automation/weldingassembly-cleaning

S M A R T FA C TO R Y

CIP SECURITY ENHANCED TO SUPPORT RESOURCECONSTRAINED ETHERNET/IP DEVICES ODVA is pleased to announce that CIP SecurityTM, the cybersecurity network extension for EtherNet/IPTM, has added support for resource-constrained EtherNet/IP devices. CIP Security can now provide device authentication, a broad trust domain, device identity via Pre-Shared Keys (PSKs), device integrity, and data confidentiality for resource-constrained devices such as contactors and push-buttons. Additionally, a narrow trust domain, user authentication, and policy enforcement via a gateway or a proxy are available options.

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espite the progress brought about by Industry 4.0 and the Industrial Internet of Things (IIoT), a large portion of the installed nodes in automation applications are still not using Ethernet. Limitations including cost, size, and power have historically been a hindrance to EtherNet/ IP pushing out to the edge of the network. The recent integration of single pair Ethernet has opened up the door to overcoming lower-level device constraints and ultimately to expanding the footprint of EtherNet/IP. Adding simpler devices to EtherNet/IP allows for the benefits of additional remote diagnostics, asset information, and parameterization capability. The addition of more nodes to the network within the context of IT/OT convergence makes device level security a fundamental need to ensure that indispensable assets and people are protected from physical harm and monetary loss.

The new CIP Security specification has added a ResourceConstrained CIP Security Profile in addition to the EtherNet/ IP Confidentiality and the CIPTM User Authentication Profiles.

The Resource-Constrained CIP Security Profile is similar to the EtherNet/IP Confidentiality Profile, but is streamlined for resource-constrained devices. The same basic security aspects of endpoint authentication, data confidentiality, and data authenticity remain. Access policy information is also included to allow a more capable device, such as a gateway, to be used as a proxy for user authentication and authorization of the resource constrained device.

Implementation of CIP Security for resource-constrained devices requires only DTLS (Datagram Transport Layer Security) support instead of DTLS and TLS (Transport Layer Security), as it is used only with low-overhead UDP communication.

“The continuous updating of CIP Security, including the recent addition of new security features for resourceconstrained devices, provides EtherNet/IP devices an enhanced defensive posture to help protect against malicious industrial network intrusion,” stated Jack Visoky, EtherNet/IP System Architecture Special Interest Group (SIG) vice-chair. “The availability of CIP Security across more portions of the EtherNet/IP network helps end users to better safeguard vital automation applications. The addition of CIP Security for resource constrained EtherNet/IP devices is an essential step in securing the edge,” said Dr. Al Beydoun, President and Executive Director of ODVA.

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The protections offered by CIP Security are now available for EtherNet/IP networks via a resource-constrained version of CIP Security that includes fewer mandatory features. This ensures that devices with the smallest power, size, and cost budgets can be secure and enjoy the communication and control advantages of being connected to an EtherNet/IP network. The latest CIP Security updates demonstrate the deep commitment of ODVA to maintain its position of device security leadership within the automation community. Visit odva.org to obtain the latest version of The EtherNet/IP Specification including CIP Security.

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