Industry Asia Pacific | 37 - July 2022 by Induportals Media Publishing

37 | J U LY 2 0 2 2

Industry

Asia Pacific THE INDUSTRY MAGAZINE FOR ASIA

ROBUSTEL’S R1510 ADOPTED BY NTT DOCOMO IN JAPAN

8 DIGITAL MANUFACTURING ENABLES CHOICE OF 40,000 MODELS IN A FIVE-DAY DELIVERY WINDOW

20 R&S RTP HIGH-PERFORMANCE OSCILLOSCOPE FOR EVEN BETTER SIGNAL INTEGRITY IN REAL TIME

FIX8™ FOR HEAVY-DUTY TURNING WITH EIGHT CUTTING EDGES PER INSERT

37 | Industry Asia Pacific | July 2022

THE INDUSTRY MAGAZINE FOR ASIA

ROHDE & SCHWARZ

EXXELIA

ROBUSTEL

6 HMS INDUSTRIAL NETWORKS

10 SECO TOOLS

SECO TOOLS

KENNAMETAL

RED LION

14 HMS INDUSTRIAL NETWORKS

MITSUBISHI ELECTRIC

WIDIA

KENNAMETAL

ADVERTISERS: MEPAX 5

www.industry-asia-pacific.com

Send your press releases to: editor@ipmediaonline.com To receive the Industry Asia Pacific newsletter, please subscribe online: www.industry-asia-pacific.com Industry Asia Pacific is the magazine for engineers published by INDUPORTALS MEDIA PUBLISHING. It contains the latest product and company news for industrial markets. Industry Asia Pacific edits its articles with the greatest of care, however we cannot guarantee the accuracy of the information presented in them. Our teams disclaim all responsibility concerning the content of this media or how it might be used. https://induportals-media-publishing.com

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ELECTRONICS

EXXELIA EXPANDS ITS RANGE OF LOW PROFILE ALUMINUM ELECTROLYTIC CAPACITORS AND DEFIES HIGH TEMPERATURES UP TO +125°C

Exxelia, a global manufacturer of complex passive components and subsystems for harsh environments, is expanding its CUBISIC capacitor range with a HTLP (High Temperature Low Profile) version. This CUBISIC HTLP offers, in a thin rectangular packaging, the highest energy density of capacitors in its class, combined with a high temperature resistance (-55° –> +125°C).

UBISIC HTLP, the new rectangular capacitor range that changes the game. 0The new range of CUBISIC HTLP by Exxelia clearly stands out! Why?

• It offers up to 60% more capacity than any other rectangular electrolytic capacitor on the market, in the same volume, while having a 5,000-hour life span.

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• Covering a temperature range of -55° –> +125°C, the CUBISIC HTLP is designed to provide excellent performance in extreme temperatures, compatible with the most severe military and aerospace applications.

Engineers facing complex design requirements and looking for an easily integrated product will gain space and reliability through the use of improved materials, fully REACH compliant. The CUBISIC HTLP withstands 20g vibrations and is lowpressure qualified, making it compatible to 92,000 feet in altitude. It is ideally suited for integration into cockpits, actuators, and power generation in commercial and military aircraft as well as radar and laser systems. Technical specifications • Capacity from 140μF to 58 000μF • Voltage from 7.5V to 350V • Service life of 5,000 hours at 125°C • Operating temperature -55°C to +125°C • 20g vibrations and 92,000 feet altitude • RoHS versions available https://exxelia.com/en/product/detail/807/cubisic-htlp

37 | Industry Asia Pacific | July 2022

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MEASUREMENT

MONTH’S PRODUCT

ROHDE & SCHWARZ ENHANCES R&S RTP HIGH-PERFORMANCE OSCILLOSCOPE FOR EVEN BETTER SIGNAL INTEGRITY IN REAL TIME

Rohde & Schwarz has paired the outstanding performance of its established R&S RTP oscilloscope with an enhanced user interface and a larger display. The result is an even more flexible oscilloscope in a compact format with a modern look and feel that continues to deliver high-performance signal integrity in real time.

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ohde & Schwarz introduces the new generation of R&S RTP high-performance oscilloscopes, which combine high-class signal integrity measurements with the fastest possible acquisition for real-time analysis. The new models come with a bigger and brighter 13.3” full HD touchscreen and a fully redesigned front panel. Users can take advantage of the crisp 16:9 screen format, which displays waveforms while allowing settings to be altered and changed quickly. The intuitive front panel increases productivity with fast, direct access to primary instrument settings. All this, without compromising the overall instrument footprint to keep occupied desk space to a minimum.

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Dr. Andreas Werner, Vice President Oscilloscopes at Rohde & Schwarz, says: “Improving overall usability so that test engineers could focus on the design problems at hand and not on operating the test equipment was paramount to our R&D engineers when we decided to update the R&S RTP. Our oscilloscope offers the outstanding performance and flexibility our customers expect, combined with a very small footprint. It has been ideal for signal integrity analysis in real time since its original launch – and it just got better.” R&S RTP high-performance oscilloscopes are available in different bandwidth models from 4 GHz to 16 GHz with a sample rate up to 40 Gsample/s. All models also support bandwidth upgrades right up to 16 GHz. At the core of the R&S RTP is the acquisition and processing ASIC from Rohde & Schwarz, which enables an unparalleled acquisition rate of 750,000 waveforms/s, making it easier for engineers to spot, isolate and analyze circuit board design defects. To reliably capture and analyze long events or sequences, Rohde & Schwarz has increased the standard acquisition memory to 100 Mpoints per channel, with a further upgrade option of

New R&S RTP models feature an enhanced user interface and a larger display.

up to 3 Gpoints per channel. This makes the R&S RTP a new benchmark in this class.

framework to support automated tests with image based guidelines and summarize results in test reports.

The hardware implemented 16 Gbps clock data recovery (HW-CDR) that enables real-time eye diagrams for longterm monitoring of high-speed serial interfaces, is a highlight of the R&S RTP. The new R&S RTP-K136 and K137 options support data eye analysis of sequential bits in an acquired data stream with maximum data rates of 8 Gbps and 16 Gbps. The timing for the bit slicing is based on the continuously running HW-CDR. This has significant advantages relative to traditional post-processing with a software-based CDR. Users can combine this function with the real-time deembedding and real-time differential math functions of the R&S RTP to complete debugging or searches for signal faults in a fraction of the time.

The R&S RTP is the most compact and lightest highperformance oscilloscope on the market with a footprint nearly half the size of comparable instruments. The sophisticated cooling concept and silent fans also make it the quietest oscilloscope in its class.

While supporting a wide range of applications, Rohde & Schwarz provides even more flexibility with the new R&S RTP-K39 user defined math option. It allows test engineers to call a Python script for complex calculations and display the results as a math signal on the oscilloscope, creating endless possibilities for users to analyze the captured data as needed. Further new application options include the R&S RTP-K27 MIPI D-PHY V2.1/2.5, the R&S RTP-K28 MIPI C-PHY V2.1 and the R&S RTP-K102 USB 3.2 Gen 1 & 2 RX compliance tests. They utilize the R&S ScopeSuite compliance test

www.rohde-schwarz.com/rtp

Rohde & Schwarz will give one of the first public demonstrations of the new R&S RTP at the embedded world 2022 conference in Nuremberg from June 21 to 23 at booth 4-218. The new R&S RTP high-performance oscilloscopes are now available from Rohde & Schwarz.

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37 | Industry Asia Pacific | July 2022

I N D U S T R I A L CO M M U N I C AT I O N S

ROBUSTEL’S R1510 ADOPTED BY NTT DOCOMO IN JAPAN

This milestone is major progress for Robustel on its mission to help customer’s businesses in industries across the world to solve their connectivity problems with robust, secure and scalable IoT and M2M solutions.

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Industrial cellular IoT gateway R1510 adoption background NTT DOCOMO have developed a IoT service package called “DOCOMO IoT Managed Service”, it is a service bundle combining communication devices, connectivity and maintenance in a complete service offering. This service has wide reaching applications beyond the IoT industry, functioning as an alternative solution for any customer using ISDN/PSTN and 3G networks as they are scheduled to be shut down in the future.

The Robustel R1510 IoT Router is an industrial LTE router offering cost competitive connectivity with various interfaces. With thousands of units regularly being shipped worldwide, the R1510 has been certified by over 20 mobile network operators (MNOs) in Japan, the United States, Europe, Southeast Asia, etc. Therefore, the router can be quickly deployed in IoT projects not only in Japan but also globally. The R1510 offers an industrial ruggedized housing that can be used in harsh environments with an operating temperature range from -25 to 75°C. In addition to the two Ethernet interfaces it can also support digital input/outputs (DI/DO) as well as Wi-Fi in client and access point modes. For more information about R1510, please visit https://www.robustel.com/en/product/r1510-industrialcellular-vpn-router/

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Robustel Cloud Manager Service (RCMS) Value Added Robustel Cloud Manager Service (RCMS) is a modular IoT cloud software platform compatible with all Robustel products. RCMS is designed from the ground-up to empower Robustel customers to build their IoT Solution(s) in a manner that is scalable, cost effective and can evolve quickly with the market. Designed to work hand-in-hand with RobustOS, RCMS unlocks the true potential of Robustel products giving customers the ultimate range of monitoring, management and control functions.

Strong Local Support Ability Together with our local distribution partner PALTEK Corporation (Headquarters: Kohoku-ku, Yokohama, CEO: Tadahito Takahashi, hereinafter referred to as PALTEK), we have also established a strong operational support system to match the service of NTT DOCOMO, offering local maintenance, warranty and support systems which have been a critical factor in the adoption of this solution. For more information about PALTEK, please visit https://www.paltek.co.jp

With its modular design RCMS enables new APPs to be added to the platform without interfering with core behavior, to create new functionality and allow for integration with thirdparty applications.

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For more information about RCMS, please visit https://www.robustel.com/en/robustel-cloud-managerservice/

37 | Industry Asia Pacific | July 2022

I N D U S T R I A L CO M M U N I C AT I O N S

INDUSTRIAL NETWORKS KEEP GROWING DESPITE CHALLENGING TIMES - INDUSTRIAL NETWORK MARKET SHARES 2022 ACCORDING TO HMS NETWORKS

Anders Hansson, marknadschef, HMS Networks

Every year, HMS Networks analyzes the industrial network market to estimate the distribution of new connected nodes in factory automation. This year’s study shows that the industrial network market is expected to grow by 8% in 2022. Industrial Ethernet still shows the highest growth and now accounts for 66% of all new installed nodes (65% last year). Fieldbuses are at 27% (28) while wireless remains at 7% market share. PROFINET and EtherNet/IP share first place in the network rankings with 17% market share, but EtherCAT closes in fast, now at 11%.

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MS Networks now presents their annual analysis of the industrial network market, focusing on new installed nodes within factory automation globally. As an independent supplier of solutions within Industrial ICT (Information and Communication Technology), HMS has a substantial insight into the industrial network market. The 2022 study includes estimated market shares and growth rates for fieldbuses, industrial Ethernet and wireless technologies.

Industrial Ethernet is growing steadily Growing by 10%, Industrial Ethernet continues to take market share. Industrial Ethernet now makes up for 66% of the global market of new installed nodes in factory automation (compared to 65% last year). EtherNet/IP and PROFINET share first place at 17% market share, but EtherCAT takes a big leap forward and reaches double digits for the first time at 11% market share. Modbus-TCP is also doing well as it grows to 6% market share.

In the study, HMS concludes that the industrial network market continues to grow and that the total market growth in 2022 is expected to be +8%, confirming the continued importance of network connectivity in factories.

Fieldbuses are growing again Fieldbuses are at 27% market share compared to 28% last year. However, there is an interesting fact behind these numbers as HMS concludes that despite losing one percent market share, the actual number of installed fieldbus nodes is expected to grow by 4% in 2022 compared to last year, following several years of decline. The underlying reason is believed to be the fact that factories favor established industrial network solutions in uncertain times such as these due to effects from corona and the challenging component situation.

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Market shares 2022 according to HMS Networks – fieldbus, industrial Ethernet and wireless.

PROFIBUS remains the most installed fieldbus with 7% market share, followed by Modbus-RTU at 5% and CC-Link at 4%. Interestingly, the Modbus technologies TCP and RTU continue to be widely used also in modern factories, together accounting for 11% of the market in 2022 compared to last year. Wireless use cases emerge – Impact of 5G is yet to come Wireless grows with 8% which is on par with the overall growth rate of the network market, thus remaining at 7% market share. Typical use cases include cable replacement applications, wireless machine access and connectivity to mobile industrial equipment. The market still awaits the deployment and impact of 5G in next gen factory automation installations.

Regional network variations EtherNet/IP and PROFINET are leading in Europe and the Middle East with PROFIBUS and EtherCAT as runners up. Other popular networks are Modbus (RTU/TCP) and Ethernet POWERLINK. The U.S. market is dominated by EtherNet/IP with EtherCAT developing strongly and gaining market share. PROFINET leads a fragmented Asian market, followed by EtherNet/IP and strong contenders CC-Link/CCLink IE Field, EtherCAT, PROFIBUS, and Modbus (RTU/TCP). VIDEO HMS TechTalk, Anders Hansson provides background to this year’s study and comments on the results. https://youtu.be/VJYV5y0O8lU Scope: The study includes HMS’ estimation for 2022 based on number of new installed nodes within Factory Automation. A node is defined as a machine or device connected to an industrial field network. The presented figures represent HMS’ consolidated view, considering insights from colleagues in the industry, our own sales statistics and overall perception of the market

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Industrial networking is key for productivity and sustainability in manufacturing “Industrial network connectivity is an absolute key to reaching productivity and sustainability objectives in modern manufacturing, and this is the main driver for the growth we see in the industrial networking market,” says Anders Hansson, Chief Marketing Officer at HMS Networks. “Factories are constantly working to optimize not only productivity and sustainability, but also quality, flexibility and cyber security, and we know that solid industrial networking is key to achieving this as well. While we see growth across all network areas, it is particularly interesting

to see that the established fieldbus technologies are getting back to growth again.”

37 | Industry Asia Pacific | July 2022

M E TA L W O R K I N G

CUT LONGER WITH KENNAMETAL’S KCK20B™ AND KCKP10™ INDEXABLE MILLING GRADES

Available for many indexable milling product lines, the new grades come with a golden top layer for fast, easy wear identification, ensuring maximum tool life for each cutting edge.

New grades offer higher wear resistance and longer tool life, increasing productivity in cast iron and compacted graphite cast iron machining.

ennametal has introduced the KCK20B and KCKP10 indexable milling grades for higher wear resistance and up to 30% longer tool life when machining cast iron and compacted graphite iron components. Both grades offer higher productivity and consistent, repeatable performance during roughing, semi-finishing, and finishing operations.

“The new grades feature High-Power Impulse Magnetron Sputtering (High-PIMS) technology that provides a smoother insert surface and optimal layer adhesion for less flank wear – one of the leading causes of insert failure,” says Gil Getz, Product Manager, Kennametal. He notes that the new coating technology also increases cutting edge strength. “The result is high-performance milling in a broad range of cast iron alloys, including grey cast iron, ductile cast iron, and compacted graphite cast iron.”

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KCK20B and KCKP10 are suitable for wet or dry cuts. These include rotor hubs used in windmills, pump housings, steering knuckles and gear housings for heavy equipment, and automotive components like crankshafts and cylinder heads. While KCK20B delivers higher productivity in roughing and semi-finishing operations, KCKP10 is applicable for finishing operations, but also works exceptionally well when profiling and copy milling cast iron and steels up to 45HRC. “For customers where high tooling cost and downtime associated with tool changes are especially important, KCK20B and KCKP10 grades promise to increase tool life tremendously,” says Getz. “And for those who wish to 37 | Industry Asia Pacific | July 2022

Flank wear comparison: KCK20B on the left and another grade on the right. Flank wear limits tool life when machining cast iron and compacted graphite cast iron. KCK20B and KCKP10 grades provide longer tool life, boosting productivity significantly.

increase throughput, the new grades deliver there as well. Either way, it is a win-win for any shop machining cast iron.” Click here for more information: KCK20B™ & KCKP10™

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37 | Industry Asia Pacific | July 2022

MEASUREMENT

RED LION LAUNCHES A NEXT GENERATION GRAPHICAL PANEL METER, PM-50

The simplicity of a panel meter meets the power of a connected future.

ed Lion introduces the next generation of panel meters, PM-50. This graphical panel meter, PM-50, expands Red Lion’s existing award-winning panel meter portfolio. The PM-50 is available as a 3.5-inch or 4.3inch graphical touchscreen display. Using simple “swipe” technology, users can easily switch between relevant screens and receive comprehensive operational data for monitoring equipment and production. Visual alerts notify the user that immediate action is necessary, either on the unit itself or via PM-50 app, available on Google Play or Apple Store.

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The PM-50 offers built-in Wi-Fi connectivity for users to remotely access critical workflow and process data from the confines of the plant floor to create a smarter plant floor. Wired connectivity is also an option via Ethernet and Modbus.

Rod Smith, Senior Director, Product Management for Red Lion offered: “Today’s manufacturing environment is changing quickly and there is a greater need for data visibility, connectivity, and collection. So, when developing this next generation panel meter, the team at Red Lion challenged themselves to create a product that would help solve these challenges and allow manufacturers to take additional steps in creating a smarter factory floor. The PM-50, with its innovative graphical display, does just that allowing for more efficient processes, improved uptime, and lower operational costs.” The PM-50 is easy to install, program, and expand. The PM-50 can replace a meter with a 1/8 or 1/16 DIN panel cut out. An on-device programming wizard, mobile app, or web browser provides an easy and intuitive setup. Additional capability is available with field-installable modules to provide outputs, communications, and AC power functionality when needed. https://www.redlion.net

37 | Industry Asia Pacific | July 2022

ENVIRONMENT

SECO GREEN FUND ACHIEVES SUSTAINABILITY GOALS FOR OVER A DECADE

To ensure their contribution to reducing climate change and negative environmental impact, Seco Tools launched the Green Investment Fund in 2012. Since then, the Green Fund has supported the investment of a diversity of sustainable projects which have reduced the environmental impact of the company’s operations.

n 2022, 10 MSEK has been dedicated to funding the longterm company goals, specifically reducing the company’s climate impact by more than 50% and reaching 90% circularity by 2030.

Solar installations around the globe Solar projects aim to decrease the climate impact through minimizing reliance on the electrical grid and increasing renewable energy production. The Green Fund has supported solar projects ranging from an off-grid solar installation in South Africa to solar installation in the UK and India sales units.

Waste circularity initiatives Seco Tools are also striving to increase their waste circularity and decreasing the environmental impact of sending waste to landfills. The Green Fund has allocated funding to other projects such as composters at their UK site and funding a sustainable infrastructure within all sites to help sort waste for recycling.

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“The Green Fund is an important asset for Seco to invest in sustainable projects and has been ongoing for over 10 years now”, says Shaelyn Meyers, Sustainability Specialist at Seco Tools. “It enables sites to drive green investment which they previously would not be able to prioritize because of traditional investment factors”

Heat recovery and reusability Another way for Seco to reduce their company’s climate impact is taking advantage of the waste heat from their production processes. The Green Fund has supported sustainability projects which increase the heat recovery systems and therefore promote circularity. At the head office site in Fagersta, the heat recovery system will be expanded through air compressors to supply heating to the site and expected district heating will no longer need to be purchased. The site’s footprint, measured in CO2 emissions, is estimated to drop by 28%.

https://www.secotools.com

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M E TA L W O R K I N G

RESEARCH BUILDING BRIDGES FOR SECO CUSTOMERS

Rachid Msaoubi

Rachid M’Saoubi’s role within Seco Tools as Senior Research & Development (R&D) Expert might sound complex, but for him it’s about building bridges between the academic world and the needs of Seco Tools and their customers to help them stay competitive and thrive.

ased at Lund University in southern Sweden, the French scientist is involved in a number of international collaborative research projects with universities and manufacturing research institutes across Europe and North America.

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Such projects are often directly connected with customer needs and industrial applications where new tooling materials and machining solutions can be explored, enabling them to be more productive and cost-effective. “The ambition we have is to support the development of technical platforms that are further utilized for developing new products and machining solutions. Bringing customer needs in at an early stage in the process means not just developing tools, but also providing complete solutions that meet the requirements of component manufacturers,” M’Saoubi says. “It’s not just the material that you provide, but the machining strategy and the support that goes with it, which is an integral part of the aspiration of Seco to go the extra mile for customers.” 37 | Industry Asia Pacific | July 2022

Understanding mechanisms M’Saoubi holds an adjunct professorship at the department of mechanical engineering sciences within the division of Production & Materials Engineering at Lund University, which puts him in a perfect position to bridge the gap between scientific discoveries and real-world use cases. His collaborations bring together customers, Seco R&D experts, PhD and masters students to address issues faced by manufacturers. Some of them are very specific, while others are the age-old manufacturing issues of endurance, quality and productivity. “At the end of the day, our work should fulfil two important objectives - one is the scientific objective, which is to deliver new scientific knowledge in the field of machining science, the second objective, which is just as important for us, is to deliver impact for the customer,” M’Saoubi says. “A lot of the research I have conducted has a fundamental character, it’s predominantly trying to understand what happens to the cutting tool during the machining process. We try to understand the mechanisms by which the tool will get damaged during the machining

NEWS

Lund University Engineering Facility

process and how this will impact the surface integrity of the machined component.” Early customer collaboration and a broad network within academia allows M’Saoubi to cast his net far and wide in the search for solutions. “We work with customers from all over the globe and with universities in the United Kingdom, France, Sweden, Germany, the U.S. and Canada, among others,” M’Saoubi says.

how to bridge between the fundamental knowledge that comes from academic research at universities and how to translate it into meaningful input that can be implemented by us and our customers,” he says. “As a scientist with a foot in both worlds, it’s a very exciting position to be in.” https://www.secotools.com/

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Focus on core business Though certain industries face specific challenges, M’Saoubi maintains a strong focus on the core of the business of Seco Tools. “Customers want cutting tools and solutions that enable high material removal rate, and at the same time are durable and easy to manage. They also want consistency in machining performance across the board. Sustainability is also becoming more and more important to integrate in material and tooling development - for example within the transport sector, where the development of near-dry or completely dry machining solutions for difficult-to-cut metals and alloys have emerged in recent years,” M’Saoubi says. With almost 25 years of experience in the business during a career that has taken him all over the globe, M’Saoubi intends to keep using his knowledge and networks to develop further his ideas into concrete solutions. “Our challenge is 37 | Industry Asia Pacific | July 2022

I N D U S T R I A L CO M M U N I C AT I O N S

HMS PRESENTS COMMUNICATION SOLUTIONS FOR BATTERY ENERGY STORAGE SYSTEMS

HMS Networks is now presenting several communication solutions for the rapidly expanding battery market. Battery Energy Storage Systems (BESS) require communication capabilities to connect to batteries and peripheral components, communicate with the power grid, monitor systems remotely and much more.

attery Energy Storage Systems (BESS) may be one of the keys to solve the energy crisis and make the world more sustainable. Since green energy sources such as wind and solar are not always available, large battery parks can make it possible to store the energy to use when there is less sun or wind.

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BESS need to communicate Battery Energy Storage Systems are made up of battery cells which are combined into battery packs which can then be combined into containers which in turn can make up battery parks the size of several football fields. The systems can use new or recycled batteries and combine many different components. However, these large battery parks need a lot of communication capabilities in order to work. HMS now presents a comprehensive package of communication solutions catered for this application area.

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Error prevention and networking of CAN-based devices Since the battery market has been spearheaded by the car industry, CAN is the com-munication standard of choice in many systems. Here, HMS offers an extensive portfolio of communication solutions via the Ixxat brand – for PC connection, networking, line extension, galvanic isolation and more. In networking, the protection of components is crucial, both from external sources (like lightning strikes) and from system-related issues (AC/DC noise). Device protection is a must to avoid damage. Networking gateways Battery Energy Storage Systems often combine a variety of different equipment from different industries within a single application – batteries, BMS, PLCs, fire detection units or air conditioning. To combine different equipment, it is necessary to interconnect various protocols and network standards. CAN, Modbus, BACnet, KNX and other protocols can be easily linked via intelligent gateways from HMS,

Networking gateways from HMS are well-suited for use in BESS.

Ixxat products from HMS for CAN-based networking and device protection. Ixxat® SG-gateways handle communication between energy and industrial protocols whereas WEBfactory i4SCADA allows highly adaptable data visualization.

which handle the all-important data exchange while also enabling centralized control.

portfolio of industrial communication solutions to solve the communication issues at hand in these systems.”

In addition, these gateways can selectively filter, map and, if necessary, manipulate the data in order to realize the best possible data exchange.

Learn more in this HMS TechTalk More about communication for Battery Energy Storage Systems: www.ixxat.com/bess

Cloud/SCADA connectivity and remote access Intelligent networking is also required in order to connect to cloud solutions or SCADA systems. This connection can be made by using SG (Smart Grid) gateways from HMS that support both energy and industrial fieldbus protocols, as well as protocols required for cloud connection.

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The SG gateways enable centralized control as well as remote access for predictive maintenance, logging or data visualization using the i4SCADA® solution from the HMS-owned company WEBfactory®. The SG gateways also provide robust cybersecurity fea-tures, such as firewall, OpenVPN®, TLS encryption and user management. These pro-tective measures are indispensable to protect against cyber-attacks. “We see a rapidly growing demand for communication solutions in Battery Energy Storage Systems as society as a whole is turning to more sustainable energy sources such as wind and solar,” says Alexander Hess, General Manager at HMS Business Unit Ixxat. “Communication is needed to get BESS systems to work and HMS offers an extensive 37 | Industry Asia Pacific | July 2022

MECHANICS DRIVES

DIGITAL MANUFACTURING ENABLES CHOICE OF 40,000 MODELS IN A FIVE-DAY DELIVERY WINDOW

Mitsubishi Electric’s Nagoya Works Shinshiro Factory, located in Shinshiro, Aichi Prefecture, Japan, has manufactured three-phase motors since its establishment in 1974. At this factory, they significantly overhauled the manufacture of a key product range, the SF-PR series. By utilizing e-F@ctory based Digital Manufacturing processes and concepts it is now possible for customers in Japan to choose from 40,000 models available in a five-day delivery window, or for those prepared to wait 15 days, the choice expands to 2.3 billion different product variations covering the majority of customer’s needs and applications. Made entirely in Japan, from material procurement to parts processing and assembly, the number of product variations and the short delivery window demonstrates the factory’s capabilities for flexible, high-quality production with shortened lead times and improved productivity.

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To deliver a wide variety of products in a short period of time, our target was to tackle the long manufacturing lead time,” said Hiroyuki Akita, General Manager of Nagoya Works’ Shinshiro Factory, Mitsubishi Electric Corporation. “We focused on how we handle the entire production schedule and how we could shorten each process, from the manufacturing of parts and products to the shipment of these products. This is where we leveraged e-F@ctory to synchronize our complex manufacturing processes.”

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Hiroyuki Akita, General Manager

Noboru Shirakura, Senior Manager

Mitsubishi Electric’s Nagoya Works Shinshiro Factory has manufactured three-phase motors since its establishment in 1974.

e-F@ctory helped the factory to increase productivity by reducing the lead time for complex procedures like the winding process and its preparation. 37 | Industry Asia Pacific | July 2022

The work time was measured by attaching sensors to the tool holders.

The final grinding process (right) was the bottleneck in the shaft production line. Closer integration with the preceding turning process helped to reduce the bottleneck (left).

One of the key variations in motor specification is the electromagnetic performance, which greatly affects the characteristics of the motor. This is varied by the density of the windings of the coil around its iron core and is matched to the customer’s selected motor performance.

Another key factor around a motor’s specification is the shaft that rotates inside the motor. The specifications of the shaft need to be customized depending on how the motor is used and that takes time to adjust on the shaft line unit by unit.

“With e-F@ctory, we were able to increase productivity by reducing the time we need for complex procedures like preparing the set-up for the winding process and also the winding process itself,” Hiroyuki Akita continued.

“Our competitive advantage would rely on the automation of the shaft machining process and how much time we can reduce in this process,” said Hiroyuki Akita.

The winding process is a mixed line where automation and manual work co-exist. The production management system gathers “work time” from the automated machines, and also sees how much time each worker needs for each process.

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“We wanted to determine where each process began and ended to measure the work time,” explained Noboru Shirakura, Senior Manager in charge of Manufacturing Engineering at the Shinshiro Factory. “Each worker’s movements are basically lifting up the tool and placing it back again, so we measured the work time by attaching sensors to the tool holder.”

Noboru Shirakura added, “The bottleneck in the shaft line was the final grinding process. We wanted to shorten this process. So, we replaced part of it with turning in the preceding process.” To reduce the machining performed by the grinder, data captured by the real time e-F@ctory process is fed back from the grinder to the NC lathe to stabilize the machining accuracy. At the Shinshiro Factory they are now considering new ways to utilize the data collected by the e-F@ctory Digital Manufacturing concept. “We are currently trying to deal with tool wear in machining equipment. Determining the optimal setting will help us manage tool life and improve efficiency,” Noboru Shirakura explained.

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With a tool wear diagnosis system, data can be automatically collected to determine the optimal wear value, or tool life.

Noboru Shirakura added, “Previously, we set tool life spans based on our experiences, but with the new system we may be able to use tools for a longer period than before. This will help us reduce tool costs.” With a tool wear diagnosis system, data can be automatically collected to determine the optimal wear value, or tool life. e-F@ctory can be linked to the software platform “Edgecross” to easily collect and leverage data from machines of different brands or even older machine tools. This helps not only to visualize machine tool data and improve productivity, but also introduce a low-cost system in a short period of time.

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“The three-phase motor is a mature product, so to be competitive in the market we would need a wide lineup and short delivery time, and in this aspect, e-F@ctory plays an essential role. Without e-F@ctory, we would not be able to provide products in such a short delivery time,” Hiroyuki Akita concluded. “By utilizing data for production, we now see new opportunities in this mature market. We will be able to create new services.” There is no end to making improvements in manufacturing. And there is no end to business development. https://www.mitsubishielectric.com

37 | Industry Asia Pacific | July 2022

FOOD PROCESSING

MITSUBISHI ELECTRIC DEVELOPS TEACHING-LESS ROBOT SYSTEM TECHNOLOGY Programs robots easily and automatically, without expert input, to work as fast as humans.

itsubishi Electric Corporation announced it has developed a teaching-less robot system technology to enable robots to perform tasks, such as sorting and arrangement as fast as humans without having to be taught by specialists. The system incorporates Mitsubishi Electric’s Maisart®1 AI technologies including high-precision speech recognition, which allows operators to issue voice instructions to initiate work tasks and then fine-tune robot movements as required. The technology is expected to be applied in facilities such as food-processing factories where items change frequently, which has made it difficult until now to introduce robots. Mitsubishi Electric aims to commercialize the technology in or after 2023 following further performance enhancements and extensive verifications.

Key Features 1) Robot movements self-programmed/adjusted based on simple commands from operator • Robot movements are self-programmed and self-adjusted in response to simple commands communicated by voice or via a device menu by a non-specialist operator. • Proprietary voice-recognition AI accurately recognizes voice instructions even in noisy environments for the first time in industrial robot manufacturers.2 • Sensors detect 3D information (images and distances) about work area, which are processed with augmented reality (AR) technology for simulations that allow operator to visualize expected results.

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• Programming and adjustments require just one-tenth or less time than conventional systems.3 2

itsubishi Electric survey of instruction systems deployed by M industrial robot manufacturers (as of February 28, 2022).

In-house comparison.

The system, responding to voice or menu instructions, scans the work surroundings with a three-dimensional sensor and then automatically programs the robot’s movements. Movements can be easily fine-tuned via further commands from the operator. Mitsubishi Electric’s 37 | Industry Asia Pacific | July 2022

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Voice entry and touch-screen entry methods (renditions).

unique voice-recognition AI, highly accurate even in noisy factories, offers the first voice-instruction user interface deployed by industrial robot manufacturers. For example, in a food-processing factory, a non-specialist could instruct a robot simply by saying something like “Pack three pieces of chicken in the first section of the lunch box.” The AI can infer implied meanings if a voice instruction is ambiguous, such as determining how much motion compensation is required if instructed “A little more to the right.” Alternatively, a tablet equipped with menus can be used to issue instructions or to select categories such as “where,”“what” and “how many” to generate simple programs. The tablet also can be used to view stereographic AR simulations that allow the operator to confirm that instructions will have the intended results. For added convenience, the system also can recommend the ideal positioning of a robot in an AR virtual space without requiring a dedicated marker, another industry first.4

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By enabling the self-programming of robot movements, including obstacle avoidance, and the system reduces the workload associated with gathering environmental information, inputting data and confirming operations using simulators and/or actual equipment. As a result, the system can complete these cumulative processes in just one-tenth or less time compared to conventional methods. In view of such advantages, the system is expected to support the automation of work sites that are not readily 37 | Industry Asia Pacific | July 2022

suited to robots, such as food-processing factories where items change frequently, requiring robot programs to be updated for each change. 4

itsubishi Electric survey of robot models incorporating AR M virtual spaces (as of February 28, 2022).

2) Technology-optimized movements enable robot to perform tasks as fast as humans • The self-programming system generates commands to control robot movements, including to avoid obstacles, in order to perform work tasks as fast as humans (minimum 2 seconds to grasp item5). • The system also adjusts and optimizes the timing of opening and closing robotic hands to reduce wasted time. • Using visual information from a camera attached to the robot’s hand, the system automatically corrects movements, including when the position of the robot or the object to be placed changes. 5

Time required to grasp and place a part in a designated place

Conventionally, increasing a robot’s operational speed requires time to realize the desired trajectories because the operator must use a simulator and/or the actual robot to determine the best conditions. In response, Mitsubishi

Robot work time equivalent to that of manual labor.

Electric has developed a trajectory-generation technology to optimize robot movements using information about surrounding obstacles and robot performance. The company has also developed an acceleration/decelerationoptimization technology that automatically generates a velocity pattern to achieve the shortest possible arm-travel time within the permissible range of force that can be exerted by the robot. Both technologies help to shorten the time required to adjust the robot’s movements. Optimizing the timing of hand opening/closing also helps to reduce work time. Conventionally, such adjustments are performed manually using simulations and operating the robot. The new technology. however, automatically adjusts and optimizes this timing according to the characteristics of the hand and the object to be grasped, thereby eliminating lengthy manual adjustments while also improving work efficiency.

humans, i.e., a minimum 2 seconds to grasp an item and place it in a designated place. Other Features Integrated system management of peripheral information To simplify the process of adding custom functions, the system supports the Robot Operating System (ROS) software platform. Also, Mitsubishi Electric has developed a ROS-Edgecross6 linkage function to centrally manage information on Edgecross, ROS and the entire system. Edgecross connectivity and multi-vendor capability simplify the monitoring and analysis of entire production lines for enhanced productivity and quality. 6

J apan-based open software platform for edge computing combining FA and IT

https://www.mitsubishielectric.com

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In addition, the grasping-recognition AI and a threedimensional sensor fixed above the system quickly determine the best position for grasping, thereby reducing wasted time. Furthermore, visual information from a camera attached to the robot hand allows the robot to self-correct its movement if the position of the robot or the target object shifts. By optimizing robotic arm and hand movements, Mitsubishi Electric’s new technology enables robots to work as fast as 37 | Industry Asia Pacific | July 2022

M E TA L W O R K I N G

PRACTICAL USE OF IOT TO DELIVER MACHINE-SHOP BENEFIT

The condition of machine tooling directly affects the quality of machined parts.

In factories, cutting tools as used in machine tools, are almost a consumable part. However, their performance and operational life can have a big impact on production costs, so keeping a close eye on their condition is no bad thing. In parallel, after all the hype around IoT and how it will revolutionize manufacturing, there are still relatively few practical use-cases with justifiable return-on-investment. Hiroshi Nishiyuki, Head of Mitsubishi Electric’s FA System Solutions Department, explains how the above two conditions converged and resulted in solving both problems.

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Hiroshi Nishiyuki, Head of Mitsubishi Electric’s FA System Solutions Department, explains the difficulties of implementing IoT to factory floors.

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lectric shavers and machine tools have one thing in common - their cutters need replacing once in a while. Hiroshi Nishiyuki explains, “Sometimes I get lazy, especially on weekends and holidays, and I don’t shave my beard. On Monday morning, I have a good shave to start the week off, but if I use the same blade for a long time, naturally it gets worn out.” “While I was shaving one day, I remembered reading an old book reflecting on the fact that the beards of many men in the world grow every day, so the shaver industry is a very attractive business to be in,” he added. This view was based on the fact that the blades for electric shavers are consumable products, just like the toner used in copy machines.

Hurdles to IoT investments.

The cutting tools used by machine tools are usually very expensive, unlike blades for electric shavers, so having lots of spare cutters is not economical. The trouble is that the condition of this consumable tooling has a lot to do with the quality of the machined parts. We can’t just let it pass like our bit of leftover beard saying, “Oh, it’s a bad-beard day.” The best solution to keep your tooling sharp is to replace it frequently, but the cost cannot be ignored, and what’s more, you have to stop the machine every time you replace the tooling. So the question would be whether IoT can be used to solve this problem. IoT is not the solution to everything “It is not widely known that implementing IoT on factory floors is quite difficult,” says Nishiyuki. “What’s making things difficult to understand is the complexity of determining the return on investment.” Some of you may have tried using IoT in a proof of concept (PoC), but probably figured it would be too expensive and with little benefit.

Is there a way to replace tooling without wasting money? Going back to machine tools, if you want to use IoT to solve this problem, it is natural that you would want to introduce a proven solution. The challenge starts there. Your first question would be, “Can we reduce machining defects and the frequency of tooling replacements at our factories, and how much investment do we need to do that?” As previously mentioned, you would need to figure out how much ROI you can expect before you decide on your IoT investment.

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There are several possible reasons for such failures, but one could be that there were no specific KPIs set before implementing the IoT solution. In this case, you might have initially believed that if you use the numerous amounts of data available and analyze that data, you will surely find something valuable. The fundamental problem is that the IoT solution is being introduced without any way to manage it through agreed KPIs.

Another case could be that IoT didn’t bring the outcome initially expected even though a specific KPI was set. Such a KPI could have been, for example, the improvement in the yield of a product by a few percent resulting in reduced costs by a certain amount. IoT and AI are not the solution to everything. Where an NG (not good) product is made in manufacturing, there is a law of cause and effect. IoT and AI is about finding the relation between outcomes and factors that cause them. However, the discovery of such rules is often done by trial and error, which is a very labor-intensive and costly process. This means that, since no clear method has been established to improve yield, IoT investment for cost reduction may become an investment in research and development, causing cost overruns.

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M E TA L W O R K I N G

Nishiyuki explained, “We have years of experience in collecting and analyzing IoT data based on our manufacturing expertise and unique technologies. As a result, we have developed products that enable anyone to easily perform tooling management and quality control based on a quantitative standard.” The solution is called the “iQ Monozukuri Machine Tool Wear Diagnosis,” which is a diagnostic package for optimizing tooling management, addressing the questions of “When should we replace the tools?,”“Can we prevent sudden tool abnormalities?” or “How can we leverage data easily?” iQ Monozukuri Machine Tool Wear Diagnosis is a diagnostic package that can predict the number of times a tool can be used based on the condition of the tooling. (Left) In the case of regularly scheduled replacements with time-based management (TBM), the tool was replaced based on the number of times it was used regardless of its condition, which often resulted in the tool not being used to its maximum lifespan.

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(Right) With the iQ Monozukuri Machine Tool Wear Diagnosis replacements are decided with condition-based management (CBM), so the number of times the tool can be used is estimated based on the condition of the particular tool and the machining history data. The tool can be used for its full lifespan.

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Customers who have already introduced this solution are now able to reduce the number of machining defects, and with some customers achieving a 40% reduction in annual tool cost, it has proved to bring significant ROI, which previously was a barrier for implementing an IoT solution. Nishiyuki concludes, “The current manufacturing environment with COVID-19 has made it difficult to produce products that rely on the experience and know-how of skilled workers, on the other hand the adoption of IoT is accelerating more than ever before. Therefore, for those who want to utilize IoT, or have already introduced it but have not yet found it effective, I highly recommend ‘iQ Monozukuri Machine Tool Wear Diagnosis’ as an IoT application package that will lead to tangible results.” To learn more about iQ Monozukuri Machine Tool Wear Diagnosis visit: https://www.mitsubishielectric.com/fa/sols/efactory/ component/monozukuri/twdiagnosis/index.html

M E TA L W O R K I N G

WIDIA INTRODUCES THE NEXT GENERATION IN VERSATILE END MILLING

The WCE4 will be a small-to-medium job shop staple with advanced, versatile geometry features at an affordable price. The WCE4 is offered in both ball nose and square end configurations.

New solid end milling platform offers affordable performance and reliability in steel, stainless steel and cast-iron applications.

IDIA™ announced today the launch of the WCE solid end milling platform, delivering affordable performance and reliability for small to medium machine shops. The initial release of the WCE platform features WCE4, a four-flute geometry which combines advanced, high-performance features with a brand new, versatile grade offered at a highly competitive price. “With its new design, the WCE4 delivers the next generation of versatile end mills to help our customers be more productive and efficient,” said Tamir Sherif, Solid End Milling Global Portfolio Manager, WIDIA. “The WCE4 is an attractively priced tool for small-to-medium shop floors where reliability and consistent tool life are high priorities.”

Two key features of the tool are its asymmetrical index and variable helix. The combination of the two reduce vibrations and enable heavy cuts, while the new grade, WU20PE, enables versatility on steel, stainless steel and cast-iron applications. These design features, coupled with the fourflute geometry, deliver an end mill with reliable performance and application versatility – even in demanding operations such as full slots and heavy cuts. The WCE platform includes four-flute, square-end and ball nose end mills with both straight and Weldon shanks and is available in both metric and inch dimensions. The WCE5 five-flute geometry will be released later in 2022. Orders for the WCE4 end mill, as well as other WIDIA metal cutting tooling, can be placed through WIDIA authorized distribution partners. MORE INFORMATION

https://www.widia.com

37 | Industry Asia Pacific | July 2022

AU TO M OT I V E M A N U FA C T U R I N G

KENNAMETAL INTRODUCES LIGHTEST WEIGHT VERSION OF ELECTRIC VEHICLE TOOLING SOLUTION SAVING SET-UP AND MACHINING TIME

The 3D printed stator bore tool with carbon fiber body weighs 7.3kg.

Award winning 3D printed stator bore tool weighs just 7kg, ensuring fast tool changes and spin-up on machining centers. Kennametal has introduced its next generation 3D printed stator bore tool for the machining of aluminum engine housings for electric vehicles. This latest version of the tool features a newly designed arm structure, a larger center tube made of carbon fiber, and a further weight reduction of greater than 20 percent over the original design. The complex tool is capable of machining three large diameters in just one operation, saving set-up time and machining time for automotive component manufacturers and delivering the highest accuracy and surface qualities.

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The newly redesigned tool recently won MM MaschinenMarkt’s Best of Industry Award in the Production

and Manufacturing category based on votes by readers and industry experts. “As our automotive customers expand their offerings of hybrid and electric vehicles, we continue to respond to their need for lighter weight tooling solutions. By leveraging advanced manufacturing techniques like 3D printing, we’ve reduced weight a further 20 percent over the firstgeneration tool, while improving chip control and increasing tool rigidity—innovations that help our customers machine faster and more efficiently,” says Ingo Grillenberger, Product Manager, Kennametal. Machining three diameters in one operation, the stator bore tool ensures the alignment and concentricity of the machined surfaces whilst reducing the cycle time significantly. The lightweight 3D printed combination tool enables a faster tool change and spin-up even on less powerful machines. The surface specifications and component tolerances are achieved without constraints. Hassle-free chip removal is ensured by means of airfoil shaped arms that are through coolant featured to ensure

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First-generation design (9.5kg) on the left, and latest tool design variants (less than 8kg) on the right for hassle free tool changing.

The airfoil shaped arms with through coolant and RIQ reaming technology. Complex internal and external features enabled by additive manufacturing.

precise and powerful coolant supply to the cutting edges and guide pads. This would be difficult or impossible to economically produce with traditional manufacturing, but 3D printing enables us to realize even such complex internal features. Additionally, the Kennametal RIQ reaming system features easy diameter adjustment and a trouble-free setup of new inserts. https://www.kennametal.com

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37 | Industry Asia Pacific | July 2022

M E TA L W O R K I N G

KENNAMETAL INTRODUCES FIX8™ FOR HEAVY-DUTY TURNING WITH EIGHT CUTTING EDGES PER INSERT

FIX8 has eight cutting edges per insert, providing the lowest cost per edge. The tangential design allows it to sustain far higher loads than traditional designs.

New system delivers highest possible metal removal rates in turning operations with lowest cost per cutting edge. Kennametal has released the FIX8™ heavy-duty turning system, delivering maximum metal removal rates in steel, stainless steel and cast iron. With eight cutting edges per insert, the FIX8 turning system increases productivity of any heavy-duty turning operation, providing the lowest cost per edge while reducing cutting forces up to 15 percent. “FIX8 is designed to cover a wide range of applications, including turning and facing, smooth surfaces, interrupted, and heavily interrupted cuts. From medium depth-of-cut to roughing in steels, cast iron, and challenging materials like stainless steel, FIX8 handles it all. Even extreme feed rates of up to 1.4mm (0.055”) and depths of cut up to 12mm (0.472”) are possible with FIX8,” says Matthew Fuerst, Product Manager, Kennametal.

The tangential design of the FIX8 insert features a rigid clamping system that pulls the insert securely into the pocket seat, offering superior stability that enables the insert to withstand large cutting forces and vibrations for optimal performance. The insert is also supported by a replaceable carbide shim, protecting the pocket against deformation and damage. The FIX8 tool holder features precision 3D coolant technology, supplying sufficient coolant precisely where needed. Three coolant nozzles are directed to the rake face, controlling temperature, chip evacuation, and supporting chip formation. Coolant exit holes in two different locations are directed toward the flank of the insert, controlling the heat in the cutting zone and prolonging tool life.

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FIX8 provides excellent chip control for any heavy-duty turning application while increasing tool life. The insert design reduces cutting forces and power consumption, making it ideal for any low horsepower lathe. https://www.kennametal.com

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FIX8 tool holder styles featuring precision 3D coolant technology. Delivers coolant sufficiently and precisely to where it is needed.

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37 | Industry Asia Pacific | July 2022