04 | N O V E M B E R 2 0 1 3
Industry
Asia Pacific The industry magazine for Asia.
Medical implant OEMs set their sights on ceramics
20 Custom-tailored drive units for baggage handling
26 100 tunnels under control PROSOFT RLX2
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Industry Asia-Pacific 11-2013 | November 2013
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KENNAMETAL
PRO-PEN
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06 TATA STEEL
KEYENCE
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HAIMER BAUMER
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18 PEPPERL FUCHS
HMS
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23 IXXAT
NORD
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NEWS
The M7000 Portable Marking Solution
The M7000 also excels by its marking performance and unparalleled ease of use, in particular thanks to its built-in touch screen.
With ProPen’s M7000 stand-alone micro-percussion marking gun, there is finally an easy way to permanently mark parts of all types and even hard-to-reach parts.
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arketed under the ProPen brand, the M7000 is the most easily portable marking gun on the market. It uses micro-percussion technology to indelibly mark text, logos, timestamps and even 2D codes on parts – even those that are heavy, large, flat or curved – for accurate traceability. The M7000 thus offers a wealth of added value to industries that, until recently, have had to make do with less practical, less durable and slower marking systems, such as labels, inkjet printing and stamps. Oil and gas, shipbuilding, railway, special vehicles, machine-tools and electrical or military equipment are just a few industries that will find the M7000 particularly advantageous. Goes where you go Unlike other systems, the M7000 is an all-in-one solution. The marking unit, controller and control interface are
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housed together in a single, compact system. No external PC, software or keyboard are necessary. As a result, it is completely autonomous and easy to carry from place to place. Another unique advantage to the M7000 is its waist-mounted Li-ion battery pack that affords unrestricted mobility. Unrivalled marking performance Offering a marking depth that is unique in its class, the M7000 accurately and indelibly marks parts of all types and materials ranging from plastics to the toughest metals. It is perfectly suited to marking rough or treated surfaces (prior to sandblasting, galvanisation, shot-blasting, application of corrosion-resistant paints and other operations) and delivers the level of quality and accuracy required for Data MatrixTM code marking. Its large marking zone (80 × 30 mm) accommodates large characters and a maximum number of applications. Outstanding ergonomic design and extremely easy operation with Touch and Mark! The M7000 is also a genuine pleasure to use. Featuring a lightweight, ergonomic design that substantially dampens
vibrations and offering excellent stability, the M7000 makes it easy to create high-quality markings on all vertical or sloped surfaces The M7000 also features a 7» colour screen with an intuitive interface for easy, unassisted programming of markings. The benefits – time savings and less risk of error – are immediate. Developed by Gravotech, the global leader in durable marking technologies, the multilingual P07 software is a simple, proven and tailored solution that enables fonts, logos and marking files to be imported and exported. The M7000 is supplied ready to use and, as touch screens are becoming a part of everyday life, requires no training. Designed in France with quality components and impact-resistant composite materials, the M7000 withstands even the harshest industrial environments. Lastly, the M7000 offers good value for money: it contains very few wear parts and does not require any consumables or preventive maintenance; the stylus is engineered for long life and can be resharpened; and the entire system benefits from Gravotech’s global support network.
More Information 04 | Industry Asia-Pacific | November 2013
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NEWS
Kennametal and Haimer Sign Agreement to Supply Kennametal’s Breakthrough KM4X Spindle Connection
John Tucker (L) and Andreas Haimer (R) sign the agreement to supply Kennametal’s breakthrough KM4X spindle connection throughout Haimer’s global markets.
Manufacturers to benefit from combination of leading toolholding and spindle connection solutions
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n an agreement signed July 23, 2013, Kennametal has granted global toolholding leader Haimer GmbH (Igenhausen, Germany) license to provide Kennametal’s new and advanced KM4X spindle connection solution throughout Haimer’s global markets. Haimer, a global leader in toolholding technology and provider of the innovative SAFE-LOCK™ pullout-prevention technology, together with Kennametal sees significant benefit for manufacturing customers. “The KM4X spindle connection is the most rigid system in the world today. This design enables manufacturing companies to maximize their capital investments. KM4X enables higher metal removal rates, which facilitates higher machine tool utilization and reduced cost per part, while increasing the manufacturer’s available capacity,” says John R. Tucker, Vice President and President of the Industrial Business Segment for Kennametal Inc. “Having an innovative technology partner like Haimer supply the KM4X
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connection in addition to toolholders like SAFE-LOCK™ will create a powerful production advantage for manufacturing companies around the world.” “This agreement is a perfect fit because it confirms both Haimer and Kennametal as leaders in high-end innovative technologies for world manufacturing,” says Andreas Haimer, director and member of the executive board of Haimer GmbH. “We are honored and plan to actively support and educate our markets to the benefits of these mutually beneficial technologies. The spindle connection, the interface between the machine tool’s spindle and toolholder, has to provide the torque and bending load capacity compatible with machine-tool specifications. Cutting forces, particularly in roughing or machining high-strength materials, generate bending moments that will exceed the interface’s limits prior to reaching torque limits. By combining high clamping force and optimized interference levels, KM4X provides a robust connection, extremely high stiffness, and bending load capacity for greatly improved performance in machining high-strength alloys and other materials. This means extremely high metal removal rates and more completed parts per day.
and thrust forces required while minimizing undesirable vibrations that deteriorate part quality and tool life. “In most cases, the tool-spindle connection determines how much material can be removed on a given operation,” says Doug Ewald, director, global product management, tooling systems at Kennametal. “This is because this interface must withstand high loads and yet maintain its rigidity. With the ongoing advances in cutting tools and machining centers, a spindle connection that makes the best utilization of available power possible is an important consideration to investigate early in production planning.” Rigid toolholding is critical as well. “From a technical perspective, the KM4X spindle connection makes it possible for us to utilize the full potential of our toolholders,” says Oliver Sax, director of product management at Haimer. “Outdated dual-faced steep-taper systems were limiting the potential of modern machine tools. Feedback from Kennametal customers led us to investigate the new KM4X spindle connection more closely. After analyzing the data, we found KM4X to be the leading interface for the high-torque, high-rpm fine balanced toolholders Haimer provides.”
By combining high clamping force and optimized interference levels, KM4X™ by Kennametal provides a robust connection, extremely high stiffness, and bending load capacity for greatly improved performance in machining high-strength alloys and other materials.
“We give a lot of seminars related to toolholding, particularly how to increase rigidity, accuracy, balance and security in metalworking,” says Brendt Holden, president of Haimer USA (Villa Park, IL).
“This is a full-system partnership between companies with identical philosophies,” says John Jacko, vice president and chief marketing officer at Kennametal. “With the KM4X spindle connection and Haimer toolholding technology, there is no reason why companies should hold back investigating high-torque, high-speed machining capabilities for both existing and new equipment. This means achieving the maximum potential of your machine tools.”
“One of the most common questions we receive is ‘what’s the best style of spindle interface?’ With a unique highstrength spindle connection that also can accelerate to high rpms safely, we believe we now have the best answer.” Advanced Materials Require Advanced Manufacturing The continuing development of high-strength, lightweight materials such as titanium alloys, Inconel, and new aluminium alloys are eagerly sought by manufacturers in many industries, including aerospace and defense, energy, and transportation. These new materials present significant machining challenges in themselves. Add the competitive pressures in these global industries, and finding advanced manufacturing solutions becomes a top priority. Machine-tool builders have responded with milling and turning centers that feature improved stiffness and damping on spindles and sizable machine structures and motors, all to provide the significant horsepower, torque
More Information 04 | Industry Asia-Pacific | November 2013
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NEWS
Tata Steel launches long-length wear-resistant rail for the world market
Tata Steel today launched a new state-of-the-art facility which will produce train track capable of lasting up to three times longer than standard rail.
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he commissioning of the new heat treatment plant at Tata Steel’s Hayange plant, in the Lorraine region of France, means the company will be able to supply long lengths of superhardened rail which its customers want.
The new facility provides a full range of heat-treated ‘stress-free’ rails of up to 108 metres in length, allowing rail operators to enhance performance and reduce costs associated with more frequent worn rail replacement. Last year Tata Steel announced it was investing more than €12 million in the plant. This followed a previous €35 million investment to enable the Hayange mill to produce longer 108-metre rails for the high-speed rail networks in France and across Europe. Heat-treated rail can last up to three times longer than
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standard rail when used in high wear conditions such as heavy traffic, high axle loads or tight curves. Henrik Adam, Tata Steel’s Chief Commercial Officer, said: “This new heat treatment plant will open up new European market opportunities to us. We will be able to meet the needs of customers in Germany, Switzerland, Belgium, The Netherlands, Luxembourg and Scandinavia who are demanding longer-length heat-treated rail to reduce lifecycle costs.” The heat treatment plant will also allow Tata Steel to support existing markets, such as Brazil, Gabon, Mauritania and South Africa where rails have to cope with heavier axle loads, as well as metro systems in Hong Kong, India and Singapore where heat-treated rails have exceptional technical performance in demanding traffic conditions. The new heat treatment plant will operate alongside an existing heat treatment line at the Hayange mill which can process rail of up to 36m in length. The new facility will more than double the annual output of heat-treated rail from 55,000 to 125,000 tonnes. Tata Steel’s heat-treated rail is produced using a unique
patented process which ensures it has exceptional wear resistance. The rail moves through an induction furnace which uses an electromagnetic field to heat the steel to 950°C. The rail is then rapidly cooled using compressed air. Steel for the Hayange mill is produced at Tata Steel’s Scunthorpe plant in the UK before being transported to France for rolling. David Petitjean, Manager of the Hayange facility, said: “We have built this plant in response to demand from valued customers, but while our heat treatment process is tried and tested, we have continued to innovate to ensure the new plant will be more energy efficient and will allow us to deliver rail to customers exactly when required. “Tata Steel has invested almost €50m in this facility over the last four years, helping to create a sustainable future for the 400 people who work here.” Tata Steel supplied the rail from its Hayange plant for the track on which a TGV broke the world train speed record in 2007. The French train reached a speed of 574.8kph (357mph) between Paris and Strasbourg.
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NEWS
High Resolution Imaging Helps to Cut Costs
Rear right panel inspection station
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onsisting of just two cameras and lower cost than the competition, R-TECH’s visual inspection system is used by PSA (Peugeot S.A.) to inspect the car door panels of its Peugot 508 sedan. The door panels for PSA’s Peugeot 508 are manufactured on semi-automated lines. Three operators working on four different lines assemble components that are then welded together. The front and rear doors of each Peugeot 508 have 24 different options. Door handles, inserts, power-window buttons, speaker foam, cloth, plastic-coated fabrics and leather are fitted and protected with plastic film. The only things not yet assembled are the sill lights and wiring. The doors are then inspected by a vision system, particularly since their components are fitted by hand. Cost and quality considerations make this system a must. Not only must it check the placement of door components, it must also have sufficient resolution to be able to spot differences in the door covers – like the slightest difference between plastic-coated fabrics, (artificial leather) and natural leather – and distinguish between different colors and stitching.
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A number of companies offered systems with three cameras on each side. However, R-TECH, a firm based in the southeastern French town of Marignier, designed a system with a total of just two cameras and a much lower price tag. “We believed that we could deliver the necessary results with just one Keyence camera on each side,” explains R-TECH Director Nicolas Galmiche. “No other solution on the market can match Keyence’s performance in terms of resolution and processing speed.” R-TECH chose Keyence’s CV-5000 Series vision system. With its 5 megapixel resolution (2432 × 2050 pixels - 61 ms processing time), this model is unique to the market. CV-5000 Series models are controlled by a high-speed color image processing engine and a high-speed RISC (reduced instruction set computer) CPU. Both are supplemented by two DSPs (digital signal processors) designed specifically for image processing. These four processors are used to achieve specific processing and attain the fastest processing speed possible. Detection was also complicated by the fact that the interior sides of the car doors contain openings and an LED.
Already a leader in vision system technology, Keyence is now also a leader in vision system software with a completely revamped offering thanks to the CV-5000 Series Second Edition. Keyence’s software offering features processing functions that stand out for their stability in varying conditions, speed, and ease of use. For example, the ShapeTRAX tool ensures stable detection without being influenced by ambient light or shaded areas on targets. ShapeTRAX is a powerful positioning tool that is easy to set up regardless of the target. The new ShapeTRAX function is ten times faster than conventional positioning tools and ensures repeatability of 1/40th of a pixel. “We’re completely satisfied with how Keyence has revamped its software solutions. The system is very intuitive, capable of displaying completely in French, highly reliable, and the new filters really are very useful.” “It’s worked out great and we’re considering deploying it at PSA’s other sites,” says Galmiche.
Keyence camera and high-resolution lens
R-TECH designed a specific lighting system that solves this problem. First, it illuminates both doors, one side at a time. The captured images are then filtered to black and white. Then the light is shut off so that the vision system can easily detect the LED. As a result, the inspection is reliable and successful each time.
Based in the heart of the Arve Valley in France’s Haute-Savoie region, R-TECH offers many turnkey solutions. It uses its industrial experience and organizational structure to create comprehensive applications that meet the specific requirements of its customers. Its automation and mechanical solutions are designed and manufactured in-house. R-TECH deploys its solutions in France, Spain, Slovakia, Belgium and Germany (www.r-tech.pro). http://www.keyence.co.in/CV5PR
“The other advantage for both us and our customer is that we worked with an existing vision system. There was no custom development involved and our customer has a nonproprietary solution,” says Galmiche. The barcode on each door is scanned by a reader that sends this information to the vision system via Ethernet so that it can perform the necessary checks. The information is then fed to the company’s central quality control system. With only around 12 seconds in which to perform the entire set of checks, time is of the essence. “The Keyence camera has no problem keeping up with this rate,” says Galmiche. PSA’s plant uses a JIT production system in which the time between electronic order and delivery on its lines is just 3 hours. The vision system has been operating flawlessly since being installed in early 2010.
More Information 04 | Industry Asia-Pacific | November 2013
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NEWS
100 tunnels under control
View of the ANAS operations centre, located in Bellano (Lecco)
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ue to its mountainous topography, Italy is a country rich in road tunnels. In the Lombardy region, a new supervision and remote control system has been designed and implemented by Gemmo S.p.A. Based on the PcVue SCADA system from ARC Informatique, it ensures the comfort and safety of users along over 140km of tunnels. The wide alpine arc that surrounds and contains Italian territory is crossed by roads which include many tunnels. The tunnels are of variable vintage and the plant used inside them is inconsistent, due to differing implementation dates and technologies adopted. Thanks to a new wide-ranging project, the tunnel system of the road network is now managed by a new supervision and control system that is unique due to its size and complexity. €140 million Project Financing The application falls within a project concerning the technological requalification and safety management of approximately 100 tunnels on state roads managed by ANAS S.p.A in Lombardy. The wide scope includes the technological requalification of the tunnels and standardization or renovation of power, lighting,
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ventilation, video-safety and data transmission plants. The single or dual ‘pipe’ tunnels have lengths ranging from 250m to 5km. The estimated value of the work is approximately 140 million euros, 50% financed by ANAS and 50% by the private sector. Tunnel Gest (a company whose majority shareholding is held by Gemmo S.p.A.) will be responsible for the management of the realized project for the next 17 years, starting in June 2013 when the 3-year construction and requalification period will be complete. This time frame, which was defined in the financial plan at the start of the project, will allow the company make a return through the provision of services such as plant maintenance. The road management will remain ANAS’s responsibility. “The first stage, nearing completion, scheduled the technological requalification of the tunnels according to ANAS guidelines, which adopt the main European standards in terms of tunnel safety,” says Ing. Ciro Ascione, Systems Business Unit Manager at Gemmo S.p.A. “Depending on their length, the tunnels are provided with plant of different complexity: from simple lighting, to equipment for ventilation, pollution analysis, heat detection, video-surveillance and image analysis, SOS management, audio for emergency situations, variable-
panels to facilitate the outflow of the vehicles from the tunnel before the tunnel access is inhibited. The hardware includes two servers in a hot backup configuration with a further server devoted to database management, two clients for ANAS, two clients for Tunnel Gest and one client for the Traffic Police. Two maintenance clients are used by the Gemmo team. From the main page which offers a system overview, it is possible to access the various tunnel subpages listed on the display. When a subpage is accessed an information window opens which aids navigation within the subpage. At the same time, when a particular system is selected (the lighting system for instance) it is possible to visualize its status in any or all of the tunnels. Finally, by opening the information window of a particular piece of equipment it is possible to visualize several aspects of its operational status, set alarm limits, visualize alarm notifications and by-pass the local control logic to remotely control the equipment. Each workstation at the control centre has two 42” monitors side-by-side which can be used independently. This allows, for instance, management of the SOS system in a tunnel and simultaneous monitoring of the complete system. “We centralized all the tunnel plant monitoring at the ANAS operating centre of Bellano,” Ing. Ascione explains. “The SCADA shows the operator a series of video graphic maps that supply the status of all equipment in real time.” The supervision and telecontrol system, designed and implemented by Gemmo S.p.A. and based on PcVue SCADA from ARC Informatique
message display panels and radio communication to support rescue organizations”. Each tunnel is provided with its own PLC-based automation system and is connected for supervision and control to the ANAS operations centre, located in Bellano (Lecco), through a communication network (WAN) using both fibre optic and microwave technology. For the integration of local systems with the WAN the Modbus TCP/ IP protocol has been widely used because it allows direct and reliable control of peripherals and relevant data. Supervision and remote control The supervision and remote control system configured by Gemmo S.p.A., a certified OEM partner of ARC Informatique, is based on a customized application of PcVue SCADA. Approximately 50,000 data points, 800 network nodes and over 500 graphical pages are managed. In fact all represented objects can operate in either automated or remote manual mode. In the case of a problem (like fire risk or high pollution) the relevant automated procedures take over, but the operator can manually intervene for better management of the situation. For instance, when an alarm procedure due to an excessive pollution in a tunnel is started automatically, the operator can watch the situation through the video system (composed of approx. 1500 cameras) and perhaps override fan settings and variable-message display
Thanks to the network connection, it is possible to connect through the web to the individual controllers. Locally, using a portable PC, it is also possible to connect as a PcVue client and query a controller, or to navigate with a browser to the network server. Starting from the graphical pages displayed by the supervision system the operator can instantly know where an alarm was triggered or if a user is calling from inside a tunnel. Maximum safety The whole system is characterized by several safety levels. In every tunnel there is a redundant LAN connected to the general WAN, to which all automation peripherals and subsystems refer. The automation system of every tunnel is independent of the centre and therefore all the subsystems interact through the tunnel LAN. A fully open system “We selected ARC Informatique’s PcVue because we appreciated that the system is really open,” says Ing. Ascione. “The openness is fundamental in our work as system integrators, because we can get inside the product to customize it and better use its capabilities, while exploiting the 50 years of experience that we acquired in the road industry.
More Information 04 | Industry Asia-Pacific | November 2013
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NEWS
Yeast foam detected, overflow stopped – level switch in brewery applications
CleverLevel – Level switch LFFS/LBFS and configuration tool FlexProgrammer
CleverLevel switch for detecting the filling level in the excess yeast tank. Heavy build-up of foam in the excess yeast tanks
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east is an essential ingredient of the fermentation process for brewers. But yeast can also be a problem for the brewery. Recently Baumer helped the Carlsberg brewery solve a problem with left over yeast from the fermentation process – by using the CleverLevel switch. The Carlsberg brewery was founded in 1847 and is today the fourth largest brewery in the world. The production and distribution center is located in Fredericia (Denmark) and runs day and night. Carlsberg produces 2.2 million hectoliters of beer annually and employs around 45.000 staff worldwide. Every day Carlsberg sells around 120 million beers globally. Baumer has been supplying Carlsberg with instrumentation for more than 10 years. Initially to the beer production lines near Copenhagen and since the relocation in 2008
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to Carlsberg’s new production and distribution center in Fredericia. Fermentation is the process by which yeast converts the glucose in the wort to alcohol and carbon dioxide gas – giving the beer its alcohol content and its carbonation. When fermentation is nearly complete (the process takes around 4 to 6 days), most of the yeast will settle to the bottom of the fermentation tank. The yeast is then removed and reused for several fermentation processes before finally being stored in an excess yeast tank and sold off as animal feed. In this final stage of filling the excess yeast tanks, Carlsberg experienced overflow problems due to the heavy build-up of foam which was preventing triggering of the traditional level vibrating forks. The solution for Carlsberg was using the Baumer CleverLevel switch for detecting the filling level in the yeast tanks. The CleverLevel uses the frequency sweep technology and is a level switch universal for all types of media, whether the media is wet, dry, sticky or in this case foam – whereas the traditional fork simply can’t recognise the range and
solved our problems with overflow in the excess yeast tanks due to its unique and easy configuration options. We are now considering using the CleverLevel switch in our CIP caustic tanks, where we experience similar issues with foam and overflow”. The change-over from the traditional fork to the CleverLevel has completely eliminated the problem with overflow in the excess yeast tanks. The benefit to Carlsberg has been a more environmentally friendly solution, as left over yeast is not entering the sewage system due to overflow. There has also been a cost saving benefit to Carlsberg due to process optimization and less required maintenance.
CleverLevel switch for detecting the filling level in the excess yeast tank
condition of media. The CleverLevel is maintenance free due to the minimal installation depth of 15 mm and the self-draining sensor tip. It is also approved to both 3A and EHEDG standards. It can be configured visually and easily via the dedicated software and the FlexProgrammer.
Lone Højbjerg Petersen, Maintenance Coordinator at Carlsberg, Denmark
The switching range can be adjusted as required to ignore foams during maximum or minimum monitoring. This function can also be used when the level switch is supposed to ignore adhesive substances, as for example in tanks with liquid chocolate. Even when the tank is empty, the sensor and tank wall are covered with chocolate. When configured accordingly, the CleverLevel will only be triggered when the tank is actually full or empty. The graphic configuration software also increases user friendliness. Using traditional forks one version is needed for dry media (powder, grain etc.) one version for wet media and one version for sticky media. The CleverLevel can be used through the entire process, from when the barley arrives in the storage tanks to the finished beer. Lone Højbjerg Petersen (Maintenance Coordinator at Carlsberg, Denmark) says: “The CleverLevel switch has
More Information 04 | Industry Asia-Pacific | November 2013
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NEWS
Paving the way through London’s soft core Conveyor drives for rapid transit tunnel construction in central London
German technology for new train lines in London: the tunnel boring machines supplied by Herrenknecht.
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he metropolis London is currently adding a new East-West rapid transit connection with a length of more than 100 km to its much-frequented public transport network.
For this major project, 21 km of new tunnels are being bored in the city center alone. The soil here mainly consists of soft clay with a sticky consistency that makes the transport of excavated material especially challenging. H+E Logistik and NORD DRIVESYSTEMS, two German industry specialists, are supplying suitable conveying technology including geared motors. Named after the mathematician Ada Lovelace and the city map pioneer Phyllis Pearsall, Ada and Phyllis are tunnel boring machines (TBMs) from German manufacturer Herrenknecht, each measuring approximately 100 m in length and weighing about 1,000 tons. Working for the rapid transit project “London Crossrail”, they have been pushing forward their 7 m wide “Cutterhead” blades below the City since 2012. After tackling the distance of six and a half kilometers between Royal Oak and Farringdon Station, they are planned to resurface in 2015. Besides Ada and Phyllis, more TBMs are currently boring similar tunnels in various other track sections for the
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East-West connection through London which will measure a total of 118 km. The first Crossrail sections will be put into operation in 2018. With an investment volume of more than 17 billion EUR, “London Crossrail” is currently Europe’s largest infrastructure project. Demanding transportation task The TBMs excavate up to 1,300 tons of “London clay” per hour in the two 6.2 m diameter tunnels that are being bored in parallel below the city center. The handling of this soft material does require solutions that are tailored to its consistency. In this case, the challenge lies in reliably transporting the excavated material away from the building site, which includes routing it over machine, tunnel, and hall conveyors before loading it onto trains. State-of-the-art tunneling includes the addition of tensides to the excavated material directly at the boring machines in order to facilitate handling. However, if the special London clay formation and these additives came into contact with standard conveyors, complications would soon arise: the mass would promptly and persistently stick to parts of the conveyor belts. Tunnel conveyors for the “London Crossrail” project were
drive variety, and the double-sided shaft allows for the versatility that we need: our systems typically complete not only a single tunneling project, but are often bought back on completion for other tasks. With a variable drive configuration, they can more easily be used in different locations”, says Uphues. Seamlessly and without delay All NORD gearbox housings are manufactured using a single piece construction with no joints or seams. This applies even to very powerful industrial gear units up to 242 kNm which are required for extreme conveyor inclines and moving very large amounts of conveyed material. The one-piece UNICASE housings of NORD’s industrial gear units feature integrated bearing seats. Thus, there are no sealing surfaces between the drive side and the gearbox housing that are susceptible to damage through torque and radial forces. With its offset bearing shaft arrangement, the UNICASE design also ensures very compact dimensions but allows for the use of larger bearings for higher loads and extended working life. Industrial gear units can be installed as left or right side conveyor drives. Most types are globally available with fast delivery times.
The project also uses German conveying technology: every hour, several thousand tons of excavated material must be transported away
therefore custom-tailored by the Herrenknecht subsidiary H+E Logistik. In addition to special plastic coatings and other measures, a wiper system developed especially for the on-site requirements serves to prevent problems caused by conveyed material sticking to exposed system components. Firstly: reliable, secondly: versatile Specifying and procuring reliable conveying drive technology proved similarly important. H+E Logistik approached its proven partner, NORD DRIVESYSTEMS from Bargteheide near Hamburg: “We have been cooperating with NORD for approximately ten years now, and have tackled hundreds of projects together”, says Dirk Uphues, the H+E project manager in charge of the London operation. “The reliability of geared motors on our conveyors has always been a decisive factor. NORD fulfills this key requirement, no matter which drive type they deliver for us.” For the London tunnel conveyors, NORD supplies helical bevel geared motors with a double-sided, smooth output shaft. An expansion coupling transfers the torque to the belt conveyor. “Of course we would like to minimize the
Even though tunneling projects can take many years, customers like H+E Logistik appreciate suppliers who can ensure short-term availability. Besides tunneling, the London Crossrail project also includes the remodeling of existing stations and the construction of new ones. Some time ago, additional manual excavation work that could not be planned in advance near Bond Street Station was scheduled on short notice. So as not to affect other project deadlines, H+E was tasked with providing suitable short conveyors within eight weeks. “The required drive technology from NORD arrived five days after ordering”, says Birgit Barian from the H+E purchasing department. “Particularly when a project is nearing completion, you can easily find yourself in a situation with tight delivery deadlines and considerable time pressure. Even if you have kept all of your own deadlines, many third party problems and sometimes unforeseen circumstances come into play. Without partners like NORD, that are available virtually on demand, you might easily find yourself in difficulty.”
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NEWS
HAIMER Power Mill range
The new HAIMER Power Mill Portfolio, with cutting diameters available from 2 to 20mm, will be made available with 3, 4 and 5 cutting edges having multiple lengths of cut. Different cutting edge solutions will be offered, also a roughing geometry.
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AIMER Power Mill solid carbide endmills are the latest tools developed by HAIMER GmbH, the European market leader for toolhoding. They are made from high end fine grain carbide and are equipped with the HAIMER pull out protection system, Safe-Lock™, which has become a standard for HSC and HPC machining in the last years. The HAIMER developed endmill geometries are based on an unequal flute and helix design for chatter free high end machining. All tools are coated with latest PVD technology and have an extremely smooth surface for the best possible chip evacuation. The new HAIMER Power Mill range, with cutting diameters available from 2 to 20mm, will be made available with 3, 4 and 5 cutting edges having multiple lengths of cut. To offer maximum flexibility in order to address the customers application requirements, different cutting edge solutions (sharp, chamfer and radius) will be offered. Also a roughing geometry with a cord profile will be part of the portfolio.
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A typical HAIMER specialty is the high precision of the tools. All end mills are fine balanced and have a run-out of 5 µm. All shanks are based on the h5 tolerance. With the launch of the new Power Mill range HAIMER has expanded the
Safe-Lock™ offering. Resulting from the wide spread and multiple customer requests for different application areas, Safe-Lock™ will be available starting from shank diameter 6mm. Andreas HAIMER summarizes: “As the inventor of SafeLock™, HAIMER steps up and offers this shank solution as a standard for all HAIMER Power Mill tools starting from shank diameter 6mm and intentionally gives up on plain round and Weldon shanks.” Due to the inherently balanced design, the Safe-Lock™ shanks can be clamped in standard shrink fit and collet chucks without any problems. In comparison, it now doesn`t make sense to clamp µm precision high performance geometries with weldon shanks and push them extremely out of center while introducing extreme unbalance. HAIMER target is to have high availability and replace the Weldon system in the next 10 years. Whereas Safe-Lock™ not only supports roughing applications, but becomes a new universal solution that continues to find more and more use during HSC applications with high helix endmills.
NEWS
Medical implant OEMs set their sights on ceramics
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ractically all of the major medical implant OEMs are actively pursuing, in one way or another, the viability of manufacturing various common implants from ceramic materials. Ceramics are perfect for implant use. They provide much higher levels of strength, wear resistance, smoothness and biocompatibility when compared with metals and polymers. However, ceramics lack one very important quality – machinability.
and, in turn, the implants extremely expensive. So much so that a limited number of patients opt for them over the more affordable metal implants.
Mention ceramics, and most people visualise dinner plates or coffee mugs that easily shatter when dropped on a hard surface. This isn’t the case when it comes to industrial and medical ceramics.
The average lifespan of metal implants depends on use. The more active the implant recipient is, the faster the implant will wear. In some instances, this may only be a short time of about 10 years, possibly 25 years for a less active person.
Those are much tougher, denser, and therefore not as brittle and, unfortunately, not that easy to machine using conventional methods. Thankfully though, laser beams may offer a remedy. Currently, a very select few of ceramic implants are being produced. They are simplistic in shape because they are produced using grinding machines with diamond wheels that have limited capabilities when it comes to accessing contours and pockets and other complex part shapes. The grinding process is also slow, making manufacturing costly
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The majority of implants produced today are made from titanium, cobalt chrome or stainless steel. And the most common implants are for knee and hip replacements, but femoral, articular and tibular components are also prevalent.
This means that, for younger recipients of metal implants, the initial implant would quite possibly have to be replaced one or two additional times in the course of the person’s life span. And it should be noted that the rehabilitation for such orthopedic type operations as knee and hip replacements is quite painful and extensive. Now consider ceramic implants, which would last on average 75 years – basically a person’s lifetime. An implant
polycrystalline diamond (PCD) and cubic boron nitride (CBN). CBN shows strong potential in several ceramic applications. Additionally, extremely hard carbide tooling has been tested for ceramics. To date, laser assisted machining has made it possible to successfully turn, mill and thread ceramic materials such silicon nitride, zirconium and alumina. But most significantly, the system increases cutting tool life and reduces processing times for these materials, while also allowing parts to be produced that were previously impossible to make. Those entities involved with the development of laser assisted machining techniques will continue to gain a better overall understanding of the ceramic cutting process, and great strides will be made in the use of ceramics within the medical industry, as well as for other applications such as automotive and aerospace engine components and bearings. Currently, however, there must be more testing to gain a better understanding of cutting tool edge preparations and chemical interactions between cutting tools and specific ceramic materials. Further testing will also help increase efficient use of the laser to heat the ceramic materials faster and improve precision in regards to the portions of a workpiece that need heated. If progress with the laser assisted method continues at its current pace, the machining of ceramics could more than likely replace diamond wheel grinding in much the same way that hard turning replaced grinding twenty years ago. recipient would undergo only one surgery and a single recuperation period. Plus, there would be no implant abrasion to generate foreign particles in the body, as occurs with metal implants when they wear.
And while the method is in its infancy, a major milestone has been passed in the quest to reduce the cost of manufacturing medical implants and components from industrial ceramics.
On the flip side, none of the benefits of ceramic implants will be realised until the material can be cost-effectively machined, making those implants more readily available and affordable. This is why manufacturing shops, universities and other research facilities have been exploring and testing different approaches to successfully machine ceramics using conventional machine tools. And so far, one technique that involves a laser is generating some very promising results. Key elements of this cost-effective ceramics machining process are specially designed cutting inserts and a radical use of a laser mounted on a multi-tasking machine tool. The machine precisely positions the laser beam ahead of the cutting insert to plasticise the workpiece material, making it easier to cut. Developments in cutter technologies that are advancing the cost-effective machining of ceramics include
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NEW PRODUCTS
40% More Space in Your Switch Cabinet; Remote I/O Modules Impress with Their Unique Compact Design
can be installed in spaces where larger switch cabinets cannot fit. The high-density modules are half the size and their slim profile creates space for more modules.
High-speed capacity of 10 Gb+ and a Category 6A classification that goes beyond the IEEE 802.3an-2006, TIA568C.2 and ISO/ IEC11801 standards to meet 10GBase-T requirements.
The analog counterparts were introduced some time ago and are the result of innovative electrical design. At just 16 millimeters wide, the high-density modules fit in existing backplanes and are easy to configure.
Small size thanks to its maximum exterior diameter of 15 mm.
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The new modules require around 40% less installation space in a complete remote I/O system including com unit coupler and power supply, depending on the signal mix. This reduced installation space increases flexibility when planning automation solutions using Pepperl+Fuchs remote I/O systems. The innovative, slim modules
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A detailed brochure on the new connector is available on the www.amphenolsocapex.com Web site
µCom-10Gb+
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Pepperl+Fuchs completes its wide range of I/O modules with the half-size, eightchannel digital input modules and offers the most compact remote I/O solution for process automation. The slim modules save valuable space in switch cabinets, thereby reduce the cost per channel.
Pepperl+Fuchs complements its product range of extra slim modules with the newly developed eight-channel digital input modules. Pepperl+Fuchs has essentially made these new modules possible by creating a new electrical design. The new housings of the digital high-density input modules are half as wide as those of the previous version, but this is partly due to the compact plug construction. The two plug-in connectors found on the front of the housing each have eight contacts. In addition, the redesigned housing features status LEDs for each of the eight available channels, enabling quick diagnostics and accelerating both commissioning and maintenance.
High levels of resistance to corrosion, impacts and vibrations and an IP68 protection level. The environmental tests are based on the MIL-DTL38999 series III military standard.
Available now: New Eplan Platform 2.3
Amphenol Socapex launches its new miniature high-speed Ethernet connector, the µCom-10Gb+ Dedicated to C4ISR, battlefield communication, aeronautics and railway applications, the µCom-10Gb+ connector combines miniaturization and high-speed capacity with resistance to the harshest environments. «This new copper-based miniature connector meets current market needs in terms of size and high-speed capacity. It provides our customers with secure, reliable signal transmission, especially for tactical military communications», says Christophe Bernardi, Industry & Networks Business Division Manager at Amphenol Socapex. The new connector meets the requirements for applications in harsh environments with:
The major new release of the Eplan Platform is launched. Version 2.3 focuses on standardisation and automation, which opens up new opportunities for users when it comes to standard-compliant design and handling safety values. Simple macro editing and extended search functions for system settings guarantee highly productive engineering for users. Another practical benefit: central administration of phased-out devices and associated test runs to give transparency and safety to existing projects. Monheim, 14. August 2013 - The latest Version 2.3
of the Eplan Platform, which has been available for download since mid-August, is characterised by standardised and largely automated engineering across a consistent database. There is comprehensive support for new standard-compliant designations based on EN 81346 and the safety values focused VDMA 66413 exchange format. The central administration of phased-out items and a new search function for system settings are additional new features of the CAE software to allow interdisciplinary cooperation and configuration. For example macros: Version 2.3 offers extensive options for handling macros/ partial circuits and their variations. What is new is the fact that these macros can be edited and if needed be updated across the entire project within an incredibly clear table view. This means that comprehensive changes can be made within the project with just a few clicks of a mouse - potential error sources are reduced by means of central data storage.
values and the user can be sure to get things right.
Secure in accordance with standards: EN 81346 and VDMA 66413 The definition of mechatronic solutions and the appropriate designations in the documentation are typical everyday designing tasks. The norm EN 81346 «Industrial Systems, Plants and Equipment and Industrial Products - Structuring Principles and Reference designations» is particularly widely accepted on an international level. The Eplan Platform 2.3 allows project structures and project designations to be implemented on a user-friendly basis in compliance with this current standard.
Easier searches, quicker results The new Version 2.3 also incorporates a high-performance search function which makes it easy to find and adjust the system settings by means of keywords. For the project data navigators available in Eplan, users can now define whether and which additional information is displayed in the tree view. The display options have been harmonized and extended and made adjustable to allow this. This makes navigation easier for the users and gives them additional flexibility in terms of individual configuration. There is a quick overview of important information to make engineering more productive.
There is also the issue of fail-safety of components and safety function in line with machinery directive 2006/42/EU. Eplan supports a consistent electronic data exchange format for the relevant safetyrelated values for automation components in accordance with VDMA 66413. The relevant safety data from the device manufacturers can be transferred to Eplan’s parts management system via a standardised interface. The values are saved directly with the components and are therefore directly available for designing purposes. This means there is no need for timeconsuming manual amalgamation of safety
Central administration of phased-out devices Phased-out items are generally replaced by a newer model, but are still used in existing projects and must be administered transparently. In Version 2.3, the Eplan Platform makes the central administration of phased-out articles easier by allowing marking in the article administration system. There are also new check runs to give users even more safety in designing. Once stored centrally in the parts management system, the information is available to all involved across the entire project. This means that the CAE software creates more transparency in the engineering process and keeps existing projects manageable. While we’re on the subject of manageability: The Eplan software offers extensive configuration options for individual adjustments to the way users work.
Industrial Networks enables users of the SIMATIC S7-1200 PLC to integrate CANopen devices into their automation systems (using the TIA Portal®). The CM CANopen is an extension module for the SIMATIC S7-1200, enabling the PLC to communicate with devices on a CANopen Network. The product is developed by HMS Industrial Networks and is fully approved by the manufacturer of the S7-1200 – Siemens AG. How it works The CM CANopen plugs into the S7-1200 and works as a translator between nodes on a CANopen Network and the S7-1200. The module fits mechanically into the standard S7-1200 system rack and can be configured to be both Master or Slave. No programming is needed to configure the communication between CANopen and the PLC – users set up how they want the data to flow in the accompanying CM CANopen Configuration Studio software. It is possible to plug in three CM CANopen modules per PLC, and 16 CANopen slave nodes can be connected to each module (each module supports 256 bytes input and 256 bytes output). There is also support for transparent CAN 2.0A for custom protocol handling, and the module is integratable into the hardware catalogue of the TIA Portal configuration suite. “The CM CANopen enables users of the S7-1200 to integrate CANopen devices into their PLC system giving them a wider selection of automation products to choose from when designing their systems,” says Mikael Mårtensson, Product Manager at HMS Industrial Networks. “This is a solution that will bring a lot of value to users of the S7-1200, allowing them to build more efficient automation systems.” The CM CANopen is available as of October 2013 from HMS sales offices and distributors.
Customers with a software service contract can download the new Version 2.3 directly from the home-page of solution provider Eplan.
More Information CANopen devices Connecting CANopen devices to the SIMATIC® S7-1200 PLC The CM CANopen module from HMS
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NEW PRODUCTS
I am honored to be asked to represent this strong brand of extraordinary products,” said Tom. “One of the things that attracted me to ProSoft was the fact that they are a company that thinks globally but acts locally. This philosophy extends throughout every part of the business. Sales and support are handled locally, with real people in your time zone who speak your language.
ProSoft Technology, Inc., a leading global industrial communication company, is pleased to announce that Thomas Crone has accepted the position of President and CEO effective immediately. “Our search for ProSoft’s next CEO began this past spring,” said Gary Joke, Chairman of the Board of Directors for ProSoft Technology. “With the help and guidance of an executive search team from Korn/ Ferry International, we were looking for a candidate with experience and expertise in leading global businesses, industrial automation technology, global sales and marketing and general business management. Most importantly, we were looking for someone who would be a strong fit within the ProSoft culture. Tom fit all of our criteria.” Tom comes with a vast array of experiences that will help take ProSoft Technology to the next level. Most recently he served in the role of Executive Vice President and Chief Marketing Officer of Valin Corporation, a provider of process control and automation solutions.
While at Valin, he was responsible for a US-based global distribution business with five divisions, 15 operations, and 250 employees. Tom’s leadership helped guide the company through organic sales growth and multiple acquisitions creating one of Inc. Magazine’s fastest growing companies in America and among Business Journal’s largest and fastest growing private companies in Silicon Valley. “I have been following the progress of ProSoft Technology for some time now and
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The other attribute of ProSoft Technology I found irresistible is the can-do, get-it-done, larger-than-life attitude that is present in all facets of the company. I look forward to being part of this dynamic group for many years.”
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Solutions for safe applications based on IEC 61508
is the IXXAT Safe T100, a complete solution for simple and fast integration of safe I/O using a safe communications protocol. The IXXAT Safe T100 safety module is integrated directly into the customer product or system – for example into welding systems, drives, counter terminals, and many more. Thanks to the comprehensive architecture with safety hardware and software, as well as precertification by TÜV Rheinland, the use of the IXXAT Safe T100 considerably simplifies the development of devices and systems with safe communications. As a result, the user also benefits from significant reductions in development time, cost, and risk. The IXXAT Safe T100 uses the well-known Anybus CompactCom modules from HMS as a communications pathway through the unsafe network – here, safe communications are implemented using the «black channel» principle. In addition to the first version now released - the IXXAT Safe T100/PS for PROFIsafe on PROFINET, additional variants will soon be available, such as for CIP Safety on EtherNet/IP or Functional Safety over EtherCAT. If there are special requirements in terms of form factor, connectors, or the number of I/ Os, custom versions of the IXXAT Safe T100 can also be implemented. The IXXAT Safe offering also includes protocol stacks for Functional Safety over EtherCAT (FSoE), CIP Safety on EtherNet/IP, CIP Safety on Sercos, and openSAFETY. Like the IXXAT Safe T100, these protocol stacks are also precertified by TÜV and permit the implementation of safe communications in suitable hardware.
With IXXAT Safe, HMS offers a product family under the IXXAT brand for fast, cost-effective implementation of safe communications solutions in industrial automation devices With the IXXAT Safe offering, HMS offers an extensive portfolio of solutions for safe communications according to IEC 61508 – from safety protocol software to finished safety I/O modules for integration into customer devices. HMS and its safety development team also support customers in the development of their safety applications, as well as in the certification of end products, also offering customer-specific development as OEM solutions. The new addition to the IXXAT Safe offering
Integration can be carried out by the device manufacturer themselves, but HMS is ready to assist with implementation, porting, and certification services. The advantage for the customer of using a precertified safety protocol stack is the significant reduction it provides in development time, cost, and risk. You can find more information about IXXAT Safe at www.ixxat.com
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Kennametal Announces Breakthrough KM4X100™ Spindle Connection
Spindle connection helps deliver maximum machine tool power for maximum metal removal in titanium and hard alloys The spindle connection is the “handshake” -- the interface between the machine tool’s spindle and toolholder. As such, this vital component has to provide the torque and bending load capacity compatible with the machinetool’s operating specifications. But when machining high-strength materials like titanium and other alloys, cutting forces generate bending moments that will exceed the interface’s limits prior to reaching the machine tool’s torque threshold. By combining high clamping force and optimized interference levels, Kennametal’s new KM4X100™ provides a robust connection, extremely high stiffness, and bending load capacity for greatly improved performance in machining highstrength alloys and other materials. The result is extremely high metal removal rates and more completed parts per shift. “In most cases, the tool-spindle connection determines how much material can be removed on a given operation,” says Doug Ewald, director, global product management, tooling systems at Kennametal. “This is because this interface must withstand high loads and yet maintain its rigidity. With the ongoing advances in cutting tools and machining centers, a spindle connection like KM4X 100™ that makes the best utilization of available power possible is an important consideration to investigate early in production planning.” Global Priority High-strength, lightweight materials such as titanium alloys, Inconel, and new aluminium alloys are eagerly sought
by manufacturers in many industries, including aerospace and defense, energy, and transportation. These new materials present significant machining challenges in themselves. Add the competitive pressures in these global industries, and finding advanced manufacturing solutions becomes a top priority. Machine-tool builders have responded with milling and turning centers that feature improved stiffness and damping on spindles and sizable machine structures and motors, all to provide the significant horsepower, torque and thrust forces required while minimizing undesirable vibrations that deteriorate part quality and tool life. By using three-surface contact for improved stability and optimized clamping force distribution and interference fit, KM4X100™’s engineering results in three times the bending moment resistant capacity compared to other tool systems. This means: -Shops can leverage KM4X-equipped highperformance machine tools to increase speeds and feeds in difficult machining applications, thus gaining the full productivity potential from the machine tool. -Often, a smaller KM4X connection such as a KM4X100™ will provide the same or better cutting performance of a larger connection. -KM4X systems can be applied on multitasking, turning, machining centers and transfer machines in manual, semiautomatic, or fully automatic mode. “KM4X 100™ by design can perform in a wide range of operations, from low-speed/ high torque to high-speed/low torque, allowing manufacturers to get the absolute most out of their production equipment,” Ewald says. ”Milling, drilling, and turning a wide range of materials just got more productive!”
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NEW PRODUCTS
Kepware Updates Communications Platform to Strengthen Support of Industry Standards and Improve Interoperability KEPServerEX version 5.13 features on-demand communications and achieves ODVA compliance with significant open standard driver updates Kepware Technologies, a software development company focused on communications for automation, released KEPServerEX® version 5.13. The updated communications platform expands Kepware’s support of industry standards, and enables improved interoperability and communications across key industries. KEPServerEX version 5.13 features client- or user-driven on-demand communications with new Device Demand Poll functionality. This added flexibility enables users to meet the client-driven polling requirements of their application.
FloBoss™ devices, which enables automatic tag generation and data access to User Defined Points. “As regulations tighten and Oil & Gas networks span increasingly greater distances, the industry requires new and innovative approaches for collecting and communicating data,” said Steve Sponseller,Product Manager of Oil & Gas Solutions at Kepware.
The drive expert’s dedicated internet portal – http://airport.nord.com/ – provides a concise presentation of solutions for the industry. NORD’s economic drive systems are based on efficient 2-stage
“The value of data to the Oil & Gas Industry is growing exponentially. With version 5.13, we paid special attention to helping the industry leverage this information to make highly-informed business decisions.”
In addition, NORD offers an electronics program featuring uniform operation across a differentiated, but manageable model range.
For more detailed information about KEPServerEX version 5.13’s other features and enhancements, please visit Kepware Technologies online or contact a representative at (207) 775-1660 or sales@ kepware.com.
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helical- bevel geared motors that are especially easy to handle due to the lightweight gearbox design.
Airport drive solutions include horizontal conveyors e.g. for check-in areas that perform simple start-stop operation as well as drives with high overload capability and brake management to propel incline conveyor belts and vertical conveyors. Economic motor-integrated frequency inverters ensure high dynamics and precision in lifting and sorting tasks. Basic screw and plug connections are all that is necessary for a very comfortable installation of these drives. NORD’s fast and expert customer service supports airports and OEMs in the planning phase and throughout delivery, assembly, and regular maintenance.
Custom-tailored drive units for baggage handling
Also included in this release, the Allen-Bradley ControlLogix Unsolicited Driver for KEPServerEX is now compliant with Open DeviceNetwork Association (ODVA) standards, ensuring interoperability with other Ethernet/IP-based products. “Interoperability issues are paramount with multi-vendor products, which is why our commitment to supporting industry standards is a top priority as we continue to advance our products,” said Tony Paine, President and CEO of Kepware Technologies. “With version 5.13, we improved the performance of our Allen-Bradley ControlLogix Unsolicited Driver and achieved ODVA certification.” The enhancements made to KEPServerEX’s EFM Suite considerably advance its communication capabilities for the upstream and midstream Oil & Gas Industry. The EFM Exporter now supports exporting collected archive data directly to any SQL database for custom applications and analysis. Furthermore, the Fisher ROC and ROC Plus Serial drivers now support User Programs in Emerson’s Fisher ROC and
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More Information NORD DRIVESYSTEMS designs individual, low-maintenance drive solutions for baggage handling systems. The international manufacturer has already equipped numerous airports throughout the world in locations as varied as Hamburg, London, Johannesburg, or Taipei.
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RLX2
ProSoft Technology® releases the 802.11n Industrial Wireless Access Point/Bridge/Repeater with Fast Roam Technology
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he 802.11abgn Fast Industrial Hotspot is an advanced, high-speed wireless Ethernet solution designed for plant-floor automation, SCADA systems, mobile worker Wi-Fi infrastructure and process control systems.
This Hotspot offers a broad range of industrial wireless capabilities including unique features such as Fast Roaming and has excellent packet-per-second performance and robust communications in demanding industrial environments. June 2013 ProSoft Technology® is pleased to announce the release of the 802.11 abgn Fast Industrial Hotspot. The new 802.11abgn Fast Industrial Hotspot (RLX2) features breakthrough advancements in client/bridge fast roaming between access points, Ethernet packet optimization, and enhanced diagnostics. These new capabilities provide seamless high-speed Ethernet connections for moving machines and vehicles traveling long distances in assembly plants, crane systems and mining. The secure, high speed wireless network reduces project costs, while improving productivity by eliminating mechanical festooning, rails and slip rings for economical and reliable mobile applications.
The radio’s Fast Roaming technology uses less than 50msec time between access points and provides full device bridging. The module provides secure 802.11i and 128-bit AES Encryption and operates securely in the 2.4 GHz or 5 GHz bands. It also has advanced management tools. These tools include IH Browser Utility, web server and OPC server. The microSD card will automatically store/load configurations, reducing down time. The Hotspot is designed for extreme environments and hazardous locations, including oil and gas systems. It is an ideal wireless solution for Producer/Consumer PLC/ PAC networking, remote I/O, safety I/O, plant backhaul networking, remote video and mobile worker connectivity. The Hotspot utilizes extended operating temperatures of -40 to +75°C (-40°F to +167°F) and has agency approvals and certifications with Class1, Division 2 and ATEX Zone 2. The module is high shock/vibration tested. The Shock IEC is 60068 2-6 (20g, 3-Axis) and Vibration IEC is 60068 2-27 (5g, 10-150 Hz).
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NEWS
IXXAT CAN repeaters reduce wiring costs and increase system reliability
HMS Industrial Networks now launches a range of CAN repeaters under the IXXAT brand. These well-proven products enable coupling of two or more CAN network segments, provide them with galvanic isolation, and eliminate the effects of EMI (Electromagnetic Interference).
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he CAN repeaters are offered under HMS’s recently acquired IXXAT brand and enable machine builders and system integrators to use extended CAN topologies including tree or star topologies. Furthermore, the integrated galvanic isolation provides a built-in protection against over voltage and the anti-noise circuit of the units eliminates the effects of EMI. IXXAT repeaters are especially designed for use in industrial environments, meeting high demands for robustness, temperature ranges and safety.
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How it works With the use of a repeater, it is possible to build independent electric segments that can be optimally terminated in terms of signals. The repeater substantially increases system reliability, partly because it increases the signal quality, and partly because it makes it possible to isolate malfunctions – keeping the remaining CANsystem fully operational. Furthermore, the implemented monitoring function detects CAN lines which are disturbed or malfunctioning. These lines are disconnected automatically, thus allowing the remaining network to continue functioning normally. After the fault has been eliminated, the disconnected segment is automatically reconnected to the network.
Depending on the type of repeater, the CAN lines are protected among each other and against the power supply up to 4 kV. In addition, the built-in CAN bus choke provides protection against signal peaks and the additional antinoise circuit helps eliminating effects of EMI like heavy noise on the CAN-bus. Wide range of use cases “The IXXAT CAN repeaters are based on proven technology and we feel that it is now time to offer these to a wider international market,” comments Thomas Waggershauser, Product Marketing Director for IXXAT solutions at HMS. “IXXAT CAN repeaters has helped users to extend topology and improve robustness of CAN-networks since 1992 when IXXAT presented the world’s first CAN repeater. Use cases vary from customers wanting to reduce the lengths of their CAN wiring, to users who need to galvanically isolate CAN lines and rebuild CAN-signals. One common example is wind turbines with fiber-optic wiring in the blades. The CAN repeaters are used for isolation in case of a lightning strike and to refresh signals to use low-service slip-rings. CAN repeaters are a great tool for any system integrator or machine builder working with CAN since it allows them to substantially reduce wiring complexity and improve system reliability.”
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SK 135E : Wear-free decentralized soft starter and reversing starter with motor protection – the economic alternative
Featuring a compact, easy-to-clean enclosure, the SK 135E starter provides for equipment-friendly soft start-up of distributed drives in all kinds of sectors
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ORD DRIVESYSTEMS presents a new motor-mounted starter with an extended performance range for the economic distributed implementation of soft start and reversing functions, for motors from 0.25 to 7.5 kW. The compact SK 135E integrates motor overload protection through PTC thermistor monitoring, mains and motor phase failure monitoring, I²t monitoring, and magnetizing current monitoring. The electronic, wear-free switching technology replaces motor circuit breakers, reversing contactors, and brake rectifiers, thus rendering entire control cabinets unnecessary in large facilities.
A voltage boost can be programmed for applications requiring high break-away torques. Various braking modes are available. The starter features four potentiometers and four DIP switches for adjusting the most important parameters. LEDs signal the operating status. Parameterization and diagnosis can be carried out via parameter boxes or via a PC, using the free-of-charge NORD CON software. NORD’s entire distributed electronics program, which also includes the SK 180E and SK 200E series frequency inverters, provides the benefit of a uniform operation concept.
As PTC thermistor connection cables and brake control cables are not required, either, installation becomes generally more cost-effective, space-saving, and faster. When the drives are ordered complete and wired with gearbox, motor, and starter, any assembly effort is reduced to simply tightening the screws and establishing the electrical connection, which is optionally with plugs. The soft start function reduces mechanical stress, preventing shocks during start-up and braking.
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NEWS
Tool coding using Industrial RFID
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ool identification using Balluff Industrial RFID increases efficiency, as it makes incorrect tool allocation or missing tools a thing of the past.
All the tool-relevant data are stored without contact on a data carrier embedded in the tool holder. Automatic loading into the system memory means all the data are always correct and up-to-date. Because the data are continuously updated when the tool is loaded and unloaded. In modern production facilities this ensures maximum tool utilization and high machine uptime. The established basis for tool identification systems is stateof-the-art RFID technology. Balluff identification systems are suitable for industrial use and designed for extreme loads from shock and vibrations and electromagnetic, thermal or chemical effects.
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BIS C was the first RFID-based identification solution that ensures reliable data transfer, even in the area surrounding metallic materials. As part of tool management systems, it enables automatic transfer of the tool parameters, which substantially reduces
non-productive time at the machine. This does not include the time and personnel savings for provision of tools and equipment and optimal utilization of the tool life. Scrap and rework due to excessive use of tools are virtually eliminated. Additional rationalization effects include easier organization of tools and equipment, greater production assurance and avoidance of errors, for example due to incorrect inputs or mixed-up tools. The core components of the Balluff identification systems BIS are robust data carriers in miniature design, a read/write head and a processor unit. In complex tool management solutions, they are also used in configuration and measurement devices, where, according to current practice, the first programming of the data carrier with identification and geometric data takes place. Balluff identification systems are available in a wide variety of versions Experience has shown that the investment pays for itself within a year or two.
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Solutions for safe applications based on IEC 61508
With IXXAT Safe, HMS offers a product family under the IXXAT brand for fast, cost-effective implementation of safe communications solutions in industrial automation devices.
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ith the IXXAT Safe offering, HMS offers an extensive portfolio of solutions for safe communications according to IEC 61508 – from safety protocol software to finished safety I/O modules for integration into customer devices. HMS and its safety development team also support customers in the development of their safety applications, as well as in the certification of end products, also offering customer-specific development as OEM solutions.
The IXXAT Safe T100 uses the well-known Anybus CompactCom modules from HMS as a communications pathway through the unsafe network – here, safe communications are implemented using the «black channel» principle.
The new addition to the IXXAT Safe offering is the IXXAT Safe T100, a complete solution for simple and fast integration of safe I/O using a safe communications protocol. The IXXAT Safe T100 safety module is integrated directly into the customer product or system – for example into welding systems, drives, counter terminals, and many more. Thanks to the comprehensive architecture with safety hardware and software, as well as precertification by TÜV Rheinland, the use of the IXXAT Safe T100 considerably simplifies the development of devices and systems with safe communications.
If there are special requirements in terms of form factor, connectors, or the number of I/Os, custom versions of the IXXAT Safe T100 can also be implemented. The IXXAT Safe offering also includes protocol stacks for Functional Safety over EtherCAT (FSoE), CIP Safety on EtherNet/IP, CIP Safety on Sercos, and openSAFETY.
As a result, the user also benefits from significant reductions in development time, cost, and risk.
In addition to the first version now released - the IXXAT Safe T100/PS for PROFIsafe on PROFINET, additional variants will soon be available, such as for CIP Safety on EtherNet/IP or Functional Safety over EtherCAT.
Like the IXXAT Safe T100, these protocol stacks are also precertified by TÜV and permit the implementation of safe communications in suitable hardware. Integration can be carried out by the device manufacturer themselves, but HMS is ready to assist with implementation, porting, and certification services. The advantage for the customer of using a precertified safety protocol stack is the significant reduction it provides in development time, cost, and risk.
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NEWS
Clever Combination: Nominated for the Automation Award 2013
Optical color band tracking used for driving, Data Matrix codes used for positioning and control codes used for navigation. The PGV positioning system is the only product that offers this combination, making it the optimal solution for controlling automated guided vehicles.
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hanks to the camera system’s powerful, integrated signal processing facility, the X and Y position, the speed, the angle, and the operating status are accurately detected at all times and are continuously reported. The wide reading window can cope with any branches, crossovers, and even tight curves with precise position feedback at all times. Uniquely Insensitive The PGV’s revolutionary camera technology makes it completely insensitive to ambient light. Even dirt on or damage to the color band or codes do not trouble the PGV. Shiny floors, changing ambient light, and strong light reflections interfere with conventional optical positioning systems, since they do not have a balanced selection of aperture, lens, and shutter speed.
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On the new PGV positioning system, the optical components are purely focused on the «region of interest» and the aperture and shutter speed selected are coordinated with optimum lighting. This makes overexposure a physical impossibility, and means that the ambient light cannot impair the reading performance. The color band for route tracking, for which any width and color can be selected, therefore no longer needs to be optically differentiated from the floor covering with contrast bands.
Reliable Processes in All Areas With its superior hardware and software, the PGV delivers excellent process reliability, flexible handling, and cost efficiency. The integrated universal interface for all standard fieldbuses and process control systems provides the positioning system with plug&play connectivity. In short, it is the perfect solution for automated guided vehicles in intralogistics, material handling, the automotive industry, the print and paper industry, healthcare, and many other areas.
Highlights Reliable and efficient production processes with Data Matrix codes and color bands being combined for the first time. Safe transport of goods using continuous position feedback and positioning. Universal, since any color bands can be used for route tracking. Large reading window can cope with tight curves. Insensitive to damage to and dirt on the color band and code tape. No moving parts in the sensor guarantee a long service life. Environmental influences have no impact thanks to the highquality LED lighting. User-friendly and simple commissioning process.
NEWS
Tata Steel: Keeping Britain on the right track
Tata Steel, Europe’s second largest steelmaker, has won a contract to supply rail track and steel sleeper plate to Network Rail for at least five years.
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etwork Rail, the company set up to operate and maintain Britain’s rail infrastructure, has chosen to source more than 95% of its rail from Tata Steel until 2019, with the option to extend this until 2024. The contract could see Tata Steel, which employs 18,500 people in the UK, supplying more than a million tonnes of rail, including premium products such as 1HPrail®, for Britain’s passenger and freight lines. Henrik Adam, Chief Commercial Officer of Tata Steel, said: “This is fantastic news. I am delighted the rail network in Britain will continue to be made and maintained with our UK rail. “This contract win has been made possible by our continued drive to be more customer focused. By working closely with Network Rail, by learning from them and by developing the products and services they need, Tata Steel has shown the benefits this close working relationship can bring.” Every day more than three million people in Britain travel on trains which run on high-quality rail developed and made in Scunthorpe. The British rail network carries 1.5 billion passengers every year – more than at any time in over 60 years.
Network Rail’s Group Finance Director, Patrick Butcher, said: «We are renewing and enhancing more and more of Britain’s railway over the next five years and it’s crucial that we have a trusted and secure supply chain to help us achieve that safely and efficiently. «It seems obvious, but rails are at the root of everything we do and this contract secures everything we need to keep improving the network.” Since 2000 more than £160 million has been invested in Tata Steel’s advanced rail manufacturing facilities at its Scunthorpe site to enable it to produce the 216-metre long rail customers want. Alongside this investment Tata Steel has transformed the manufacturing logistics to handle the new long rail products required by customers such as Network Rail. Henrik Adam added: “This contract is a clear demonstration of the contribution foundation industries like steel make towards rebalancing the British economy. We are supporting high-skilled manufacturing jobs, developing innovative new products and services – and we are helping to build infrastructure for the 21st century.” The latest Network Rail deal will account for around 5% of the annual steel output from Tata Steel’s Scunthorpe site.
More Information 04 | Industry Asia-Pacific | November 2013
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