Industry USA 03

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INDUSTRY USA industrial market Magazine

TRITEX II™ AC POWERED ELECTRO-MECHANICAL ACTUATORS

08 New KSSM8+™ Face Milling Platform for Cast Iron

18 Kollmorgen drives the lightweight helpers of Universal Robots

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Magazine Industry USA | April 2014

Balluff vision sensor BVS-E Universal

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ARC INFORMATIQUE

IXXAT

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6 EXLAR

HMS

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KOLLMORGEN

BALLUFF

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12 SOURIAU

IXXAT

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13 KENNAMETAL

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EPLAN

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NEWS

Champagne producer Veuve Clicquot chooses PcVue to supervise its tanks

The operators control the PcVue supervision software via a 42» touch screen installed at the entrance to the fermentation cellars.

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orld-renowned top-quality champagne house Veuve Clicquot uses instrumented and automated facilities. Thanks to PcVue, it now has a smart system that supervises fermentation in its 400 fermentation tanks.“The VHX microscope was first selected by our German Technical Centre. We were so impressed by its capability and value that we chose to standardize this tool across all our R&D facilities throughout the world”, concludes Derek Marsella.

Veuve Clicquot is a French champagne house known the world over. Founded in 1772, this prestigious house is now a subsidiary of LVMH. Its reputation is obviously no accident. The house does not compromise on quality and its motto is ‘Only one quality – the finest’. In order to ensure that it always makes the finest champagne, it also needs to be able to closely supervise its production systems.

That is why, in late 2012, Veuve Clicquot revamped its fermentation cellar supervision system. The fermentation cellars are where the house makes its wine from harvested and pressed grapes. Supervising the tanks in which alcoholic and malolactic fermentation take place is crucial.

However, the software being used by Veuve Clicquot was at the end of its life and the publisher was no longer

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supporting it. It was therefore necessary that the house replace its 10-year-old supervision system by a more recent and better performing solution. «We needed to replace it by a lasting solution that would be supported for many years to come,» says Franck Berruyer, sales engineer at Arc Informatique, the company behind the PcVue supervision system installed at Veuve Clicquot. «In addition to various technical factors, we chose the PcVue 10 software suite because of the relationship of trust we have maintained with Arc Informatique and because the cost of the licences is economically suited to Veuve Clicquot’s needs,» says Stéphane Fournier, manager of SF2I, the company that developed and integrated the supervision software.

Another advantage of PcVue is that it has the same HMI as the previous software, meaning that the operators were able to use PcVue immediately. Furthermore, Guy Jendryka, manager of the electricity, automation and industrial computing department at Veuve Clicquot, stresses that one of PcVue’s strengths is that it is easy to adjust and program.

«With the previous system, you really had to be an IT specialist to be able to upgrade the software. PcVue is much easier to modify as needed.»

The development architecture is based on PcVue objects and greatly facilitated the supervision software’s design.

Because Veuve Clicquot’s fermentation cellars contain 400 tanks of various types and volumes (50 hl to 725 hl), the

developers had to be able to use models so as to reduce programming, and hence maintenance times. Depending on their type, the tanks are fitted with up to three temperature-control sensors and manual or automatic valves. The application manages some 40 variables per tank for a total of 16,000! «The object development architecture saves time and simplifies operations. Once the model was made for the dozen existing tank models, it was simply a matter of instantiating the objects and automatically generating the communication variables,» says Mr Fournier.

With its virtual architecture, PcVue runs on a server that is installed in a secure, air-conditioned and filtered room protected from the damp. The application’s maintainability and portability on new physical machines is thus simplified.

The fact that, in such a virtualised environment, the software is decoupled from the hardware means that reinstallation and commissioning times in the event of failure are considerably reduced.

Five web-based clients allow the cellar managers to view the supervision system and select its setpoints via their PC. Operators can also monitor and control the software via a 42» touch screen that is installed in the lobby and within view of all visitors. The software communicates with the programmable logic controllers (PLCs) over a Modbus

TCP/IP network while a VPN (virtual private network) link is used to collect information from the tanks in the house’s other fermentation cellars. Fourteen fermentation modules are housed in the main cellar in Reims and four others are located in various towns across the Champagne vineyard at distances of 30 to 200 km from the main cellar!

The VPN saves a tremendous amount of time. «Being able to supervise all our fermentation cellars from one place eliminates the need to drive to each cellar. The supervision system issues an alert if a serious temperature control issue crops up,» says Stéphane Fournier.

Mr Jendryka can now monitor all his tanks from his desktop PC. «PcVue supervisor has made our fermentation cellars smart. We can monitor every aspect of temperature control from just one place.»

Encouraged by this positive experience, Veuve Clicquot’s technical teams quickly realised how PcVue could be used elsewhere. Not only does it supervise the fermentation of wine in the tanks, it also monitors the production of cold during cold stabilisation after final blending.

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NEWS

Fast and efficient – the new CAN FD PC interfaces from HMS

Under the IXXAT brand, HMS is bringing a new CAN PC interface series for CAN FD to the market, supporting it with an extensive suite of drivers and tools.

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ith the new CAN-IB 500 and the CANIB 600, HMS offers two interface cards (passive/active) that support not only CAN but also the new CAN FD standard.

Both cards are for the PCI Express

standard.

They have up to two CAN interfaces, which can be operated in either CAN or CAN FD modes. Galvanic isolation of the channels is optionally available.

The active CAN-IB 600 also has a built-in microcontroller, so it can even be used in applications with increased requirements for data preprocessing such as high-precision timestamps or active filtering of the messages to be sent from and received by the card.

The cards are supported by both the IXXAT Windows driver packages (VCI) and the real-time driver packages (ECI for Linux, RTX, Intime, QNX).

The IXXAT APIs for CANopen and SAE J1939 also support the new interfaces in CAN mode. For the analysis of CAN and CAN FD networks, HMS offers the IXXAT canAnalyser, a powerful Windows tool.

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Classical CAN, with its eight bytes of payload data and a

maximum transmission rate of 1 MBit/s, is part of a wide variety of applications, not least due to its favorable price and versatility. Applications that require the transmission of larger quantities of data, however, have had to move to other technologies until now, which is of course associated with higher costs.

Now, with its capacity of up to 64 bytes of payload data and a higher bit rate for payload transmission, CAN FD is eliminating the old limitations of CAN, making it attractive also for applications that have never been able to work with CAN.

You can find more information about the new CAN FD cards at www.ixxat.de

NEWS

Fast, easy, flexible: USB 3.0 Board Level Cameras

New board-mount models allow greater flexibility in cramped installation spaces

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aumer further develops the MX camera series by adding the fast USB 3.0 interface and additional performance features, increasing added value for users in industrial image processing installations or medical and laboratory technology.

Diverse application possibilities, easy USB connection and maximum flexibility in minimal installation spaces characterize the ten new camera models.

Plug-and-play functionality enables quick and easy camera integration. The USB 3.0 interface allows for a single cable solution for data transmission and power supply.

The small, remote 28.5 x 28.5 mm sensor head is connected to the system printed circuit board by flexprint with only an 8.2 mm overall height. This allows the utmost flexibility in camera integration where space is very limited.

MX Series models are available with resolutions from VGA to 4 megapixels and high performance Sony CCD and CMOSIS sensors. Fast motion sequences are detected at up to 160 frames per second and global shutter sensors in monochrome and color.

The MX Series’ proven large range of functions, including sequencer or storable user sets and matching Baumer GAPI SDK v.2.2 software, round out the benefits of the new USB 3.0 board level cameras.

All models are certified in accordance with the new USB3 Vision standard, making them compatible with software libraries for industrial image processing such as NI LabVIEW, MVTec HALCON or Matrox Imaging Library.

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NEWS

TRITEX II™ AC POWERED ELECTRO-MECHANICAL ACTUATORS

Tritext AC Powered Linear Actuator

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xlar announces the Tritex II™ Series electric actuators, offering up 1500 Watt, AC powered operation and digital position control within a single, space-saving housing. These actuators combine a brushless servomotor with either rotary or linear (output) actuation, assembling all elements into a compact, sealed housing for demanding environments.

With their built-in mechanical converters, Tritex II actuators eliminate the need for traditional ball screw or gear reducer mechanisms—they incorporate all the required position control and power electronics into the actuator itself, providing a complete system solution. This design additionally eliminates the inconvenience and expense of an external servo amplifier and cables, which are often required with typical servo systems.

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The new Tritex II actuators operate from 100-240 VAC, allowing direct connection to factory power sources.

Enhanced software features include 16 programmable indexes, linked moves and firmware flash upgrade capability via the actuator’s Modbus port. This port, via a RS/485 protocol, allows complete control, programming and monitoring of all aspects of the Tritex II actuator as it performs an application. Planned communications options include Modbus, Ethernet/IP™, HART, Modbus TCP/IP, CANopen, and CAN J1939 protocols.

The Tritex II actuator has ample I/O capability: 8 digital inputs, 4 digital outputs, plus one analog input and output.

Feedback choices include analog hall effect (standard), incremental encoder for higher positioning resolution and an absolute feedback option that eliminates the need for performing home routines after power loss. The new Tritex II design offers excellent connectivity with internal terminals accessible through the actuator’s removable cover. Tritex II also offers a provision for Imperial or metric threaded ports for cable sealing glands, optional M23/M16 connectors for power and I/O, with an M8 connector for the RS485 port.

Tritex II linear actuators provide the same form factor as hydraulic and pneumatic actuators and provide for simple, clean all-electric retrofits in what were formerly fluid power applications. They are available with many different mounting options (metric or imperial) such as front flange, rear clevis mount, side mount, trunnion mount, extended tie rod, and rear flange.

Tritex II rotary actuators are available in standard IEC metric dimensions. Direct drive units, as well as units with integral planetary gearing, provide compact, powerful solutions for most rotary applications. Custom mounting and options for both rotary and linear actuators are available to meet a wide range of installation requirements.

NEWS

Powerful Powerlink connectivity in the new Anybus CompactCom 40-series

Anybus CompactCom 40-series products allow Ethernet Powerlink connectivity for industrial devices.v

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owerlink is an industrial Ethernet network originating from the Austrian automation company B+R. It is now receiving recognition from many manufacturers of automation products and systems around the world.

Powerlink is one of the first networks to be offered in the new Anybus CompactCom 40-series which will be released in April. The CompactCom 40-series allows very fast and accurate communication between the host device and Powerlink. Communication speed and reliability are important since Powerlink networks are often used for demanding industrial applications such as synchronized servo drive systems. The CompactCom 40-series Powerlink products come in three different formats – chip, brick and module – and are all equipped with the same software interface from the host device. This enables full flexibility for customers when preparing their automation product for CompactCom. «We see Powerlink as an important network in the future, especially among device manufacturers and machine builders that need high performance network technology that combines reliability and fast data transfer,» comments Leif Malmberg, Product Line Manager, embedded at HMS. «We get many requests for Powerlink connectivity from

around the world, especially from the Central European markets. Therefore, we are now pleased to be able to offer connectivity to Powerlink in our newest series of embedded products. The new Anybus CompactCom 40-series will allow device manufacturers to get connected to Powerlink with a single development project and at the same time get connectivity to 19 other networks.»

Anybus CompactCom is the most widely used concept for industrial multi-network connectivity world-wide. By implementing Anybus CompactCom, device manufacturers can achieve instant connectivity to 20 industrial networks including Powerlink, by simply plugging in the corresponding Anybus product. This opens new business opportunities for the device manufacturers and widens their market considerably.

Anybus CompactCom is a series of industrial network interfaces which are integrated into an industrial device to offer connectivity to different industrial networks.

CompactCom comes in chip, brick or module format, allowing the user to choose level of integration. The Anybus CompactCom 30-series is already in use in millions of industrial automation devices. The new 40-series will be released to the market in April 2014.

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NEWS

Kollmorgen drives the lightweight helpers of Universal Robots

The six-axis robots are being used in processing and production facilities for example. The robots are easily programmed to accomplish repetitive tasks. Photo: Universal Robots

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R 5 and UR 10 are the names of the two models with which Universal Robots aim to establish the flexibility of articulated-arm robots in industrial production. The focus is on work areas in which conventional robots have thus far been too big, too expensive, and too loud. Due to their low weight they can be used wherever they are needed. A large part of the power density of the six-axis articulated robots comes from specially adapted KBM direct drive motors from Kollmorgen. Universal Robots was able to embed the motors directly into the articulation axes without need for additional housings.

Universal Robots (www.universal-robots.com) developed the UR5 and UR10 models for small and medium-sized enterprises in particular. The handling units lift a payload of five and ten kilograms, but only weigh 18 and 25 kilograms themselves respectively. This low weight makes it possible to move the units easily without complex subcomponents.

The multi-functional robots are just as flexible in operation given their user-friendly software. This multi functionality supports the Danish company with a user-friendly piece of software. Using this, the six-axis lightweight robots are ready for new tasks in no time. No special knowledge of robotics is necessary for the programming.

The exceptional ratio of dead weight to loading capacity

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Close partnership with people: the robots from Denmark have been design

is the result of a sophisticated lightweight construction that does not contain anything it does not need. With the drive technology, this minimalist strategy means integrating Kollmorgen’s frameless kit motors directly into the articulation axes. In so doing the robot takes on the function of the motor housing, while the gear unit simultaneously serves as the primary bearing of the rotor.

Viewed as a whole, the components used by UR frequently take on multiple functions, and this ultimately reduces the number of mechanical components such as ball bearings, couplings, or shafts considerably, thus decreasing overall system weight and form factor. In addition, with their high power density, the Kollmorgen motors increase the lifting capacity of the UR5 and UR10 platforms. With their high power density, the KBM motors increase the lifting capacity of the UR 5 and UR 10 at the same time.

The KBM motor series offers advanced electromagnetic designs for optimized torque and minimal cogging and harmonic distortion. These benefits are offered over a large operating speed range. The electromagnetic technology with a high packing density in the stator increases torque and keeps thermal losses low. High strength rare earth magnets are used in the rotor, which allow a continuous torque of 1.45 to 3,445 newton meters along with a peak torque of 4.91 to 12,812 newton meters. ÂŤThe high

consequently achieve a longer service life. The improved temperature behavior also prevents the entire construction from heating up. «The motors we used in the past became pretty hot when in continuous operation. Because of the lower losses, the KBM motors from Kollmorgen simply stay colder. We can therefore run our robots in continuous operation without derating,» states Östergaard, and he refers to test procedures with long operation periods and comparatively high loads.

The KBM series is an innovative direct drive frameless motor technology provided by Kollmorgen. The frameless kit motors offer mechanical and plant engineering a wide range of solutions for creating applications with a maximum degree of flexibility, power density, dynamics, and durability. In addition to the technical advantages provided by this product, the KBM platform includes 14 frame designs and many pre-engineered standard options with competitive lead times. «We can basically order as many motors as we want, when and how we want,» emphasizes Östergaard. This aspect is of particular importance because Universal Robots is growing strongly.

«We therefore need a partner in drive technology who is a good fit for us.» In this regard, Kollmorgen was able to impress the Danish robot specialists with delivery reliability and has since established a UR-specific production line at the Czech location in Brno.

ned for collaborative work in production. Photo: Kollmorgen

quality of these motors was a reason why we opted for Kollmorgen,» explains Esben H. Östergaard, technical business manager of Universal Robots.

Given that the KBM motors are embedded in the robot housing and directly drive the load, the robots are able to achieve high level of precision in movement and force control. Targeted force control is critical in this regard, because the robots constantly have to move different workpieces perfectly with high variability. In practice they recognize the size and elasticity of the objects and adjust the force to be applied accordingly. This force must be stronger than just 25 newtons to do this. With a precision of ± 10 newtons and an accuracy of ± 5 millimeters, the required force and desired position can be programmed and executed for each of the six joints.

Another advantage of the robots is its low-noise and energy-saving operation. From a total-cost-of-ownership perspective, the economical use of resources directly increases the efficiency of the robots overall. The competitiveness of this technology thus increases as a result. An additional benefit of high energy efficiency is closely linked to reduced losses in the motors. As efficiency is high, less heat is produced. This means the motors stay cooler, operate below their maximum ratings, and

Ultimately, the quiet operation and high-quality control of the synchronous servo motors ensure the robots can be used outside of handling applications, too. Up until now Universal Robots’ focus has been to use the robots as a tool for performing simple tasks. «We are therefore not competing directly with other robot manufacturers who deal with more complex tasks. Instead we are saving people from having to perform tiring, monotonous manual work,» stresses Östergaard. As the company from Odense has developed light constructions without uncontrollable oscillations and vibrations, however, there are new application possibilities; such as with welding and gluing.

«We can expand our business channels,» says Östergaard.

This development is accompanied by the fact that due to sophisticated safety technology both models are even able to be employed without additional shielding. This opens the path to a safe and comfortable cooperation between staff and technology.

KBM direct drive motors: http://www.kollmorgen.com/en-gb/products/motors/ direct-drive/kbm-series-frameless/

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NEWS

Balluff vision sensor BVS-E Universal

Universal sensor for all applications

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he new BVS-E Universal vision sensor from Balluff with integral processing electronics, lighting and two digital outputs is a genuine all-rounder because it combines the functions of the proven BVS-E Advanced and BVS-E Ident vision sensors in a single device. For the first time, a single model is suitable for almost all inspection tasks and simplifies stock management considerably.

Not only can the BVS Universal inspect a large number of characteristics in one pass, it can also simultaneously perform various tasks such as checking brightness, comparing contrasts, counting edges, checking positions, detecting patterns and reading codes at speed. New additional tools such as a 360° contour, barcode and data matrix check as well as the option of counting and checking contours offer virtually unlimited application possibilities.

The result of the check is issued either as an OK or error signal via the digital outputs or the RS 232/Ethernet interface. The position of the detected part can be transmitted to a PLC or robot control, for example, so that the part can be aligned for subsequent process steps.

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The universal device is extremely fast. Up to 40 barcodes and data matrix codes are located per second, and then

read and verified independently of their position. The code data is available for further processing via an interface.

In addition, an optical character verification (OCV) function can verify printed sequences of characters and numbers such as batch numbers or minimum shelf life dates.

The BVS-E Universal vision sensor is available with different lens versions. Powerful integral red light or infrared LED lights illuminate the image area perfectly. The power supply and peripherals are connected via two industry proven M 12 connections.

The robust, high-end sensor the size of a credit card is easy to use via the supplied ConVISÂŽ software with its intuitive user interface. The user only has to connect the sensor to a PC to configure parameters and operate the sensor using free configuration software. It runs on Windows XP and Windows 7 and also offers the option of storing up to 10,000 inspection images on the computer for troubleshooting purposes, for example.

NEWS

Powerful test systems for test benches and vehicles

IXXAT has extended its FRC-EP series with the new, compact FRC-EP170

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ith the FRC-EP series, which consists of the FRC-EP170 and the FRC-EP190, IXXAT offers universally usable hardware platforms for applications on the test bench or in the vehicle, attractive for their high performance, favorable prices, broad range of applications, and support for a wide variety of software solutions.

benches in the automotive communications world.

These devices have FlexRay, CAN, CAN FD, LIN, K-Line, USB, Ethernet, EtherCAT, Bluetooth, and RS232 interfaces, along with analog and digital I/O. Expansion slots make it simple to add other interfaces, including WLAN, GSM, or GPS. This makes the devices scalable, adaptable to specific applications, and ready for the future.

Demanding Restbus simulation and gateway solutions can be implemented quickly and easily based on either device, using the corresponding software packages from IXXAT. There are also extensive development packages available for the development of specific solutions. Custom functions and applications can be implemented quickly and easily by customers in-house thanks to the use of the Linux operating system and the availability of a free Software Development Kit.

With the new FRC-EP170, IXXAT has now introduced a very compact, cost-effective variant of the familiar FRC-EP190.

Both devices have the same processor and the same operating system, making the new variant completely software-compatible and just as powerful.

Thanks to the large number of identical interfaces and its galvanic isolation, extended scalability, and especially its optional EtherCAT slave functionality, the primary target application of the FRC-EP190 is integration with test

The handy FRC-EP170 was developed for use in vehicles.

Its main application areas are gateway solutions for connection to different ECU integration levels, prototype controllers, expansion of data loggers with additional interfaces, and wireless signal display using off-the-shelf mobile phones or tablet PCs.

You can find more information about the new FRC EP series at www.ixxat.de

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NEWS

Esterline Connection Technologies – Souriau wins Airbus’ award for best supplier of electrical components and systems for sixth time

Esterline Connection Technologies – Souriau is pleased to announce that, in recognition of its top overall performance, it is the recipient of Airbus’ 2013 Best Supplier Award in the category of electrical cables and components. The award was given during a ceremony held in Toulouse, France, on 15 January 2014. This is the sixth time in eight years that Souriau has won this award.

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n order to determine this year’s award winner, Airbus assessed its suppliers against two criteria – their operational excellence, i.e., logistics, number of returns and quality; and their strategic excellence, or how well their strategy meshes with Airbus’ strategy. Esterline Connection Technologies – Souriau’s selection as winner is the culmination of more than 15 years of efforts by all its teams and recognises the group’s implementation of three strategic areas of development.

The first is its competitiveness. Esterline Connection Technologies – Souriau has had operations in Morocco and India for nearly 20 years and has recently established operations in Mexico. With the acquisition of Sunbank, 37% of its workforce is based in low-cost countries.

The second area is the quality of its supply chain. Operating factories in low-cost countries requires having a well-oiled supply chain.

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The third area is its continual improvement policy, which was also launched 15 years ago and is driven by Kaizen, Lean and QRQC (Quick Response Quality Control) and the cross-organisational deployment of these approaches throughout the group’s operational units. Upon receiving the award from a group of persons consisting

of one representative each from Airbus’ procurement, quality, supply chain and R&D departments as well as a representative of each harness maker of the sqal group, the Esterline Connection Technologies – Souriau teams were asked to present and explain how they achieved their winning level of excellence.

«We are extremely proud to receive this award for the sixth time,» says Jean-Luc Gavelle, President of Esterline Connection Technologies – Souriau. «It is the culmination of the daily commitment of the entire company and of all our teams to total quality and operational excellence and the constant quest on every Souriau site for continuous improvement and innovation.»

Recently, the company’s efforts have also garnered other awards, such as the 2012 Supplier of the Year Award given in June 2013 by Labinal at the Paris Air Show and the Best Supplier Performance – QRQC Award presented by Safran in December 2013.

Esterline’s recent acquisition of the American company Sunbank will strengthen the group’s presence in the USA. Its connection technologies platform, consisting of Souriau and now Sunbank, will allow the group to provide its cutomers with a comprehensive offering of connectors, accessories and conduits.

NEWS

Configure PLCs and machines remotely with Netbiter® Remote Access

HMS Industrial Networks now introduces Netbiter Remote Access into the Netbiter Remote Management solution. Remote Access is a technology that provides an instant, secure communication tunnel to remote equipment, such as PLCs and machines. It allows users to employ their usual PLC configuration software such as Rockwell RSlogix® or Siemens TIA Portal®, just as if they were connected to the machine on site. This makes it possible to instantly take action in case an operational problem occurs and reduces the need to travel to the site.

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The solution provides a secure communication tunnel for PC-based software applications and allows PLC programmers and machine owners to configure, reprogram and debug the machinery from any location saving both time and travel costs while improving customer service.

Simplicity and security “Simplicity and security are the main traits of Netbiter Remote Access,” says Henrik Arleving, Product Line Manager at HMS Industrial Networks. “After connecting the Netbiter gateway to a machine, users can access their machines and be up and running within minutes from any location. This is a much sought-after functionality that will save machine builders, system integrators, PLC programmers and maintenance staff a lot of time and effort, not to mention substantially decreased travel costs.”

How it works Users first connect a Netbiter EasyConnect™ 300-series gateway to their remote device or machine. By running the Netbiter QuickConnect™ software on a computer, a secure tunnel is created to the Netbiter gateway and the device/machine to which it is connected. PLC programmers or machine owners can simply open their regular configuration software (such as RSLogix or TIA Portal) and configure or debug just as if they were on site.

Solid security Data is encrypted both to and from Netbiter Argos and it is also possible to choose a two-step verification method (logging in with a password and also getting an SMS to verify the user’s identity). This ensures secure data connection to the remote equipment. Since the connection is made through the Netbiter Argos, which acts as a routing portal for all communication, there is no need to bother with fixed IP addresses or holes in the users’ firewalls.

The secure connection is established via the cloud-based Netbiter Argos data center. This means that there is no need for opening inbound ports in firewalls or setting up VPN connections on site. The result is a secure connection which is set up a matter of minutes.

Netbiter Remote Access is available as of April 2014.

etbiter Remote Access makes it possible for machine builders, system integrators, OEMs and end users to instantly connect to devices, equipment or machines from any location.

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NEWS

New Beyond™ Medium Roughing Geometry Insert for Stainless Steel

John Tucker (L) and Andreas Haimer (R) sign the agreement to supply Kennametal’s breakthrough KM4X spindle connection throughout Haimer’s global markets.

Unique geometry maximizes smooth cutting and chip flow, minimizes stress

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ew Beyond MR (medium roughing) inserts from Kennametal are a “synergy of geometry and grade,” with smooth cutting action and higher wear resistance among the results.

Tools, it is said, are extensions of man’s ability to work, therefore those that create tools extend the benefits of mankind. With 75-plus years of history making, creating, and further refining tools, Kennametal again adds to the ability of manufacturing customers around the world to further their productivity with the new Beyond™ Medium Roughing (MR) geometry for turning.

Turning more parts per shift or extending tool life is a common “either-or” tradeoff throughout the world’s shop floors. Suitable for a wide range of workpiece materials, but ideal for stainless steels, Kennametal’s new Beyond MR inserts are a product of ongoing design leadership, engineering, materials science, and manufacturing that

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delivers a perfect combination of smooth cutting action and stable edge performance. Faster cycle times and long tool life are the results.

“It’s a synergy of geometry and grade that results in higher wear resistance and smoother chip flow,” says Dr. Igor Kaufmann, senior manager, product engineering, RD&E at Kennametal. Double-sided indexable inserts commonly feature four cutting edges per side with cutting edges facing away from each other.

A chip step consisting of an inlet region and an outlet region usually separates each cutting edge. While these chip steps help to control chip flow and cutting action, the commonly fluted design of incremental inlet and outlet regions tend to be an area of concentrated stresses during cutting, shortening tool life.

The uniqueness of Beyond MR is based in part on designing the geometry of the chip step in a continuous curve so that alternating stresses are reduced.

The radius of curvature of the chip step surface is initially very large, becoming appreciably smaller, constituting the inlet region of the chip step, Kaufmann explains. From the lowest point of the chip step, the small radius of curvature

grows larger, constituting the outlet region. As the surface of the chip step always has a curve, uniform chip forming occurs. Chips tend to deform continuously within the chip step, minimizing the friction of the chip on the tool face.

Rake angle, the incline of the top surface of the cutting edge that makes contact with the chip, also helps control the degree of cutting forces and cutting edge strength.

The Beyond MR insert has a high positive rake angle that works with the smoothly curved cutting edge to reduce cutting forces and extend tool life. “In terms of chip flow, it’s like nothing ever seen before,” says Jan Andersson, senior product manager, turning products.

Indexable double sided inserts, though, subject as they are to high cutting forces, are commonly seen as less stable. Beyond MR’s rake profile without the points of load concentration results in an extremely stable insert body, despite the high positive rake.

Even with high depth-of-cut applications, turning processes are safer and more stable, ensuring lower load on the machine tool and workpiece. Additionally, Beyond MR inserts also feature formed-in coolant channels that deliver flood coolant efficiently to the cutting edge. Improved heat control translates into smoother cutting and extended tool life.

“It’s truly been a question for generations of shops – more parts per hour or more parts per tool,” says Manuel Sedan, senior product manager, turning products at Kennametal.

“Running faster may mean process problems with chip wrapping or longer setup times due to clearing chips from the machine.

Plus the days of one man-one machine are long in the past. With one operator running a cell or any number of machines, greater predictability and performance with tools is an increasingly crucial component for success.

Beyond MR is a truly exciting development that promises higher operating speeds, more pieces per shift, excellent chip control, and long tool life.”

Beyond MR is available in six grades, covering a complete range of applications for turning stainless. Grades are also available for steels and cast irons as well.

For more information, visit www.kennametal.com.

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NEWS

EEC One: Automation of documentation increases engineering efficiency

With its new multi-lingual functionality, EEC One provides even better interaction of automation in the international arena.

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he new version of Eplan Engineering Center One (EEC One) has arrived. Detail engineering and hence engineering times can be drastically reduced with comprehensive frameworks. Now available in 17 languages, the software supports important interna-tional standards and norms for the global market.

What started with English, Spanish, Russian and Chinese at the Hanover Trade Fair in 2013 is now being expanded: EEC One, the automation software from solutions provider Eplan, is now available in all 17 platform languages. The newly integrated dictionary function also ensures direct access to the Eplan diction-ary and hence to translations of the entire documentation of the schematics in all possible languages. At the same time it ensures consistency in the descriptions due to the use of uniform terms, phrases or special characters. Language barriers are removed and the efficiency level of the software usage increased. In particular, interna-tional companies with sites in multiple countries will appreciate this benefit.

Efficient engineering is not only reflected in streamlined, automatic processes but also in the user-friendliness of the software. Furthermore, Eplan continues to use the tried & tested Excel environment with the EEC One, which allows

intuitive use. New colouring supports the error search function. Additionally, in the current version a fixed value can be specified for the position of macros with respect to the predecessor macro. This supports rapid and clear positioning.

The deep connection to the Eplan Platform is also reflected in the integrated parts selection. The EEC One directly accesses the Eplan parts database and transfers parts and their reference data. Transmission errors can be avoided due to the automated data transfer, and efficiency can be increased at the same time. Moreover, the new EEC One version is compatible with the current Eplan Platform 2.3 and the predecessor version 2.2.

Nowadays, efficiency in engineering is no longer a supplementary benefit for most companies, it is necessary to remain nationally and internationally successful.

Software tools that relieve the user from routine tasks are an important building block on the way to the efficient engineering process. This leaves more time for innovative developments and problem solving. Based on the macrotechnology that already offers options for standardisation within the Eplan Platform, the creation of schematics in electrical and fluid power engineering can be automated via EEC One.

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NEWS

New KSSM8+™ Face Milling Platform for Cast Iron

8-sided inserts equal lowest cost per cutting edge

W

ith eight cutting edges, the new KSSM8+™ face milling platform from Kennametal is focused on maximum metal-cutting performance in cast irons and steel workpieces at the lowest

possible cost.

Cutting cast-iron parts is tough and it should be. Cast-iron pump housings, brake calipers, turbine housings, and many other parts are critical foundation components for entire industries, including automotive, heavy equipment, energy, and fluid power.

Achieving the highest level of milling performance at the lowest cost per cutting edge is essential for success.

The IC10 size provides a 9mm (0.354 in.) depth of cut, while the IC 12.7 achieves a 6mm (0.236 in.) DOC. Both have high lead angles (88 degress and 87 degrees, respectively), making them good choices in applications where fixture limitations or part designs call for close to 90-degree shoulders.

More Information 03 | Magazine Industry USA | April 2014

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The double-sided insert design with eight cutting edges provides users with the lowest cost per edge, while the –LD geometry’s positive rake face and honed edges result in

lower cutting forces and good floor finishes in medium and finish machining.

While face milling is a common, everyday metal-cutting task, it is one with many critical considerations. Depth of cut must be balanced against maximizing speeds and feeds for long tool life. High surface finish requirements must be factored into achieving high production efficiencies.

That is why a range of insert grades for the new KSSM8+ platform is available for face milling steels, stainless steels, and wet or dry machining of ductile cast irons. Together with the choice of medium- and fine-density cutter bodies makes KSSM8+ the right solution in addition to the preferred low-cost choice when milling cast irons.

For more information, visit www.kennametal.com.

Order your free copy of our 1,300-page catalogue now at www.nke.at/catalogue NKE AUSTRIA GmbH www.nke.at