A&D Aug-Sep 19

VOL 12  AUG-SEP 2019  ` 100 www.industr.com/en

AUTOMATION & DIGITISATION

ACCELERATING DIGITAL INDUSTRIAL JOURNEY Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong

Actionable insights Enterprise Resource Planing (ERP)

SCADA & Automation (PLC | DCS)

Computerised Maintenance Mgmt. System (CMMS)

Condition Based Monitoring (CBM)

Digital Industrial App

Operation Head FGI Optimisation

Yield / Process Optimisation

Engineering Head Smart Factory

Maintenance Head

Digital Product (Engg. Design)

RCM

Asset Predictive Analytics

Service Transformation

A&D - Interview Axel Schneider, Chief Technology Officer, Schmersal Group (p. 28)

FOCUS Machine Tools

P. 30

Artificial Intelligence

P. 48

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E D I TO R I A L

Staying competitive in downturn!

“It is important to analyse that how economic crises provide an opportunity for companies, industries and the entire nation to restructure production facilities and explore new opportunities”

Consistent focus on innovation and advanced technology adoption is a key driver of technological progress and economic prosperity. The initiatives towards innovation and advanced technology adoption, especially in downturn periods, can affect corporate success, because it improves an organisation’s position relative to competitors during the recovery period. It is therefore interesting to understand that why some companies are consistently successful than others and how do they respond to recession so effectively. It is also important to analyse that how economic crises provide an opportunity for companies, industries and the entire nation to restructure production facilities and explore new opportunities.

However, today’s increasing uncertainty, global trade issues and more binding financial constraints complicate such innovation activity, which also affect the advanced technology adoption initiatives. In this scenario, turning to digital tools and advanced analytics helps to bolster productivity and sustain growth. Look at the automotive industry in India, for example, which has been going through a slowdown phase currently. Both auto OEMs and suppliers, today, have to deal with massive shifts in mobility and digital transformation, apart from managing falling volumes.

Whether it’s slowdown or growth phase, the industry players have to work continuously on their research on new products/variants, new norms, customer behaviour and supply chain upgradation. In this case, digitalisation will become the de facto way of operating along the value chain, and technologies such as advanced automation, AI, additive manufacturing will help reshape traditional processes and achieve the required flexibility to synchronise with the growth cycles.

In short, staying competitive will require investing in new technologies and adapting to changing economic cycles. Moreover, the downturn should be used as an opportunity for renewal and advancement. Let’s keep our fingers crossed and hope for the best!

Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net

EDITORIAL ADVISORY BOARD P V Sivaram Chairman - Non Executive B&R Automation President - AIA (Automation Industry Association) Ravi Agarwal Director Pepperl+Fuchs (Factory Automation) Vice President – AIA (Automation Industry Association)

Jasbir Singh Vice President – Electrical & Instrument Essar Project Management Consultants

Raj Singh Rathee Managing Director Kuka Robotics India

Ganapathiraman G Vice President & GM (South and South-East Asia) ARC Advisory Group

Anup Wadhwa Director – AIA (Automation Industry Association)

Arcot Rajabahadur Automation Consultant

Dr KLS Sharma Advisor Automation Education & Training

Mandar Phadke CEO, Abhisam Software Former Head – Process Control Lanxess India Pvt Ltd Thampy Mathew Chairman, Fieldbus Foundation India Managing Director, Pepperl+Fuchs (Process Automation)

Overseas Partner: China, Taiwan, Hong Kong & South-East Asia

A&D India | Aug-Sep 2019

5

CONTENTS

Market

10

Management

Interview

NEWS 28

14

16

Machine Tools 30

“LAUNCHING INNOVATIONS AS

“A PACEMAKER IN THE CONTEXT OF INDUSTRY 4.0”

QUICKLY AS POSSIBLE”

Interview with Roman Rosswag, Managing Director, Balluff Automation India

Axel Schneider, Chief Technology Officer, Schmersal Group

CNC SOLUTION WITH A DIFFERENCE

The article discusses the system used for drilling holes several metres deep into very tough materials, which enables detection and correction of lateral drill movement

“INDUSTRY 4.0 IS ALREADY A REALITY IN THE

Leadership Insights

PRODUCTION PROCESS”

Interview with Sanjay Kulkarni, Managing Director, Pilz India 17

Focus

20

Start-up

“NEGATING DISRUPTIVE INNOVATIONS WITH EVOLVING TECHNOLOGIES”

Clayton Magleby Christensen, Consultant, Entrepreneur, Author & Professor

“SMES SHOULD CONSIDER AUTOMATION AS AN IMPORTANT PREREQUISITE FOR GROWTH”

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Interview with L R Katrat, Managing Director, Katlax Enterprises

“ACCELERATE TOWARDS MAKING THE INDUSTRY MORE DIGITALLY FORWARD”

Interview with Daniel Raj David, Co-founder, Detect Technologies

Event Report 54

“ROBOTICS MAKING THEIR MARK IN THE

Cover Story

AUTOMOTIVE INDUSTRY”

22

A post-event report on ‘Robotomation – Symposium for robotic automation trends in automotive industry’ in Pune, organised by VDMA Robotics + Automation

UV

Enterprise Resource Planing (ERP)

SCADA & Automation (PLC | DCS)

Computerised Maintenance Mgmt. System (CMMS)

Condition Based Monitoring (CBM)

Digital Industrial App

Operation Head FGI Optimisation

IR

Yield / Process Optimisation

Engineering Head Smart Factory

Digital Product (Engg. Design)

Maintenance Head RCM

Asset Predictive Analytics

Service Transformation

ACCELERATING DIGITAL INDUSTRY JOURNEY – ACTIONABLE INSIGHTS

The modern-day organisations deem digitalisation to connect the silos to overcome various obstacles, like unplanned downtime, process variations and more. The cover story explores potentials of digitalisation, factors hindering its adoption, its future, how it will conceivably transform the entire industrial ecosystem, and the need for an outcome driven consulting in this area.

Expanding the field of vision

CONTENTS

Advt

Technology

Industrial Maintenance 34

OPTIMISING PREDICTIVE MAINTENANCE THROUGH

Artificial Intelligence 48

ARTIFICIAL INTELLIGENCE –

DIGITAL TWIN – THE WHY AND HOW

THE DRIVING FORCE OF INDUSTRY 4.0

The article explores ways to have an automated predictive maintenance, a few benefits from using digital twin for predictive maintenance, challenges in the digital twin creation and recommendations to build a reliable and accurate digital twin

The article corroborates on Artificial Intelligence aiding the Industry 4.0 model, and how this powerful technology is already being used in the industry to drive efficacy, advance quality and successfully manage supply chains

New Products 61

Lubrication-free two-component bearing; Control cabinet inverter; Double clamping vises; Multi-code readers

62

New smart probes with additional features; Intelligent UPS system; Safe sensor technology

63

Comprehensive image processing in PC-based control system; Motion control software; Cables for the rail industry

Wires & Cables 38

The article explores the evolution of the Ethernet, its real-time capabilities and the trends in the Ethernet cables

Wireless Automation 42

Event Report

ETHERNET BECOMES SLIMLINE & REAL-TIME CAPABLE

ADDING WIRELESS COMMUNICATION TO

58

“SUCCEEDING IN THE DIGITAL TRANSFORMATION JOURNEY”

A post-event report on the 17 th India forum on ‘Driving Digital Transformation in Industry and Cities’ in Bengaluru, organised by ARC Advisory Group

Columns

VIBRATION MONITORING

05

The article explains how transmitting vibration monitoring data via wireless networks makes continuous monitoring of rotating equipment more practical & cost-effective

06 08 64 64

Editorial Contents Guest Editorial Highlights – Next issue Company index

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INTEGRATED MACHINE VISION More than embedded Complete portfolio: www.br-automation.com/vision

Atul Dave

MANAGING DIRECTOR SICK INDIA

The automation industry does not exist on its own but is a reflection of how the Indian industry incorporates more use of automated machines. The need for automation started initially, largely to improve efficiency and productivity and to avoid human intervention in a risky work environment. Today, its scope has been enlarged, enhancing working conditions, along with rising the civic sense to pollute less and protect our environment.

The current trends, which are quite visible, are the prolific use of ‘sensors and controls’ in almost all the machines used in all types of industries. Quality control is the most interesting field of automation today. More industries are now deploying vision sensors, 2D & 3D cameras and bar code readers to ensure that the right component or product is shipped to the right customer. Vision sensors ensure that any defect in the goods produced are detected before they are shipped and corrected at the manufacturing plants.

Though it is quite new, I foresee that more industries will embrace 8

COMMENTS & COMMENTARY

GUEST | EDITORIAL

“WE HAVE TREMENDOUS SCOPE FOR DEPLOYING MORE ROBOTS” new concepts – Automated Guided Vehicles (AGVs) or Automated Guided Carts (AGCs). The advent of latest technologies in the field of LiDAR sensors and localisation software, along with complex algorithm for efficient route mapping of AGVs, make it the most inevitable tool in the large scale automated warehouses in the e-commerce industry.

However, the efficiency and reliability of the AGVs with reduced cost over a lifecycle make it an attractive choice for other industries, too. The work force required doing the monotonous repetitive work of moving bulky and unwieldy components inside a factory or warehouse can be eliminated entirely by using such AGVs. The anti-collision sensors complying with stringent safety levels make it the industry’s most reliable assistance, besides robots.

Talking of robots, I see that we have tremendous scope for deploying more robots, particularly in the automotive and consumer goods industry. Most of the automotive industry now uses robots in its production lines, particularly in welding and assembly operations, packaging, loading & unloading of goods etc. We will see in the future that the Indian industry will use more robots.

It is now safer to work with robots since safety sensors, along with safety control system, ensures that the hazard is avoided in all working conditions and safety of human and machinery is guaranteed all the time. Moreover, with new software and advanced sensors, more people are talking about collaborative robots.

The use of data generated by sensors mounted in machines in the industry and making sense out of this data will be the future of automation in the Indian industry. Industry 4.0 is nothing but collecting data, analysing it based on the customer’s need – be it predictive maintenance, predictive quality or improving productivity. With this background, automation in the industries will ask for ‘sensor intelligence’. ☐ A&D India | Aug-Sep 2019

MARKET | NEWS

Emerson helps drive 60% production increase at BPCL refinery Emerson Industrial Networks AB (publ) recently announced the completion of the Bharat Petroleum Corporation (BPCL) Kochi Refinery upgrade. Throughout the project, the company provided engineering and project management services as well as automation technologies that helped BPCL in its goal of increasing the production capacity from 9.5 million to 15.5 million metric tonnes per annum. BPCL leveraged Emerson’s Plantweb digital ecosystem to modernise plant operations for greater production and continuous, safe operations. This refinery utilises the company’s wireless sensing technology. The Ovation™ control system helps BPCL manage the refinery’s electrical load to optimise operational efficiency and safety. Discussing the value an advanced digital automation technologies can bring to the Indian refining sector, Anil Bhatia, VP & MD, Emerson’s Automation Solutions business in India, cited, “This critical foundation of process control will help improve production, operational efficiency and safety and prepare BPCL for the next steps in its digital transformation journey.”

Sectigo partners with NetObjex to protect the Edge of IoT Sectigo recently announced a secure edge computing technology pact with NetObjex. The collaboration provides enterprises and manufacturers with a secured, trusted computing infrastructure that extends from IoT edge devices to the cloud and blockchain. This partnership brings to market products and solutions that comprehensively address problems, reducing the risk of security compromises to data and firmware logic. This enhanced security fulfils a growing need in the market as enterprises increase investments in IoT, AI, and blockchain, which all thrive on clean, pristine data. Discussing the strength of the partnership, Damon Kachur, VPt, IoT Solutions, Sectigo, said, “By teaming with NetObjex, Sectigo is securing devices’ firmware, data and communication, protecting against a variety of botnet attacks like Silex and Mirai, and ensuring the secure bi-directional transmission of data. We are protecting against data loss and device takeover attacks, enabling OEMs to achieve compliance with regulatory frameworks, including NIST IoT Cybersecurity requirements, GDPR, IEC 62443, and the FDA Cybersecurity guidance for medical devices.”

B&R to present advanced automation technologies at Automation Expo 2019 B&R will be participating in the Automation Expo 2019, sheduled to be held in Mumbai, on September 25-28, 2019. The company will be presenting cutting-edge technology and solutions enabling smart manufacturing. OEMs and manufacturers are searching for flexible, responsive manufacturing solutions to achieve smaller batch sizes with frequent and quick changeovers. Visitors at the expo can experience a revolution in product transport for adaptive manufacturing, which offers flexibility and usability.

Machine vision system At the expo, the company will highlight its machine vision system, a solution enabling machine builders to integrate vision application in existing automation systems. The portfolio includes intelligent cameras, quality lenses, flexible lighting and image processing algorithms.

The solution is being used in product inspection and position detection, raw material, quality, process and label inspection, presence check, and registration mark inspection to achieve high quality and efficacy. Also, the company’s SuperTrak and ACOPOStrak redefines production economics and equipment effectiveness. Its design delivers technological advantages for adaptive, connected manufacturing by producing small batches efficiently and benefit from higher margins in personalised products.

Complete system with consistency Similarly, the edge architectures from the company make life easy for factory operators and plant owners by providing a variety of options tailored to their requirements. Edge Connect allows them to gather data directly from sensors and actuators in the field, which can then be shared securely with any cloud platform using the open-source OPC UA protocol. Edge Embedded provides basic intelligence, trends, reporting, data aggregation and the possibility of viewing data locally on the shop floor, while Edge Controller provides factories with comprehensive on-site analytics, business intelligence and machine learning. These two can also be equipped with energy and condition monitoring tools.

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A&D India | Aug-Sep 2019

NEWS | MARKET

Digitalisation is a key topic at EMO Hannover 2019 The growing importance of digitalisation is a key topic at EMO Hannover 2019. The “IoT in Production” exhibition area offers a complete overview of key aspects of digitalisation, such as industrial security, data analytics, industrial cloud services, process monitoring, predictive maintenance, Artificial Intelligence (AI), machine learning and Big Data management. In its new umati (universal machine tool interface) brand, VDW (German Machine Tool Builders’ Association) is developing an open interface standard for connecting machine tools to higher-level IT systems. This significantly simplifies digitalisation and allows medium-sized companies to tap into the potential of modern production environments. This will be demonstrated in the form of a complex showcase at EMO Hannover 2019. VDW’s umati, based on OPC UA, aims to ensure that data from machines equipped with different control systems is routed through an open, standardised connection.

Siemens builds Protection Automation & Control Laboratory for POWERGRID Siemens recently set up the Protection Automation & Control Laboratory, a part of POWERGRID Advanced Research and Technology Centre (PARTeC) for Power Grid Corporation of India (POWERGRID) Manesar, Haryana. The laboratory has been designed to be used for advanced studies and research on digital substation technologies, multivendor interoperability studies, conformance tests of servers, clients and engineering tools, cyber security-related vulnerabilities and patch management activities, network optimisation tests and studies, training and competency building. Commenting on the set-up, Robert Demann, Head—Smart Infrastructure, Siemens, quoted, “The capability spectrum of research and technology development of PARTeC has expanded due to addition of the Protection Automation and Control Laboratory. This is a key milestone in India’s journey towards reliable power and widespread installation of digital substations. Together, Siemens and POWERGRID are envisioning the future of energy in India, especially for the power transmission landscape.”

C4i4 organises seventh edition of ‘C4i4 Knowledge Club’ C4i4 Lab, Pune recently organised the seventh edition of ‘C4i4 Knowledge Club’. The event got the head-start with an opening note by Dattatraya Navalgundkar, Executive Director, C4i4 Lab, Pune, followed by a brief introduction about the company by Sagar Bhosale, MD, Schmersal India. Then Axel Schneider, CTO, Schmersal Group, focused on ‘Safety/Industry 4.0’ and concluded with a vote of thanks. While addressing the opening note of the event, Navalgundkar, said, “We have done a few good things in the industry in last 6 months. As the technology is changing dramatically, it is not easy to predict what is about to come next.” He added, “We have created our own ‘Digital Maturity Model’, which has changed our definition of Industry 4.0. This is something we have done at the ground-level. Also, we have started ‘Digital Champions Program’ which creates middle management leaders for digital transformation within the factories. Similarly, we take safety for granted, which should not be so. Hence, Safety 4.0 will be a right idea to talk about, which will lead us to take some action in this regard.”

Introducing the company, Bhosale cited, “This is a family-owned company, mainly focusing to be a solution provider for safety. There are 3 different verticals in the company, namely, safety service, industry solution and safety products.” He further added that the company is trying to create awareness and a mindset of the people in India for considering Safety 4.0. “The standards adopted by Bureau of Indian Standards (BIS) will have a reference to where we stand in terms of standards and where we need to go ahead,” he said and went on, “presently, 32 ISO machine safety standards are adopted and printed by BIS. Plus, regulatory framework from Government of India is under discussion.” Taking the discussion forward, Schneider averred, “Industry 4.0 is the vision of a production environment in which logistics and machines organise themselves with minimal human intervention. Some of the design principles of Industry 4.0 are: Interconnection, Information transparency, and Technical assistance.” He further added that, safety in the era of Industry 4.0 is popular as Smart Safety 4.0, which has future challenges like, mobile machines, smart and dynamic protective fields, self-learning robots, intuitive man – machine communication and safety and security integrated.

A&D India | Aug-Sep 2019

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MARKET | NEWS

Rockwell Automation 2019 TechEd India presented opportunities in Industry 4.0 Rockwell Automation recently conducted the Rockwell Automation 2019 TechEd India with participation from 300+ attendees from 120+ companies, witnessing 70+ sessions, including thought provoking keynote presentations, expert-led technical sessions, interactive hands-on labs, and demonstrations to learn about the latest techniques and technologies to optimise production data and build secure networks to transform their business. In order to help Indian manufacturers bridge employee 4.0 industry skill gaps the company announced e-learning and instructor-led courses to certificate programs and training workstations to partner companies.

TechEd 2019, which was designed for end-users, systems integrators, distributors, partners and machine builders, created opportunities for participants to learn from industry experts and hear how their peers are solving manufacturing and production challenges. The sessions focused on data analytics and on the convergence of IT/OT to achieve smart manufacturing by capturing industrial data. The event also provided attendees with the latest innovations in mobility and virtualisation, information management and analytics, as well as safety and security.

Speaking at the premier industrial technology training and education platform TechEd India, Dilip Sawhney, Managing Director, Rockwell Automation India, said, “India Inc is witnessing a shift towards smart factory shop floors designed to boost productivity, improve quality, and optimise costs to help companies stay competitive. However, we are also staring at a huge skills gap in the country’s workforce when it comes to operating Industry 4.0 technologies. This must be addressed at both the corporate and government policy levels to accelerate India’s digital transformation and achieve our collective vision of becoming a $5 trillion economy by 2024”.

The event began with an informative keynote presentation by Joe Bartolomeo, Vice President, Enterprise Accounts & Software Sales, Rockwell Automation, that highlighted the importance of investing in smart manufacturing and production to remain competitive on a global scale. He explained that with a growing consumer market demanding more choice, manufacturers needed to embrace new technologies to address changing requirements. Industrial IoT is estimated to have an economic impact of 4.6 trillion dollars by 2025 as new technologies including analytics, mobility, app platforms and the cloud, help securely connect plant information with enterprise systems.

“In addition to investing in the right technology & systems, businesses also need to invest in people right now to build the workforce of tomorrow. To make the Industry 4.0 enabled Connected Enterprise a reality, we first need to start creating a pipeline of skilled problem solvers, builders, makers, and innovators. It is towards this goal that Rockwell Automation will continue to partner with industry and academic organisations in India and across the region,” emphasised Bartolomeo.

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A&D India | Aug-Sep 2019

MARKET | INTERVIEW

“A pacemaker in the context of Industry 4.0” … says Roman Rosswag, Managing Director, Balluff Automation India, in this interaction with Anvita Pillai, on occasion of the inauguration of the new Balluff Automation India centre in Pune.

He confers on how the new centre will aid market development, their role in the ‘Make in India’ movement and more. Excerpts…

Balluff has been in the Indian market for almost 30 years. Now having its own base in India, how do you think it will strengthen the company’s position further in the Indian market?

To have an own subsidiary is always beneficial to look at the market development, as well as to execute the company’s global strategies considering the local needs. India is one of the key markets for Balluff in the Asia Pacific region. With the start-up of Balluff Automation, India, we are now able to provide services to the Indian and foreign invested enterprises. This means we have direct and close contact with our customers and can understand their needs in the best possible way. Pune was the perfect location to dive into the fast-developing technological sector. With further representative offices and an own supply chain centre in Mumbai we can demonstrate a strong commitment to the Indian market.

We came across the news of Balluff India planning to be a part of ‘Make in India’ movement. How does Balluff plan to move ahead in this direction?

Balluff aims to be a partner in the ‘Make in India’ movement and bring added value to local manufacturing capabilities. We want to support companies that invest in Indian production facilities with a strong global approach. Till now, we didn’t have our own production facilities in India. With the establishment of the Technical Knowledge Centre in Pune we are focusing on application and solution support, as well as strong after-sales service to add value to the Indian manufacturing market.

Can you brief us on the IO-Link introduced by Balluff India?

How does it benefit the Indian market?

Balluff understands itself as pacemaker in the context of Industry 4.0 and provider of machine data to be able to set up intelligent and integrated systems. IO-Link is a key communication therefore, and Balluff was one of the first companies introducing this to the market in a larger scale.

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IO-Link itself is a point-to-point bidirectional intelligent communication to have process data available or to set parameters on the fly. Users benefit with increased efficiency, machine uptimes, extended decentralised parametrisation and much more, for example, produce in smaller lot sizes while keeping the same level of efficiency. We, therefore, provide all kinds of different sensors and solutions, like inductive sensors, power supplies, RFID and even high-tech vision systems.

Which are the industry sectors under focus for Balluff? What would be the growth drivers going further for your company?

Our global focus industries are mobility, machine plant engineering, packaging, food & beverage. While extending our core business in India looking on the local automotive market, we are now gaining market share in the packaging, food & beverage market.

India, with a population of 1.4 billion people, shows an increasing demand for automated machines in this sector. Moreover, we’re focusing on the steel market. Since decades, we have been developing special hightemperature and robust portfolios to place our products in the rough steel plants. India, as the world’s second largest steel producer, represents a big potential.

What kind of potential do you see for your products/ technologies in the Indian industry? Can you highlight your short-term and long-term plans?

We do see a strong growth in the fields of machine vision, RFID, safety and connectivity products. These technologies are not just hardware components but require a complete understanding of the situation and environment on customer site. For that, we are geared up to provide an intensive on-site consultation. Our Technical Knowledge Centre will support our customers to implement new technologies in a very fast way. To meet mid and long-term special requirements of the food and beverage processing industry we will have an increasing amount of washdown, hygiene and eco-lab products in the future. ☐

A&D India | Aug-Sep 2019

MARKET | INTERVIEW

“Industry 4.0 is already a reality in the production process” … cited Sanjay Kulkarni, Managing Director, Pilz India, in his conversation with Anvita Pillai; wherein, he discusses the evolving automation industry, progress in safety and security adoption, the journey of Pilz India and furthermore. Excerpts...

How according to you has the automation industry grown over the years and do you think that the Indian market is ready to adapt to this evolving industry?

In the last two decades, technology has evolved and transformed the nature of the manufacturing industry. Digitalisation and IoT are playing an important role in industrial automation.

Industry 4.0 transforms the idea of smart factory’s connectivity within factories, suppliers and customers into reality. It will be important, and the Indian market should be ready to adapt to these requirements. It is no longer just an initiative, it is already a reality in the production process, and we feel this is also a need of the Indian market. The Indian industry should explore these changes and invest in latest technologies in order to adapt these changes Safety and security are of upmost importance in your industry but it is often taken lightly. How does your latest product, PSS4000 system, prove as a solution for safety and security?

Since its inception, Pilz India has worked very hard for creating safety awareness in the Indian market. Initially, cost was the most sensitive factor for the industry, but now people are moving towards adopting safety and security.

Communication with each other, information on work pieces, and self-organisation; these are the three important factors of a modular and decentralised structure of smart factory.

And for this, Pilz offers its customers fool-proof automation solutions for Industry 4.0. The PSS 4000 automation system is the ideal solution for smooth production and that includes project safety and automation. We always guarantee the safety of humans and machines without compromising the security.

Which are the industries under focus for Pilz in India? Where is the maximum business coming from?

We offer solutions to diversified industries. Our major focus

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is on OEMs like robotics, packaging, wind energy, metal processing and other machineries. When it comes to the end users, automotive, food & beverages, health care and process industry are the focus sectors of Pilz India. We get our maximum business from automotive, food & beverages and pharmaceutical manufacturing.

Could you tell us about some of the noteworthy projects accomplished by Pilz during its journey in India?

Under the motto of ‘We automate, safely’, Pilz India since 2011, has completed many projects in India as well as in Asia. We have offered services of complete safety life cycle to a gear manufacturing company for 70+ machines, safety upgradation of various machines to pharmaceutical manufacturer, automation of press line in automotive industry, assessment and validation of new production line for a food & beverage plant (from procurement to production), automation solution with PSS 4000 for a rubber manufacturing line and tyre manufacturing line. Apart from these projects, Pilz has also completed CE marking of production lines for gear box assembly, clutch assembly, duel mass flywheel assembly and many more.

What is in store for the future of Pilz? What would you say are your short-term and long-term plans?

Considering latest automation trends, we are aligning ourselves with products as well as services. We have already entered into Human Robot Collaboration (HRC) with services and products.

Offering this to the Indian market is our top-most priority in addition to the PSS 4000 automation systems. At Pilz India, technology leadership and professional competence is our priority and we will invest more into this and grow with the changing industry trends. ☐

A&D India | Aug-Sep 2019

MARKET | INTERVIEW

“SMEs should consider automation as an important prerequisite for growth” …says L R Katrat, Managing Director, Katlax Enterprises, in an interview with A&D India.

He also elaborates on how his company is coping up with the change the digitalisation technologies are bringing in and automation strategy for SMEs. Excerpts…

In one of the blogs from your company, it was mentioned that Katlax is in the midst of a new automation boom that promises to fundamentally transform how manufacturing is done.

Would you like to share more details with us on this?

We are transforming from conventional machinery to automated machinery for continual mass production for better output and higher productivity, which is doing more than we expected, impacting individuals and businesses, in many instances without even being noticed. A new generation of robots, which are user-friendly and flexible, usher the SME sector in an era of human-robot coexistence in the workplace. Especially for small and mid-sized manufacturers, a question is arising sooner than most probably expected: “If prices keep declining and capabilities of robotic technologies keep expanding, is it now the time to hire some automated help?” Indeed, many have already answered this question.

According a PwC survey of manufacturers, 59% of SMEs are already using some sort of robotics technology.

What are the current trends and new applications in the integrated automation solutions?

The three biggest trends to influence the industrial automation control market from 2016 to 2020, according to a new report released by international market research company Technavio, are cloud-based SCADA systems, increased use of analytics and growing use of programmable automation controllers (PACs).

What should be an ideal automation strategy, especially for SMEs, in today’s uncertain economic conditions?

As machines increasingly complement human labour in the workplace, we all need to adjust to reap the benefits. Automation and Artificial Intelligence (AI) are transforming businesses and will contribute to economic growth by improving productivity.

At the same time, these technologies will transform the nature of work and the workplace itself. Machines will be able to carry out more of the tasks done by humans, complement the work that humans do, and even perform some tasks that go beyond what humans can do. As a result, some occupations will decline, others will grow, and many more will change. In the fourth industrial revolution, or as many call it, Industry 4.0, rapid advances in

A&D India | Aug-Sep 2019

technology are upending business models, blurring lines between industries and companies and demanding an entirely new way of thinking about business.

The SME sector in India has emerged as a highly vibrant and dynamic sector of the Indian economy over the last five decades. It contributes about 8% to GDP, besides 45% to the total manufacturing output and 40% to the exports from the country, which has the potential to spread industrial growth across the country. With this and looking at the trends mentioned earlier, the SME sector should consider automation as an important prerequisite for the industrial growth in today’s uncertain economic conditions.

With digitalisation coming in a big way, what are the initiatives from your company in this area, to cope up with the change?

Digital transformation is forcing companies to change their business models and adapt to the new market reality. Today, customers expect relevant content in relation to what they’re doing anytime, anywhere and in the format and on the device of their choice. It’s their journey that dictates your strategy. Katlax has been already in-line with digitalisation and adopted digital technologies like B2B sales, social media selling, Google adds, blogs, flexible IT environment and more.

Where do you see the major growth coming from for your company’s business? Which are the industry sectors under focus?

Our major growth comes from export market and our focused industry sectors include OEMs and online distributors. Industry 4.0 describes the trend towards automation and data exchange in manufacturing technologies and processes which include cyber-physical systems (CPS), IoT and IIoT, cloud computing, cognitive computing, artificial intelligence and analytics.

Katlax is focusing on connectivity systems in these areas, like M12 A-coded connectors for sensor/actuator application, M12 B-coded for Profibus applications, M12 D-coded connectors for Profinet applications, data transfer up to 100 Mbps and M12 X-coded connectors for Ethernet/EtherCat applications, data transfer up to 10 Gbps. ☐

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S TA R T- U P | I N T E R V I E W

“Accelerating towards making the industry more digitally forward” ... says Daniel Raj David, Co-founder, Detect Technologies, in his conversation with Anvita Pillai.

Herein, he discusses the technologies patented by Detect, the concept behind forming the company, how it is assisting in the betterment of the industry, the industries they are venturing into and more.

What was the concept/idea behind establishing Detect Technologies? What were the challenges faced during the early inception years?

The concept behind starting Detect was that we wanted to build patented technologies to do both, people and asset integrity monitoring across the industry. During our graduation from IIT Madras, we realised that there is abundant technological talent in our country, but most of them go and work abroad. With Detect, we wanted to retain talent and build co-patented technologies.

We wanted to make the oil & gas industry much better from the digital and technological perspective. As for the challenges, the industry wasn’t technologically advanced until very recently. So, there was scepticism towards accepting new technologies and they didn’t want to take a risk. Also, the industry is very capital intensive and considering that we started Detect in our college days, the funding was also a bit of a hinderance.

The usual practices in industries are run by complex processes and gigantic equipment that are expensive and unsafe as well. How do the products offered by you aid in overcoming the long-standing challenges faced by the industry?

In the oil & gas industry, the returns are high, but the risks are also higher. If you have leakages, it can lead to environmental damage; production loss per day is almost $2 million and worst of all is safety, which can be hazardous because of the protocols not being followed. Our range of technologies works towards extending the life of a plant accordingly. For example, our patented sensor can do complete pipeline monitoring in real-time, even in high temperatures, and it is the first in the world to do so. It solves the universal problem of pipeline and pipeline leakage and gives one real-time data and exact information on when the pipe might fail.

We have also built drones that can do a complete inspection of these structures and safety monitoring of people as well.

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What are some of the major achievements of Detect till date? Is there any noteworthy success story of yours that you would like to share with us?

I think our biggest achievement is that we have been fortunate enough to be prevalent and widespread in an industry that was once upon a time technologically constrained.

Aside from this, we are now present in the almost all oil syndicates in India and are working simultaneously for sectors, like mining, chemical, etc. We have raised a funding of almost $4 million and have partnered with some of the major companies like Reliance Industries, DMPL and more. We have nearly 13 R&D departments headed by some of the best minds in India and our technologies are getting deployed internationally as well. Currently, we are scaling up to other markets across the world.

Which are the current industries that you cater to and which are the ones that you wish to expand your services to in the coming years?

Beside oil & gas, we are currently scaling into steel, cement, fertiliser, petro-chemicals, chemicals and renewables.

Basically, any process industry for that matter can operate our products.

What is the mission and vision of Detect Technologies?

Where does the company see itself in the next five years?

Our mission & vision is to revolutionise the process industry sector by focusing on both the key components, assets and people.

We will continue to build patented innovative technologies and accelerate towards making the industry more digitally forward.

In the next five years, I see us having a plethora of products and being present in all the process industries/sectors all over the world. We see ourselves being a global leader in technology in the coming years. ☐

A&D India | Aug-Sep 2019

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LEADERSHIP INSIGHTS

Negating disruptive innovations with evolving technologies Clayton Magleby Christensen CONSULTANT, ENTREPRENEUR, AUTHOR & PROFESSOR

Famous for his theory on ‘disruptive innovation’, Clayton Magleby Christensen detected the most intractable problem in all capitalism of why great companies die and what leads to its losses and eventual death.

Spindly and soft-spoken, Christensen tries to put through the messages with a dry wit that would efficiently impart the message without being very devastating. Gauged amongst the top experts on innovation and growth, he has served as a director for various companies and helped them generate tens of billions of dollars in revenue each year by offering guidance on products and service innovations inspired by his research.

Post completing his MBA from Harvard University, Christensen began working as a consultant and project manager for the Boston Consulting Group in 1979. After three years of brief stint there, he moved on to work in Washington DC as an assistant to the US Secretary of Transportation.

Post two years of service as an assistant, Christensen proceeded and began his own advanced ceramics company with several professors from Massachusetts Institute of Technology and served as the CEO there through the 80s; post which he returned 20

MOTIVATION IS THE CATALYSING INGREDIENT FOR EVERY SUCCESSFUL INNOVATION. THE SAME IS TRUE FOR LEARNING. to Harvard to pursue his doctoral study in business administration.

His famous work ‘disruptive innovations’, advocated the process by which new products or systems compete for the lower end of a market, then compete successfully with established businesses by enhancing in quality. His works also professed that leaders can respond to such “disruptive innovations” by focusing on their organisation’s core task/goal, while down the road simultaneously try to figure out better ways to achieve success. Even though technology available to get the job done has changed quite dramatically, the job itself remains quite unchanged. It is necessary for leaders to adopt the evolving technologies before the

old one is obsolete. It is also essential to set up a separate business unit to pursue new technologies to cultivate it and build it for easy adoption through the entire process. He accentuated, “Motivation is the catalysing ingredient for every successful innovation. The same is true for learning.”

His works conveyed that irrespective of whether a company is successful for decades with established products, it can get pushed aside in the market if managers don’t know when to abandon traditional practises. Christensen cited, “To succeed consistently, good managers need to be skilled not just in choosing, training and motivating the right people for the right job, but in choosing, building and preparing the right organisation for the job as well.”

Anvita Pillai SUB-EDITOR & CORRESPONDENT A&D India | Aug-Sep 2019

C O V E R S TO R Y | T E C H N O L O G Y

ACCELERATING DIGITAL INDUSTRIAL JOURNEY Actionable insights

Enterprise Resource Planing (ERP)

SCADA & Automation (PLC | DCS)

Computerised Maintenance Mgmt. System (CMMS)

Condition Based Monitoring (CBM)

Digital Industrial App

Operation Head FGI Optimisation

Yield / Process Optimisation

Engineering Head Smart Factory

Digital Product (Engg. Design)

Maintenance Head RCM

Asset Predictive Analytics

Service Transformation

With the advent of the fourth industrial revolution, digital technologies are enabling operational optimisation and are adopting automation and intelligence within processes. Modern day organisations deem digitalisation to connect the silos to overcome obstacles, like unplanned downtime, waste, process variations and more.

The cover story explores potentials of digitalisation, factors Sayantan Roy, hindering its adoption, its future and how it will conceivably Global Head, Digital Industrial transform the entire industrial ecosystem, and the need for an Consulting & IIoT, Tata Consultancy Services sayantan.roy1@tcs.com outcome driven consulting in this area.

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A&D India | Aug-Sep 2019

T E C H N O L O G Y | C O V E R S TO R Y

Real GDP growth (Annual per cent change)

There has been a lot of advancements in the field of industrial automation & technology over the decades especially during the last three industrial revolutions. The economy has grown over the years but at the same time, there has been an increase in the competition. Organisations realised the need for managing growth and delivering sustainable business performance.

However, the sudden downturn of economy in 2008 has upset the plans of many and suddenly there were over-capacities across the industry. Although the economy has recovered since then, it has made organisations realise the importance of optimisation within their operations. The cost of unplanned downtime, inventory, waste, energy and so on have become more expensive than ever before. This marked the need for the 4th industrial revolution which primarily intends to leverage evolving digital technologies, like industrial IoT, to avoid such deterrents and make operations more predictable. Capital expenditure has taken a back seat for a while, with the focus being more on utilising the existing capacities and unleashing the capital/resources hidden within the operations.

Deriving business outcome before technology adoption Organisations have adopted various technologies/products which have provided significant level of automation and intelligence already. But still, there have been surprises in industrial operations which one can ill afford in the current competitive market in a not so growing economy. Organisations have become very cautious in making further investments in products/technologies unless and until they are sure of the outcome with a shortest payback period.

They are looking at filling up the silos which are still existing,

A&D India | Aug-Sep 2019

despite their substantial investment in products and technologies. Modern day organisations expect digitalisation to be the thread which can fill up the gaps and connect the silos to overcome the bad actors, like unplanned downtime, waste, process variations and so on. They do not want another product/ technology whose features are generic and not clearly aligning to the business need. The CIO/CDOs of the world are making their intent amply clear that they are not willing to invest on anything which is ‘nice to have’, but not a ‘must have’. They are being equally challenged by the business stakeholders to implement solutions delivering a business outcome.

Need for outcome driven consulting – discovering use cases of transformation Advisory level strategic consulting has been prevalent in the industry for quite some time. Organisations have derived benefit and have high regards for such consulting firms. But for adoption of digitalisation, they are expecting consulting which can encircle the total journey starting from the discovery of the use cases which can drive business outcome & ROI, the solution blueprint and finally implementation followed by adoption leading to realisation of the envisaged benefit. This challenges the basic taxonomy of the players serving the industrial market in various forms. Typically, the advisory level consulting is followed by the recommendations which are fulfilled by the respective solution providers typically the OEMs & product companies. The scale-up is then done through the System Integrators (SIs) typically the IT service providers. But the current expectation of the industry on digitalisation, challenges this segregation and expects a complete ownership from discovery of the use cases up to fulfilling the outcome realisation.

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C O V E R S TO R Y | T E C H N O L O G Y

Global non-financial corporate capex growth

This is driven by the lack of confidence from the end user on whether the offered technologies would be able to fulfil the business outcomes envisaged. The consulting has to be done by a team of experts who are not only well-versed with the understanding of management goals but are also able to leverage the various technologies to design and implement solutions which can derive the expected business outcomes. In other words, a team which can connect all the dots and becomes the single window of engagement for the customer. This can be achieved by a combination of experts who have industry domain of operations, maintenance, digital technologies and also have a good understanding of the overall industry business process.

Digital industrial apps – The crystal ball So, how should digitalisation-enabled industries look like & what should be their deliverable? As explained earlier, the customers expect digitalisation to fulfil the gaps & connect the silos across their existing systems. The gaps may be fulfilled by providing contextual visibility or AI driven analytics or a digital thread which ensures flow of information between the systems.

But the key deliverable of apps needs to be an actionable insight on near real-time basis maximising and integrating the data generated from the existing systems. In other words, a single pane of glass equivalent to a ‘crystal ball’ which can connect people, data and machines together to drive the desired business outcomes. Such apps differentiate from a typical product approach, which are sometimes generic, along with overlapping functionalities compared to the existing systems. The apps have to be designed for a customer on the basis of consultative assessment, which can fulfil the ‘delta’ or ‘gap’ in the existing automation footprint needed for an enterprise to deliver a

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specific outcome. Thereby, complimenting the existing automation system to become more effective.

For instance, maintenance engineers are typically governed by the CMMS and also derive a lot of insights from conditionbased monitoring enabled through frequent inspections. But even then, there are unplanned downtimes which are very costly. The need is of a system which can provide data science driven early warning advisories which can detect the anomaly at an early stage ahead of the CMMS and condition-based monitoring. The important point in this case is that the ‘delta’ or the ‘gap’ is the need of a system which can provide actionable insights at an early stage complimenting the existing CMMS and condition monitoring system. This can in turn improve the effectiveness of the maintenance personnel in avoiding downtime and also reduce maintenance cost. Such a system is also called a ‘digital twin’ of an equipment or a process.

Disruptive business models The customers are shying away from a Capex-based investment for IT/digital technology, spending and preferring an Opex-based investment. They would like to measure the outcome of the investment on quarterly basis with a flexibility of an exit if the desired outcomes are not met. Moreover, technological advancements are occurring at a pace faster than the companies can digest. A Capex would mean to remain stuck with a technology for a longer period even if at a later point it does not provide the envisaged benefit for an organisation.

While, Opex offers the flexibility of a changeover aligning with the company’s need, what it means for the market players is that the development cost has to be borne by them and cannot be passed on. In other words, one needs to offer a SAAS model.

A&D India | Aug-Sep 2019

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C O V E R S TO R Y | T E C H N O L O G Y

Global non-financial capex growth by sector in 2019

The SAAS model is quite accepted in the B2C world which has adopted an app-driven culture already with the advent of smart devices based on android or IOS. Such an evolution is not so easy in an industrial environment, which deals with equipment and processes, where internet enablement is still evolving. What it also demands from the market players is to develop apps on use cases, which are repeatable across the industry, to derive a desired benefit of scale resulting into a sustainable business. On top of this, people are also grappling with the aspect of sensors.

Implementing sensors in aging equipment is not easy without the OEMs support.

While it is true that some equipment are black boxes where one cannot proceed without putting additional sensors but there are also many equipment where data driven models can still be developed with existing set of sensors. But in either case, the physics of the equipment/process needs to be understood by the app development team. We need to be clear while selecting an equipment/process whether the cost benefit ratio of implementing sensors would make sense. There are certain wireless sensors available in the marketplace which can be installed in any rotating equipment without disrupting the existing wiring or installation. All the above factors are a major showstopper in accelerating adoption. There are quite a few pilots being done which is encouraging, but still the market is at a nascent stage of adoption.

Some of the customers / end users are putting up their own team of developers, data scientists to embark upon their digital journey. Such customers are offered a platform of their choice on a PAAS model. In such a scenario, a right mix of insourcing and outsourcing has to be thought through for a successful adoption, and thereby, realise the desired business outcome.

The purpose of setting up an in-house team should be on delivering outcomes needed by the organisation and not

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drifting away from their core competency. Although some organisations are planning to set up such teams to generate additional revenue stream for themselves in addition to their core business, such decisions surely have to be driven by market study and the vision of respective organisations.

There is a need for all the approaches to converge and align towards a sustainable business strategy for all the stakeholders.

Only then the pandemonium in the marketplace can be put to rest and a proper ecosystem can evolve.

Who owns the business outcome?

Business outcome has been the driving force for the entire journey of digital industries, as explained earlier. Logically, the end-user who owns the operations should be the outcome owner; after all, the benefits would add up to the organisation’s margins. However, the ownership can be on the basis of the actionable insight proposed by the solution provider at the consulting stage. This would enable a seamless connect between use case identification, solution blueprinting, implementation and realisation of the business benefit.

Digitalisation driving optimisation The digital industry journey is still at a nascent stage. Although a sustainable business strategy is yet to be seen, many customers have started the journey. The current state of global economy is driving the need for optimisation across the industry stronger than ever before. We eagerly await the 4th industrial revolution to finally find its ‘holy grail’ as in turn, digital industries become the new way of life for the entire ecosystem. ☐ Disclaimer: The views express in this article are solely of the author and are not to be construed as views of the organisation he works for.

A&D India | Aug-Sep 2019

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MANAGEMENT | INTERVIEW

“Launching innovations as quickly as possible” …says Axel Schneider, Chief Technology Officer, Schmersal Group, in this interview with Juili Eklahare. He explains how Industry 4.0 affects machine safety, what makes the company unique and how it is more economical to consider safety technology at the planning stage. Excerpts…

What do you see as the single most important technology trend influencing machine safety system in a company?

Industry 4.0. is a real ‘mega trend’ that is sweeping through the industry. Virtually, every company has been touched by this mega trend and we’re likely to see significant changes in every stage of industrial production as a result. This also affects machine safety in a multitude of ways. New machines and production concepts impact the design of safety systems.

If components are manufactured in highly automated onesize production batches, machines need to offer much greater flexibility, as too must the safety equipment.

What are your thoughts on the current pace of digital transformation in the industry?

Could you please tell us about the work you are doing in the digital domain when it comes to machine safety and appliances?

The industrial production in times of industry 4.0 is data driven. Real-time data of every machine and component will create more transparency and will be used to leverage further potential for efficiency. Therefore, our company will continue to focus its R&D efforts to

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develop intelligent and reliable sensors and integrated system solutions. For example, we work on solutions that enable our components and systems to also deliver non-safety related data. The advantages are obvious: Components used to comply with safety standards can simultaneously contribute to productivity gains as a “data supplier”. So, it kills two birds with one stone.

What is your strategy for improving and accelerating the innovation processes in your company? When you say new ground needs to be broken when it comes to the introduction of new technologies, how do you think that can be done?

In times of rapid technological change, we need to make sure that we deliver our customers with innovations and “working” products as early as possible. So, we started introducing agile development methods at our R&D department. The biggest change with this method is a new way of thinking and interacting. For example, the way we listen to and communicate with our customers or the way R&D engineers and sales people work together in self-organising teams. So far, we have achieved excellent results with this method.

How do you visualise the establishment of groupwide R&D standards in terms of Schmersal’s global product portfolio?

We have eshtablished seven R&D locations to turn new ideas into marketable products. After a successful implementation in Germany, we will roll out the new agile approaches globally with a focus on

A&D India | Aug-Sep 2019

INTERVIEW | MANAGEMENT

Field Connectivity Simplified Axel Schneider is Chief Technology Officer at Schmersal group since November 2018. As head of the R&D Division at the headquarter of Schmersal Group in Wuppertal, Germany, he is responsible for the global coordination and reconciling of development capacities and innovation projects. A graduate in electrical engineering, he has served in senior positions at international companies in the automation and telecommunications industry.

building interdisciplinary development teams. In addition, How is your approach different from other machine safety we leverage the individual strengths of the global R&D system companies in this space? Can you share some recent community by forming competence centers, covering a wide success stories? range of technologies from cost-effective electromechanical Our safety services division named tec.nicum makes us products through high-end electronic safety sensors and unique in the market. We have seen an increasing demand for solenoid interlocks to IoT/cloud-based qualified support on different aspects of software solutions. Our aim is to launch machine safety. Also, our global customers innovations as quickly as possible, which expect from their suppliers a single point meet customer-specific requirements of contact to be available for all their IT IS MORE ECONOMICAL TO and bring real competitive advantages questions and problems, a contact who CONSIDER SAFETY TECHNOLOGY knows and understands their applications to our customers. and has comprehensive know-how. That’s AT THE PLANNING STAGE What are some of the best practices the reason why we have set up this business and tips for companies on handling unit. This safety service division offers all machine safety problems today? What are some of the machine manufacturers and operators a manufacturer-neutral potential mistakes companies make? consultancy on all statutory guidelines and supports them with We have many leading customers who have incorporated the safe design of their machines. safety well and considered the safety strategy of their machinery from the very first pencil sketches. In these What is the vision that your company has for itself? cases, the safety chain, i.e. the sensors and interlocks Our vision is to be the leading system and solution provider combined with safe analysis, have already been in machine safety by reaching the highest level of customer incorporated in an exemplary fashion. But unfortunately, satisfaction. This means that we want to meet the specific needs that is not the norm. There are machine manufacturers of our customers even better than before. There are various who only consider safety at the very end of their design ways to achieve this. For example, our global customers are chain. The machines are often already completed and the increasingly demanding complete solutions from a single source.

by Murrelektronik safety technology is then spoilt. There is no doubt that it Therefore, our company is entering strategic Connecting machinery and plant couldn‘t be alliances with other is more economical to consider safety technology at the suppliers. Satech Safety Technology is one of our sales partners, easier with switches, cordsets and front panel planning stage. After all, besides protecting the operator, whose safety fences are an optimal tool to safeguard, e.g. robot interfaces Murrelektronik. machine safety also has a second essential objective – from workstations – and even more so when combined with our process efficiency. A well-planned safety solution can help company’s safety sensors and solenoid interlocks. The product reduce downtimes of machines and increase availability ranges of our companies complement one another perfectly, and productivity. meaning that we can offer one-stop shop solutions. ☐

‘‘

Network technology

A&D India | Aug-Sep 2019

Communication made easy

www.murrelektronik.com 29

M A C H I N E TO O L S | F O C U S

CNC solution with a difference The CNC technology has introduced various methodical approaches that tackle the existing problems faced by the industry with technological advancements. One such innovative solution adopted is the X-Cut, a CNC solution developed by Vienna University of Technology with the support of B&R Industrial Automation. This article discusses the system used for drilling Sivaram PV, holes several metres deep into very tough materials, which Chairman Non Executive, B&R Industrial Automation enables detection & correction of lateral drill movement.

Scientists are people who look past the usual answers and ask themselves questions, like: “Why should machine tools always be constructed the same way, just because it’s been done that way for decades?” Answers to such questions lead to new approaches and innovations in the industry. Customers are found in all branches of the industry – wherever conventional development methods fall short, because new problems demand an innovative approach.

Innovations in CNC technology has taken a new scientific approach to solve concrete problems faced in the industry, and one such is the X-Cut, a CNC solution with a difference, developed

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by Vienna University of Technology supported by B&R Industrial Automation. The CNC functions can be implemented on a general-purpose hardware platform together with the standard control and safety technology systems. This results in a significant increase in the performance; decrease in costs and at the same time protecting know-how of the developers.

New approaches to machine manufacturing The search for new approaches to machine manufacturing will lead you directly to the X-Cut, a machine whose main

A&D India | Aug-Sep 2019

F O C U S | M A C H I N E TO O L S

Division of CNC channel into separate functional units

spindle has complete freedom of movement on two axes to position itself in the available space. A third and potentially fourth axis can be added by moving the tool carrier laterally on the spindle or by moving the work piece carrier. The X in the name comes from the high level of parallel kinematics, with a parallelisation degree of 2 for positioning the spindle.

The spindle is located at the apex of a triangle formed by two arms, whose other ends are moved parallel in opposite directions on a common track, moving the spindle in the x and y directions. When this triangle is stretched to an extreme angle (very flat or very sharp) where the two arms become nearly parallel – what scientists call a singularity – rigidity is lost in one direction. For this reason, a second pair of arms is used to make the triangle into an X. At any one point, the weakness of one pair of arms is compensated by the strength of the other pair.

The four differentiating factors This construction has four advantages over a conventional approach: 1. Vertical tracks in which the arms move and give the machine a very small footprint, so it takes up less of the valuable floor space in a production hall.

2. Construction of the machine gives it exceptional stability in the z direction, much more than conventional solutions.

3. Stability in the x and y directions can be directly controlled by independently moving the two triangles and more or less “wedging” them to achieve extreme rigidity.

4. Finally, compared to machines with a Cartesian axis structure, the kinematic translations of the X-Cut allow high accelerations of nearly 2g, thanks to the small amount of mass to be moved, which also increases energy efficiency.

A&D India | Aug-Sep 2019

CNC path calculation The core of this CNC system is the path calculation, which is performed on the CNC channel and requires close attention.

Path calculation is performed stepwise on the CNC channel and can be broken down into separate functional units.

The CNC channel consists of five functional units. These include the interpreter, which interprets the CNC program; the path planner, which plans the path described in the CNC program; the cutter diameter compensation, which corrects the generated path; the dynamics calculation, which determines the path velocity; and the path generator, which converts the path information into cyclic set points for the individual axes.

Interpreter: The interpreter reads CNC programs and compiles the G-code they contain into a symbolic representation for further processing in the system.

Path planner: The path planner generates a geometric representation of the programmed path movements.

Cutter diameter compensation: The cutter diameter compensation function interprets the geometric representation as the outer contour of a work piece and uses the tool dimension data provided by the user to create a new geometric representation of the programmed path movements.

Dynamics calculation: The dynamics calculation creates a velocity profile to match the geometric description of the path movement, taking into consideration the limit values defined by the user (velocity, acceleration, jolt) for the axes and the path.

Path generator: The path generator represents the “cyclic processing” (real-time processing) functional unit of ARNC0 path generation. Its task is to generate output and set points for the axes involved. To do this, it uses the data it receives

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M A C H I N E TO O L S | F O C U S

Simulating system prior to constructing prototype reduces engineering time and cost

from the “background processing” functional units of ARNC0 path generation.

Machine control as a mathematical task The control of the X-Cut’s parallel kinematics is therefore a task that goes way beyond sequential programming of individual movement steps. Rather than programming linear axis movements, the mathematical model of the kinematic transformation is used, and it can be extended for all necessary path corrections. The development environment allows the developer to program these transformations together with the application program.

Model-based development The model-based development is based on the principle of simulation. A complex process is first depicted in an algorithmic model. Here, it is important that the processes that are necessary for and relevant to the development are contained in the model, because further development is based on the simulation model.

During the test phase, continuous improvements due to the test results can be made on the model.

Since production of the complex individual components of the machine is expensive, simulating the system prior to constructing the prototype reduces engineering time and cost.

This applies to the machinery construction, where the distribution of forces needs to be tested under all possible load scenarios using finite element analysis. It also applies to the open-loop and closed-loop control logic, which is tested using MATLAB / Simulink before it is allowed on the machine as a program. The target for Simulink provides the ability to generate the program code directly from the simulation model and transfer it to the

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controller. This saves time and increases safety. When there are changes, the finished program is downloaded on the machine only minutes after performing a successful simulation. In addition, it is done without potentially introducing new errors to the simulation result during programming.

General-purpose automation – the heart and brain of the machine Gone are the days when a dedicated controller was needed for CNC control. General purpose automation controller has the necessary processing power to compute G-codes, interpret the commands and define a profile suited for any application.

Using the real-time communication, such as, Powerlink has proven itself to deliver a much-needed latency in high-speed CNC operation. Not only does it require very little wiring and a small amount of switching cabinet space, it can also handle the high data throughput that results from the high dynamics and precision of the parallel kinematics, and from the fact that feedback and diagnostics data runs on the same network.

Vision out-of-the box The milling centre doesn’t necessarily have to consist of axes boxed up in the Cartesian coordinate system. A little outsidethe-box thinking at the Vienna University of Technology resulted in the development of the X-Cut, a highly dynamic three-axis processing machine that boasts of exceptional stability, high energy efficiency and compact dimensions. From the CPU to the motors, the sophisticated control concept was implemented using general-purpose automation technology from B&R and goes to validate a claim that for truly complex applications, one should look beyond customary solutions. ☐

A&D India | Aug-Sep 2019

23 - 28 January 2020, Bangalore, India

INDUSTRIAL MAINTENANCE | TECHNOLOGY

Optimising predictive maintenance through digital twin – the why and how Predictive maintenance solutions driven by digital twins prove as an advantage to accurately monitor equipment condition and aptly identify probable irregularities.

The article highlights some industries that benefit from using digital twin for predictive maintenance, challenges in Yeshraj Singh the digital twin creation and what is needed to build a General Manager and Strategic Initiative Leader – Digital reliable and accurate digital twin.

Transformation, QuEST Global All industries are undergoing a rapid digital transformation designed to meet the two objectives of faster product regeneration and systems optimisation. While digital building blocks, such as, DSI & MBE, IIoT platform form the first part of achieving this transformation, the second is all about getting a deeper insight from collected data, using statistical, machine learning & deep learning techniques.

With this transformation, there is a data collation aspect involved for every part of the industrial process and its related systems. However, as time passes, the parts and hardware experience wear and tear, and soon small problems snowball into an exponential breakdown. Pre-empting and identifying this

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critical breakdown point using relevant data is a step for predictive maintenance. This could be the start of a series of activities performed for extending the lifecycle of a part or a process in a timely manner, as all technology teams are aware.

While there are various kinds of monitoring that could help with advance warnings of a breakdown, most of them are really manual. Electrical monitoring among several other mechanical systems can serve a forewarning about equipment going out of shape, but can never really be accurate in prediction. This is where automation steps in.

The best way to stay a step ahead of this situation is to have an efficient automated predictive maintenance system in place.

A&D India | Aug-Sep 2019

INDUSTRIAL MAINTENANCE | TECHNOLOGY

Investing in processes and systems that help to identify critical any future risks or need for maintenance. risk points in a predictive manner could be the only difference between a smooth supply and production chain and critical Challenges to meet production loss and disruption in market activities. The focus The foremost challenge in creation of a digital twin is the need here is to ensure a PM system that actually simplifies the process rather than make it more complex than even the original system. for its accuracy to ensure complete mirroring of the real process.

For an efficient predictive maintenance strategy, the answer is Any minute difference in the structures can trigger a completely different outcome for the real process. It may not always be the digital twin. possible to get an absolute modelling of the physical asset with the properties and characteristics that faithfully mirror the entire The digital twin and its advantage mechanical and electrical properties of the asset and modelling.

Being a cloud-based virtual copy of the system, the digital Secondly, there is always a risk of blueprint failures that may arise twin facilitates a virtual expert analysis of its health and operation at a later stage of development. And thirdly, duplicating each efficiency, remotely. Its biggest advantage is the elimination of modification of every component in the digital twin is a constant downtime for maintenance. Without interfering with the running challenge. It needs to be mirrored in the virtual twin to ensure of the system on ground, it allows the freedom to analyse accuracy of predictions. The intensity of these challenges outcomes in hypothetical situations, what happens in case of increases during the construction of the twin to the component unexpected loads, changes etc. and plan maintenance accordingly. sub system level. Replicating virtually at the lower components As we go a step ahead, many of these analysis processes can level of the equipment is a much faster process than the system be automated and twin process will occur in the digital twin. So, level or the sub system level, which is more prone to errors. by automating activities like vibration analysis, lubrication And finally, while this remodeling is achievable, the real analysis using sensors in the real system and feeding this data roadblock is the lack of maturity of the technology stack in into the digital twin real time, the entire predictive process can most instances. That is a roadblock that enterprises need to be automated. work around.

So, essentially, the digital twin functions are based on four data sets – engineering data, manufacturing data, historical data The simplification recommendations & real time data. The predictive analytical model is developed The path ahead could be smoother with more accurate for process, part or system in consideration. It becomes the core component of digital twin. Once loaded with real time data, it planning. If dealing with a complex system, it is difficult and helps to predict various breakdown scenarios on the virtual expensive to build accurate digital twin for predictive twin, allowing for efficient predictive maintenance heads-up. maintenance. Hence, it is essential to identify critical components The digital twin can help to forecast the behavior of the real for sub-systems based on failure modes or reliability model of time process and equipment in various different circumstances overall system. Once such components or sub-systems are that can be simulated virtually, using any incidence scenarios identified, it would make sense to develop a digital twin of an individual component or a sub-system. This helps to mitigate and relevant prototypes. the challenges of accuracy of a virtual model that should precisely reflect the physical twin’s properties, and allow for a detailed Use cases in industry blueprint of a component’s/sub-system’s failures to be developed A number of industries benefit from using digital twin for more easily than the whole system’s image. predictive maintenance. Preventive and predictive maintenance In order to build a credible and accurate digital twin, of aircraft (a critical requirement since lives depend on it), of enterprises need expertise across all the building blocks of digital automotive manufacturing industry (again, life is a critical transformation – design system integration, model based need), and even in healthcare monitoring equipment (yet again, enterprise, digital manufacturing, fielded product support, and a lifesaving technology application), are a few critical examples digital software engineering and strategic partnerships with of the significance of this technology. In some cases, the twin of leading IIoT players. With a mature technology stack, the the whole system can be generated – aircraft engine, the human concept of digital twin and its relevance on predictive body or the engine system for the care – and can be studied for maintenance will be increased manifold. ☐

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A&D India | Aug-Sep 2019

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WIRES & CABLES | TECHNOLOGY

Ethernet becomes slimline & real-time capable The proliferation of data transmission standards in factories is coming to an end. OPC-UA and TSN are making Ethernet realtime capable and are finally establishing a consistent standard.

The article explores the evolution of the Ethernet, its real-time capabilities and the trends in the Ethernet cables.

The automation pyramid is crumbling. The individual levels, from the ERP system at the top right down to the field level at the base, were once strictly separate. A level could only communicate with the one directly above or below it. This hierarchy is too outdated for the smart factory, where everything communicates with everything else. For example, an order in the online shop will immediately trigger the corresponding actions in the machine, and the sensors in the machine will report directly to the ERP system if there is a threat of production losses. It’s all about predictive maintenance. The aim is that every customer receives a product that is tailored to them and is made as cheaply as it would be if it were mass produced.

This has consequences for communication networks in factories. When the automation boom began during the 1980s & 1990s and the automation pyramid emerged, the data, which was still sparse at the time, flowed via fieldbus protocols. To cut their products off from competitors, many suppliers created their own fieldbus standard. This continued in the same vein in the 2000s with Ethernet. Once again, suppliers managed to “bend”

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Ralf Moebus, Head of Product Management Industrial Data Communication, LAPP

Ethernet so that there are now a dozen different versions that are all incompatible with one another.

But this may all be about to change. On one hand, users have had enough of grappling with dozens of transmission standards, as it involves accepting a huge outlay for network planning and design. On the other hand, all standards have the same flaw: Standard Ethernet not being real-time capable. Thus, proprietary real-time expansions that require special network components were developed. This has resulted in the network having “real-time islands”, which restricts the consistent and coexistent transmission of real-time and non-real-time data.

When everything exchanges data with everything else in a factory – from the online order page via the ERP and MES systems to the machine and each and every sensor, and then back to the cloud – there needs to be a consistent standard that transmits and processes information reliably and accurately in under a millisecond. This is the only way to make good on the key promises of Industry 4.0 and mass customisation.

A&D India | Aug-Sep 2019

WIRES & CABLES | TECHNOLOGY

The cables are thin, light, robust, fit into tight spaces and can even achieve a range of up to 1200m at 10 Mbit/s

Borrowing from technology used in concert halls

faster, further”. Ethernet cables are now available in Cat.7 version with up to 10 Gbit/s, and even faster versions are about to come into the market.

But is this always necessary? No. Only a few applications – digital image processing being one of them – generate such huge data volumes. It is often the case that “slow” Cat.5 cables can do the same job at 1 Gbit/s.

The various fieldbus standards are far from extinct, but they are losing so much ground to Ethernet, which has been the dominant force in office communications for decades. As the office and production line need to communicate seamlessly, it was only a matter of time until Ethernet wormed its way into factories. The flaw of insufficient real-time capability is remedied

by Time-Sensitive Networking (TSN). This set of standards is Slimming is the new black based on a proposal by the IEEE802.1 Ethernet working group.

Downsizing is one trend that LAPP has identified. Fast TSN is the outcome of the work by the IEEE’s Audio Video Bridging Task Group and was originally designed for the Ethernet cables have four pairs of conductors. Why not just do without three of the pairs? Just one pair of conductors is all it synchronised transmission of audio signals in concert halls.

If automated, there would be many advantages to TSN. All takes to transmit data, which can still be done at 1Gbit/s. Of participants in a TSN network are time-synchronised, so they course, compatible terminal devices with new, already available perform the right action at precisely the right time. Its priority PHY chips are required here. These single-pair Ethernet cables mechanisms enable every application to receive their data on will become more important in the future, especially when time and information can be fast-tracked; bandwidth and time connecting sensors. The cables are thin, light, robust, fit into tight slots are reserved for this. High priority is given to drives, for spaces and can even achieve a range of up to 1200m at 10 Mbit/s. example, that need to be supplied with the latest data in And, of course, they are excellent value for money as they are milliseconds. The compatibility of components from various cheaper to buy and easier to install because technicians only need manufacturers is currently ensured by interoperability testing in to connect two cores rather than eight here.

For users who do require the highest transfer rates of 10 several global TSN testbeds.

Gbit/s, LAPP makes the ETHERLINE® PN CAT.6A fast connect.

Inside the cable is a plastic cross separating the four pairs of OPC-UA gives new meaning to data conductors and features an inner sheath. The fitter no longer TSN ensures that data is transferred on time. However, it needs to remove a foil shield from each of the four pairs of does not contain information on where it should go and what conductors. It saves up to 50 per cent of the time. It prepares the this data means. There is a second standard to handle this; OPC- cable for connector assembly in just one step. This saves time UA is an open communication protocol for exchanging data and protects the cores when stripping and the inner sheath on from machine to machine and between machines, the ERP the fast connect cable also prevents the core insulation from system and the cloud. OPC-UA is now accepted as a de facto being cut while removing the shielding. standard in communications for the Industry 4.0. It has now become real-time capable with TSN, which enables data TSN-capable switches in sight networks to be standardised and the flow of information from In the OPC-UA with TSN and single-pair cables one thing is the base to the top of the automation pyramid to be unimpeded. still missing: the TSN-capable active components, such as, With this, the pyramid disappears into thin air.

The cables will not change for now as an Ethernet cable does switches. Especially, as switches do care which protocols run not care which protocol it carries. High quality is what’s through them. New real-time capable hardware is needed, and important. Perfect shielding, for example, so that the data for now, their standards are still being fine-tuned. Many sensors arrives without disruption. So far, the suppliers of these kinds of in the smart factory of the future will be connected with singlecables have been developing them along the lines of “higher, pair Ethernet cables. ☐

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A&D India | Aug-Sep 2019

W I R E L E S S A U TO M AT I O N | T E C H N O L O G Y

Adding wireless communication to vibration monitoring One of the chief hurdles in the way of rotating equipment is vibration. The article explains how transmitting vibration monitoring data via wireless networks makes continuous monitoring of rotating equipment more practical & cost effective.

When we think of process manufacturing facilities, we tend to picture pipes, tanks, valves and instrumentation. This picture is correct, but we often tend to overlook how much rotating equipment there is and how critical it is to overall operation. If a pump, compressor or other device fails, it can have a serious effect on production. The fact that many pumps are configured in dual redundant installations gives an indication of their importance.

One of the great enemies of rotating equipment is vibration, which has a variety of causes. Consider a typical ANSI pump driven by a motor with a flexible coupling. If the two shafts are not truly on a common centerline, the coupling will compensate for the misalignment, but it will likely introduce vibration into the installation. Vibration creates detrimental

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Shuji Yamamoto Wireless Strategy Section, Business Initiative Department, New Field Development Center, IA Platform Business Headquarters, Yokogawa Electric Corporation

forces within the ball bearings, causing premature wear, which further increases the overall vibration. Over a long enough period of time, the problem will compound until one or more of the bearings fail. The pump’s mechanical seals may also suffer damage and begin to leak. Before long, the installation must be shut down and overhauled.

In addition to the vibration inherent with any rotating equipment, at least at some level, vibration can also be transmitted via piping and support structures from other equipment within the process unit. Consequently, vibration cannot be eliminated entirely, but it can be measured. Sensors are available to characterise and quantify the amount of vibration, and to capture characteristic patterns, often referred to as signatures. These vibration monitoring systems typically

A&D India | Aug-Sep 2019

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W I R E L E S S A U TO M AT I O N | T E C H N O L O G Y

Fig 1: The vibration monitoring sensors can be mounted using a pedestal which is screwed to the motor housing, usually near the bearings

use a piezo-electric sensor to create and transmit a signal proportional to measured vibration.

Vibration sensors have been available for many years, but older systems were costly to install, limiting their deployment to the most expensive and critical rotating equipment. For other installations, technicians carried portable units on routine inspections of the plant, manually checking bearings, seals and other critical points. Sophisticated portable systems could capture historical information and compare specific installations over time, but the readings were still performed at potentially lengthy time intervals, and depended on operators carrying out the inspections. Performing such rounds has always been expensive and time-consuming, and when plants have minimal head counts, they can be delayed or skipped when more pressing tasks emerge.

Advantages of continuous monitoring Short of a catastrophic failure of some component, vibration problems don’t usually advance drastically in a brief period of time. This fact is usually cited to support the idea of periodic inspections. Unfortunately, vibration problems may increase slowly until they reach a critical point, and then the climb becomes much steeper toward failure, which can easily happen before the next scheduled manual inspection. Continuous monitoring can detect those situations when the vibration curve begins to climb toward a failure point, informing maintenance technicians while there is still time to respond before a failure and outage. Software can spot those kinds of movements and sound alarms appropriate to the urgency of the situation and criticality of the equipment.

Less expensive vibration sensors have made permanent

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installations more practical for more pieces of equipment, but the costs of wiring a sensor have not gone down, and in many situations have become even more expensive. One of the biggest technological advances of the last decade has been the emergence of effective and practical wireless instrumentation protocols, including ISA100 Wireless.

A new wireless vibration sensor The piezo-electric acceleration sensor is compact and easy to install near the device’s bearings (Figure 1). A cable connects it to a wireless communication module, which can be mounted wherever it is convenient, and where it can be clear of obstructions able to interfere with its signal propagation. The complete system is self-powered using a battery in the communication module. With a one-minute data update rate, one set of batteries can run for up to 10 years. The data is sent via the wireless network to the system gateway. If other ISA100 Wireless field devices are already in use in the facility, the vibration monitors can become part of the same network, communicating with the gateway just like any other communication module or sensor.

The wireless vibration monitoring system has all the specifications necessary to perform the functions required for condition monitoring. Data from the units installed throughout the plant can be directed to a control or monitoring system to inform operators and maintenance personnel as conditions change with the equipment being monitored.

Vibration analysis methods The piezo-electric vibration sensor is an accelerometer

A&D India | Aug-Sep 2019

W I R E L E S S A U TO M AT I O N | T E C H N O L O G Y

Fig 2: Each unit can be configured to make the type of measurement required for the application

capable of measuring velocity and acceleration (Figure 2). The nature of the vibration and the type of equipment helps determine which analytical method is best when the primary objective is determining equipment condition. The rule-ofthumb suggests that where frequencies are low, velocity is the preferred measure, but when frequency increases, it’s better to measure acceleration.

Plant personnel can make the determination of how frequently readings should be taken, and what analytical techniques should be used for each installation. Ranges of what is considered tolerable vibration versus dangerous have been published by various sources, but the ultimate guidelines for a given piece of equipment in each plant may need to be established in cooperation with the equipment OEM. While the sensor can send a new reading as often as every 10 seconds, the need for such rapid refreshment is rare, and it comes at the cost of battery life. Switching to an update rate of once per minute can extend battery life significantly, while still providing more than enough data for most applications.

If more sophisticated analysis is required, software packages are available from third-party vendors to look for patterns and identify sources of abnormal vibration. This type of work is done in the host system rather than the individual devices, and often combines signals from multiple sensors deployed around the equipment to pinpoint sources of trouble.

Launching a vibration monitoring program Implementations of vibration monitoring programs are usually incremental, working down the list of installations beginning with the most critical. In this context, “critical” takes different forms, the foremost of which typically involves the likelihood of production being interrupted due to an outage. If

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the process cannot run without a given pump and there is no spare ready to switch over, it’s very critical, regardless of its cost.

Most plants are aware of those installations, particularly if they have a history of problems. Secondary and tertiary levels can get more complex. Some companies select based on equipment cost. At the same time, other considerations, such as difficulty of repair or availability of spare parts, enter into the picture, but they are more difficult to quantify. Ultimately it is important to include a variety of measures from different viewpoints when making such decisions.

It is also important to select an appropriate asset management platform to gather and process the data from the sensors around the plant. Once more information is available, questions emerge as to how it is used and where it goes. Who should receive alarms? Maintenance? Control room operators? If a highly critical installation is beginning to show signs of a problem, the control room may need to be informed if operators need to take action before the situation is turned over to maintenance for repair. An effective asset management system can handle these sorts of situations.

The combination of effective technologies Process manufacturers can benefit from this combination of economical sensors combined with wireless networks.

Working together, they provide critical information to operators and other plant personnel to warn of potential problems before the plant suffers damage or lost production.

In some situations, the avoidance of a single outage saves enough money to pay for monitoring many pieces of equipment. This approach is highly flexible and scalable, allowing a facility to begin in one area, and then expand as needs and circumstances permit. ☐

A&D India | Aug-Sep 2019

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ARTIFICIAL INTELLIGENCE | TECHNOLOGY

Artificial Intelligence the driving force of Industry 4.0 With the manufacturing industry moving towards adopting Artificial Intelligence (AI), it is of utmost importance to understand the advocacy behind it and how it plays a crucial role in the smart factory revolution. The article corroborates on AI aiding the Industry 4.0 model, and how this powerful technology is already being used in the industry to drive efficacy, advance quality Lior Akavia, Co-founder & CEO, Seebo and successfully manage supply chains.

A lot of the hype surrounding Artificial Intelligence (AI) Industrial AI’s impact on manufacturing in manufacturing is focused on industrial automation, but Artificial Intelligence’s impact on manufacturing can be this is just one aspect of the smart factory revolution; a natural next step in the pursuit of efficiency. What AI also organised into five main areas: brings to the manufacturing table is its capability to open up completely new avenues for business. Below is an outline 1. Maintenance/OEE Predictive maintenance has become a very sought-after use that covers both these aspects of Artificial Intelligence within the Industry 4.0 paradigm, and how this powerful technology case for manufacturers looking to advance to Industry 4.0. is already being used by manufacturers to drive efficiency, Instead of performing maintenance according to a predetermined schedule, predictive maintenance uses algorithms to predict the improve quality and better manage supply chains.

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A&D India | Aug-Sep 2019

ARTIFICIAL INTELLIGENCE | TECHNOLOGY

next failure of a component/machine/system and then alerts personnel to perform focused maintenance procedures to prevent the failure, but not too early to waste downtime unnecessarily.

One of the most common applications of AI in manufacturing is machine learning and most predictive maintenance systems rely on this technique to formulate predictions. The advantages are numerous and can significantly reduce costs while eliminating the need for planned downtime in many cases.

By pre-empting a failure with a machine learning algorithm, systems can continue to function without unnecessary interruptions. When maintenance is needed, it’s very focused – technicians are informed of the components that need inspection, repair and replacement; which tools to use, and which methods to follow. Predictive maintenance also leads to a longer Remaining Useful Life (RUL) of machinery and equipment since secondary damage is prevented while smaller labour forces are needed to perform maintenance procedures.

2. Quality 4.0 Manufacturers are finding it harder than ever to maintain consistently high levels of quality. This is due to the rising complexity in products (that integrate software, for example) and very short time-to-market goals. Despite these challenges, managers are highlighting quality as the top priority, realising the importance of customer experience of a product and the power of customers to push a brand forward as well as being aware of the pain point of high defect percentages and product recalls.

Using Industry 4.0 techniques, this new quest for quality has been appropriately named Quality 4.0 and Artificial Intelligence is at its forefront. Quality issues cost companies a lot of money, but with the use of AI algorithms developed through machine learning, manufacturers can be alerted of initially minor issues causing quality drops, similar to the way alerts are created for predictive maintenance. Quality 4.0 allows manufacturers to continually improve the quality of their output while collecting usage and performance data from products and machinery in the field. This data becomes a vital source of information that forms the basis for product development and crucial business decisions.

3. Human-robot collaboration The general approach is that as jobs get taken over by robots, workers will be offered training for higher-level positions in programming, design and maintenance. In the meantime, the efficiency of human-robot collaborative work is being improved as manufacturing robots are approved for work alongside humans. As the adoption of robotics in manufacturing increases, AI will play a major part in ensuring the safety of human personnel as well as giving robots more responsibility to make decisions that can further optimise processes based on real-time data collected from the production floor.

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4. Generative design Manufacturers can also make use of AI in the design phase.

With a clearly defined design brief as input, designers and engineers can make use of an AI algorithm, generally referred to as generative design software, to explore all the possible configurations of a solution. The brief can include restrictions and definitions for material types, production methods, time constraints and budget limitations. The set of solutions generated by the algorithm can then be tested using machine learning. The testing phase provides additional information about which ideas/design decisions worked, & which did not.

In this way, additional improvements can be made until an optimal solution is found.

5. Market adaptation / Supply chain AI permeates the entire Industry 4.0 ecosystem and is not only limited to the production floor. One example of this is the use of AI algorithms to optimise the supply chain of manufacturing operations and to help them better respond to, and anticipate, changes in the market. To construct estimations of market demand, an algorithm can consider demand patterns categorised by date, location, socioeconomic attributes, macro-economic behaviour, political status, weather patterns and more. This is ground-breaking for manufacturers who can use this information to optimise inventory control, staffing, energy consumption, raw materials and make better financial decisions regarding the company’s strategy.

Industry 4.0 demands collaboration The complexity of using AI in industrial automation requires that manufacturers collaborate with specialists to reach customised solutions. Attempting to build the required technology is costly and most manufacturers don’t have the necessary skills and knowledge in-house.

An Industry 4.0 system consists of several elements/phases that need to be configured to suit the manufacturer’s needs: • Historical data collection • Live data capturing via sensors • Data aggregation • Connectivity via communication protocols, routing and gateway devices • Integration with PLCs • Dashboards for monitoring and analysis • AI applications: Machine learning and other techniques To truly leverage AI, manufacturers will do well to partner with experts who understand their goals and who can help create a clearly defined roadmap with an agile development process that links the AI implementation to relevant KPIs. ☐

A&D India | Aug-Sep 2019

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EVENT | REPORT

Robotics making their mark in the automotive industry For several years, the automotive industry has been thoroughly using industrial robotics.

They expand on quality and bring down costs, while growing capacity. In this context, VDMA Robotics + Automation recently organised ‘Robotomation – Symposium for robotic automation trends in automotive industry’ in Pune.

The symposium explored how robotic automation can Juili Eklahare increase the standard and quality of the automotive industry.

Features Writer juili.eklahare@publish-industry.net A post-event report…

The automotive manufacturing industry has been one of the fastest adopters of industrial robotic technology. Keeping this in mind, VDMA Robotics + Automation recently organised ‘Robotomation – Symposium for robotic automation trends in automotive industry.’ The symposium focused on the global robotics and automation trends available for the Indian automotive industry & how robotic automation can increase excellence in this sector.

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India-Germany relations The symposium took off with an enthusiastic welcome by Rajesh Nath, Managing Director, VDMA India. He emphasised that the automobile industry in India is expected to reach a figure of $260-280 billion by 2026. Next, Dr Juergen Morhard, Consul General of Federal Republic of Germany, Mumbai, expertly highlighted the Indian-Germany relationships. He stated,

A&D India | Aug-Sep 2019

EVENT | REPORT

“Germany is the number one trade partner in India after Japan.

We are especially strong when it comes to academic partnerships.”

This was followed by an engaging address by the chief guest of the day, Dr Abhay Firodia, Chairman, Force Motors. He threw a bit of light on the history of the automobile industry, the affordability of EVs and the robotic automation trends in the industry. He explained that the automobile industry was mainly European from 1855 to the first World War, which was the basic innovation. “After World War II, Japan became the centre of innovation in the industry,” he said. Turning to EVs, he further asserted that once battery costs go down, the affordability of EVs will go up. “And, it will not allow older technologies to surive, while the industry will have to adjust to these changes,” he pointed out.

on how a robot is flexible to multitask with robotic tool changer, an end-effector with two mating parts, a master side and a tool side that have been designed to couple together automatically, carry a payload and have the ability to pass utilities. This was followed by a gripping presentation by Prashanth Alevoor, Head – Application Technology Division, Dürr India, on ‘Latest technologies and innovative solutions for automotive paint applications’.

It was soon time for the high point of the symposium – the first panel discussion of the day. The discussion on ‘Efficient handling solutions for automotive industry’ was moderated by Dr Ranjit Date, President and Joint Managing Director, PARI. The esteemed panellists were Nilesh Jadhav, Technical Consultant – Automotive, Siemens; Ashwin Vanikar; Satish Sadasivan, Managing Director, Schunk Intec India; Vivek Sharma, Vice President – Central Manufacturing Engineering, Mahindra & Robotics globally & in India Mahindra; and Rajesh Sharma, Head ICT – Infrastructure, After this, Patrick Schwarzkopf, Member, Executive Board of Security & Compliance, Fiat India. the International Federation of Robotics & Managing Director, VDMA Robotics + Automation, gave the audience a clear picture Being more export & skill oriented of global robotics and that in India, through his keynote address The first question shot at the panelists was whether the on ‘The global robotics and automation boom’. He maintained, “Asia is the biggest user of robots.” Coming to robotics in India, robot density in India is adequate. To this, Sadasivan responded Schwarzkopf claimed that the robotics market in India is small, that there can be an improvement in the density. “When we where the country has about 23,000 robots in operation, which is look at some countries that are high in density, we see that they are more into exports,” he answered and continued, “so, we not much. So, there is a big opportunity. need to be a more export-oriented economy.”

Sharing his views, Vanikar asserted, “We need to move from Integrating robot with CNC control being labour-oriented to skill-oriented; skill-oriented jobs come Shortly after, Vundavally Madanmohan, Chief Manager – with automation and there is a high potential because of the Product Portfolio Management, Siemens, took over and gave a skills being used.” Jadhav added that we are still behind in terms winning presentation on ‘Integrated robotic solutions for of robots. “It’s not just about the level of automation but what machining’. He specified that with growing mass customisation, kind of requirement it fits,” he cited and continued, “it’s not just having the integration of robot with CNC controller will make it about production, but we also need to serve the society.” much easier. “By integrating robot with CNC control, the robot gains all available CNC functionality,” he implied.

It’s about opportunity Subsequently, Ashwin Vanikar, Head of Cluster India: The discussion further examined the challenges that India Application Engineering, Festo India, spoke on ‘Enhancing automation in collaboration with robots’. “Modern information faces when it comes to getting high-level of automation. To this, and communications technologies are being combined with Vivek Sharma opined that automation comes with a scale. He traditional industrial processes, thus, fundamentally changing expounded, “If we consider an automotive company in China, various areas of production by integrating OPC UA interface in then we see that their scale of operating is a lot more. So, we must look at how we can be flexible with our automation and robotics.”

Industry 4.0 host enviornments,” he put forth.

So, what should customers look at while considering automation? “There’s no risk factor,” Rajesh Kumar Sharma Robotic tool changer explained and went on, “It’s about opportunity. One needs to Succeeding this, Tushar Mense, National Sales Manager – identify what his/her requirement is, which should go into the Robot Accessories, Schunk Intec India, spoke on ‘Flexibility in business plan. Also, people are becoming more aware & laws are robotic automation with tool changers’. He expertly expanded becoming more stringent.”

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EVENT | REPORT

Machine vision system

Hasabnis, Managing Director, Baumer India; S Devarajan, Senior Vice President – PE, TVS Motor Company; and Rajesh Nath, After the first panel discussion, Dr Horst Heinol-Heikkinen, Managing Director, VDMA India.

CEO, ASENTICS; Member of the Board, VDMA Robotics + Automation; and Chairman, VDMA OPC Vision Working German presence in India Group, had the audience engrossed with the next presentation on Gurtoo put across his first question, asking speakers their ‘The VDMA OPC UA initiative – Industry 4.0 becomes reality’.

He threw light on what machine vision system is, in which a outlook on German companies responding to collaborative system for machine vision is any complex machine vision system technology. Nath returned that we are seeing the presence of or vision sensor or any other component, which, in the production more and more German companies in India, bringing the latest context, is capable of extracting information from electro- technologies with them. The panellists further deliberated magnetic waves in accordance with a given image processing task. whether robots make the industry more dependent on them.

“No interface standard exists between a machine vision system Sharing his views on this, Devarajan conferred that with variety and production IT systems,” he explained and continued, “for on the rise, flexibity is needed, which in turn requires robotics. each new project, new proprietary interfaces have to be developed.”

The trend of electrification

Robots are becoming more intelligent

Gurtoo went on to ask the panellists that as the automotive industry changes, what was the support system from their side.

Giving an insight on what his company is up to, Raibagi replied that robots are becoming more intelligent. “Robots are being used in South-East Asian countries even for shoe manufacturing,” he said and continued, “these changes are beneficial developments to bring the cost down. Our company is getting geared up and catching up with these changes.” Coming to applications of collaborative robotics working successfully in India, Swami asserted, “There are not many. Worldwide, we have at least 30 applications only from automotive.”

Besides, the question was raised that if sensors fail, then how will one ever know that? To this, Hasabnis responded, “Even simple systems like, milk storage are using GSM technology to give an advanced warning to the collection plant through wireless Requirements of automobile manufacturers internet that the milk is supposed to be collected, which is done This was followed by a captivating presentation by Sven directly through what sensors sense. With IO-Link, you can get Baumer, Global Industry Manager – Assembly & Handling, an advanced warning if the sensor is working or not.”

Baumer Management Services AG on ‘Efficient sensor solutions VDMA Robotics + Automation division conferred the in automotive-related production enviornments’. Baumer champions serving the automotive industry in India with the focused on the current requirements of automobile 1st VDMA Robotics + Automation Innovation Awards for the manufacturers, which includes refining automated processes, automotive industry under the category, Efficient and ensuring readiness for greenfield investments and increasing Effective Production. The winner was International flexibility. “Also, a company like ours should focus on Automotive Components (IAC) and the runner-up was TVS technological excellence, application competence and adding Sundaram Clayton. value to the process”, he added.

The symposium eventually delved into the last segment – the Robotics thriving in the automotive industry second panel discussion, which was on ‘Collaborative technology The symposium made clear that robotics have certainly taken for automotive manufacturing’. The discussion was moderated

by Sudhir Gurtoo, Managing Director & CEO, Leadec India. The their place in the automotive industry. They are a push towards revered panellists were Sunil Raibagi, Vice President – Business today’s smart manufacturing lines in the automotive sector, while Development & Strategy, Zimmer GmbH; Vikas Swami; Sunil innovative technologies are making them more resourceful. ☐

The ensuing presentation was an interesting one on ‘Technology trends in engine shop & electrical vehicles’ by Markus Böhmer, Senior Sales Manager Systems International, Zimmer GmbH. He conveyed, “The trend towards electrification already has a much earlier impact on the industry than can it be directly seen by considering the expected sales volume.”

The presentation posterior to this was on ‘Manufacturing excellence through robotic automation’ by Vikas Swami, Vice President, KUKA Robotics. The audience paid rapt attention as he explained how OEMs want to make multiple vehicles on one line for which they need more and more robots. “So, our target is to squeeze and make slimmer robots,” he verbalised.

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EVENT | REPORT

Succeeding in the digital transformation journey The digital transformation of industry, infrastructure, and cities is underway. Disruptive new technologies have already gained a foothold in most organisations. In this context, ARC Advisory Group recently organised its 17th India Forum on ‘Driving Digital Transformation in Industry and Cities’ in Bengaluru. The event highlighted how industry and infrastructure are moving towards digitalisation, automation trends, new processes and best practices across all industry verticals. A Juili Eklahare Features Writer post-event report… juili.eklahare@publish-industry.net Industrial organisations around the world are entering a period in which new digital technologies augment people and processes to an unprecedented degree. Also, cities require a combined approach to IoT, AI and other technologies.

Keeping this in mind, ARC Advisory Group recently organised its 17th India Forum on ‘Driving Digital Transformation in Industry and Cities’ in Bengaluru, which discussed conducting the digital transformation journey, business value from IoT,

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building a national level data strategy and more.

The two-day event kicked-off with G Ganapathiraman, Vice President & General Manager, ARC Advisory Group, welcoming and addressing the audience. He briefed on the forum agenda, highlighting the topics that will be adressed and discussed, mentioning that the forum is a platform for everyone to connect and share information. “The automation industry is developing and growing at a very fast rate,” he commented.

A&D India | Aug-Sep 2019

REPORT | EVENT

Undertaking the digital transformation journey The first keynote presentation was by Bradley G Houk, Senior Engineering Advisor, ExxonMobil, on ‘ExxonMobil process automation journey’, where he highlighted the objectives for ExxonMobil OPA Test Bed. “The objective is to create ‘Test Bed’ to support continued testing of components and standards,” he said. Another intriguing presentation soon followed; Sal Spada, Research Director, ARC Advisory Group, spoke on ‘Driving digital transformation in industry & cities.’

He explained that more than 80% companies undertake the digital transformation initiative, but less than 11% succeed.

The event then turned its attention towards ‘Industry 4.0 applications in Indian industries’ by Dr Rajashekhar Malur, Chief Technology Officer, Tata Consulting Engineers. He said, “We started getting into smart cities in around 2007. All our cities are in various stages of development.” Subsequently, Sameer Prakash, General Manager, Head – Digital Enterprise, Siemens, gave an engaging presentation on ‘Thinking industry ahead’ in which he stressed that when we talk about digitalisation, it is about one ecosystem against the other ecosystem.

tube leakages’. “Tube failures is the common cause of availability lost,” he revealed. Succeeding this, Sudheesh Narayanan, MD & CEO, Knowledge Lens, spoke on ‘Leveraging AI and data science for Industry 4.0’. Handily throwing light on the business value from IoT, he said, “It’s about taking devices on an open platform and making them available.”

Benefits of digital retrofits

Going digital is integral to the commercial delivery of safe, flexible operation, which was addressed by Peter Saddington, Business Development Lead – Enerlytics, Uniper Technologies.

In his talk on ‘Digital retrofits for power plant efficiencies’ he expounded, “There are various benefits of adopting a digital retrofit, from 10-15% reduction in outage & overall expenditure to 56% internal rate of return (IRR).” Delving further into the event, Sheetal Paralikar, Manager – Business Development, Siemens, spoke on ‘Advanced automation control solution for industries & cities’. Taking a tunnel project into consideration, she conveyed that instead of having everything on paper, we can have a digital twin and hand it over to the end-user.

The event moved into its last segment of the day, ‘Going digital – the Indian scenario’. Transforming the mobility The role of AI business by selling e-bikes, not as a product but a service, was The ensuing presentation was a gripping one on ‘Creating, an area which was further elucidated upon by Lokesh Payik, managing and leveraging digital twins’ by Anne-Marie Walters, Chief of Digital Enterprise, Bosch. Through his talk on Industry Marketing Director – Process & Resources, Bentley ‘Digital transformation for industry’, Payik stressed that they Systems, where Walters proficiently emphasised that digital twin first acquire companies and give them complete empowerment, generates insights. “A digital twin is continuously synchronised asking for a good product. “Then, whatever we develop, we from multiple sources,” she said. invest & keep it completely ready and then send it to the How just adding Artificial Intelligence (AI) does not change market,” he put across. everything magically, but where a lot more is needed, was expertly highlighted by Chris Hazlewood, Senior Manager, Promotion Digital empowerment Section, Overseas Planning & Administration Dept, Factory Presenting the topic ‘Smart manufacturing, IIoT and Automation Systems Division, Mitsubishi Electric Corporation, in his presentation on ‘Artificial Intelligence’. “AI does not Industry 4.0 for India’, Madhusudan Kestur, Director, Ace understand the difference between right and wrong,” he implied Micromatic Manufacturing Intelligence Technologies, stressed that Industry 4.0 is necessary as manufacturing data will grow and went on, “but it will revolutionise our processes and lives.” exponentially and because it also brings global opportunities.

The session after this was led by Uma Balakrishnan, CEO, Business value from IoT Axcend Technologies & Vice President, Automation Industry After the keynote presentations, it was time for the next Association (AIA), presenting the topic ‘Bridging ecosystem for segment of the day, ‘Moving toward digital enterprise’. Dr digital empowerment in manufacturing’. Balakrishnan Tomasz Kaminski, Project Director – System Technologies suggested that the management must empower the operator Division, STEAG Energy Services GmbH, gave a captivating and give them the opportunity to see themselves grow. presentation on ‘Use of predictive analytics for detection of Following this, the first day saw its last session with Subhash

A&D India | Aug-Sep 2019

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EVENT | REPORT

Chandra Bankey, Senior Manager, IT-Digital & SBU Operation; & Indradyumna Datta, Digital Lead – Operations & Enabling Functions, Cairn Oil & Gas, Vedanta, who gave a presentation on ‘Doing more with less in production operations with exceptionbased surveillance’. They explained that with a growing economy, India has an immense appetite for oil and emphasised the types of artificial lift systems that help suck oil from the well.

The second day of the event was initiated by Ganapathiraman in his presentation on ‘Digital transformation overview’. He distinctly remarked that every organisation needs digital transformation, or else it won’t be in the business for long.

Building data strategy

Being proactive Subsequently, Retd Lt Col L Shri Harsha, Deputy Program Director & Construction Manager, Visakhapatnam Smart City Project, discussed ‘Big Data in city administration’. He emphasised that smart city concept is about how proactive one is going to be in decision making. “Without this, data is completely useless,” he elucidated. The next session began with Arun Yadav, Manager & MES Solution Lead, Pulp and Fiber Business, Grasim Industries, discussing ‘Global implementation of smart manufacturing solution and design and implementation of greenfield smart factory.’ He pointed out some basic business needs like, single system to access all plant process and asset related data & eliminate spreadsheet and calculations in silos.

We are rapidly progressing from a knowledge-driven economy to a data-driven one. From this perspective, Achyuta Ghosh, Head of Research, NASSCOM, spoke on ‘Building a Heading towards digital success national level data strategy for India’. He earnestly cited that The second day came to its last segment – ‘End user India has the opportunity to gain significant competitive advantage in the data-driven economy. He also put across some experiences – going digital’. The first session of this segment had illustrative national data strategy considerations, such as, Anuradha Shenoy, Chief Manager – Information Systems & addressing ownership & control of data, enabling safe, legal data Digital, Bharat Petroleum Corporation, talking about ‘Digital initiatives at BPCL refineries’. Shenoy focused on the company’s sharing and data governance. strategic focus for refineries, in which operational excellence, project conceptualisation and innovative technologies, are all tied Challenges impeding IIoT growth up with people engagement. In addition to this, the interest of the The third session of the day commenced with Vivek Roy, audience was further augmented by the session on ‘Digitalisation Chief Manager – Marketing, Siemens, speaking on ‘Cybersecurity in Tata Steel’ by Gaurav Saran, Senior Manager, Process & network transparency’. He said, “As digitalisation is changing Technology Group, Tata Steel. “We go for data empowered everything, to stay successful, three key elements need to be decision making, internal collaboration to establish the digital considered – availability and application performance, backbone and process visualisation and diagnostics to embrace transparency and security.” After this, Amit Shrivastava, Director, digital disruption,” he told the audience.

Business Development – Digital Twin Solutions, Bentley Systems, The event soon came to its last session – ‘Digital gave a presentation on ‘The digital twin solution for process transformation in Indian industries – an end-user survey’ by industries’. “Digital twin is one of the top ten strategic technology Rajkumar Paira, Senior Analyst, ARC Advisory Group. Paira trends for 2019,” he conveyed. explained that the ARC research is intended to shed light upon The second day turned to its next segment – ‘Digital the digital transformation of the industry, including IIoT uptake transformation for industry and cities’. The subject of in the industrial space. “To head towards successful digital ‘Challenges in digital transformation for Indian process transformation, it is important to make honest assessments, industry’ was taken up by Vivek Gupta, Assistant Vice account for the human element and have a cohesive strategy,” President – Instrumentation, DCM Shriram & Steering he affirmed.

Committee Member, Digital Transformation Council, ARC Both the days of the fastidious event had one-on-one Advisory Group. While elucidating on the challenges impeding discussions with the audience where the presenters and speakers IIoT growth, Gupta pointed out that lack of end-to-end answered questions on their presentations. ☐ encryption, disparate regional standards, and scalability With inputs from Sharada Prahladrao, Editor & Public Relations Manager, ARC Advisory Group challenges are some of the challenges standing in the way.

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A&D India | Aug-Sep 2019

NEWS | TECHNOLOGY

Lubrication-free two-component bearing

Control cabinet inverter

igus recently expanded its range of bearings by developing iglidur Q2E, which is a lubrication-free two-component heavy-duty bearing and closes the gap between existing bearings and solutions made of metal and composites. The bearing consists of high-performance plastics making it completely lubrication and corrosionfree. Dirt and impurities cannot adhere to the bearing points hence minimising the wear. In addition, less grease and oil escapes into the environment. iglidur Q2E Another advantage is that the injection-moulding method used to manufacture the plain bearings is costefficient. It ensures wear-resistance, and a hard polymer shell protects the bearing. Two materials in an encapsulated design ensure that the bearing can cope even with the most extreme edge loads. This is because the new bearing has a hard polymer shell and a tribologically optimised core composed of iglidur Q2 as the material. When used for a plain bearing with a diameter of 20 mm, this material is also very dimensionally stable and wear-resistant even under high loads of up to 7 metric tons. Functioning as a protective sheath, the shell makes the bearing very sturdy and ensures that it has a longer service life.

Nord recently launched a control cabinet inverter, NORDAC PRO SK 500, with an impressive number of interfaces for communication and fieldbuses, innovative features as well as several extension possibilities, so that they can be easily integrated into all automation architectures.

The devices can also be parameterised via the USB port without an external power supply.

With their various versions, the new frequency inverters can be optimally assigned to a wide range of application requirements. The functions of the modular series can be extended by plug-in control, safety and option NORDAC PRO SK 500P series modules. The slim design saves space in control cabinets and enables side-by-side installation. The inverters are available in a power range from 0.25 to 5.5 kW. Also, the precise current vector control can provide the optimum torque in various load and speed situations and guarantees operational reliability with high overload reserves.

The integrated brake chopper for 4-quadrant operation is a part of the basic equipment for the entire series. The new solution for the control cabinet installation is available as a machine inverter (SK 500P) and as an application inverter (SK 530P and SK 550P).

igus India | Bengaluru Email: vinayak@igus.in | Tel: +91-9341136381

Nord Drivesystems | Pune Email: india@nord.com | Tel: +91-20-39801200

Double clamping vises

Multi-code readers

Schunk recently expanded its series of KONTEC KSC-D double clamping vises.

The light and flat double clamping vises with the jaw width of 125 mm are available in seven body lengths: 320 mm, 390 mm, 460 mm, 530 mm, 600 mm, 670 mm, and 740 mm. While in size 80, the length of 300 mm is standardised. The double clamping vises are designed for continuous operation in automated machine tools with workpiece storage. Also, it Schunk KONTEC KSC-D features an induction-hardened body, long jaw guidance, fitted slides, case hardened chuck jaws, and an encapsulated drive ensure that a high degree of precision, maximum wear resistance, and minimum cleaning effort. Completely nickel-plated, the vise is perfectly protected against corrosion for continuous use in pallet systems or on tombstones. The workpieces can be inserted side-by-side and clamped together via a third-hand function. The trapezoidal threads allow for high clamping forces with little effort. The clamping pins of the pallet system Schunk VERO-S are connectable into the base body of the vise with screws.

The clamping force blocks can also be fitted with a wide variety of chuck jaws from the Schunk standard chuck jaw program.

ifm recently added the O2I50x series to its bouquet of multi-code readers devices. This series can evaluate different kinds of one or two-dimensional codes. The multi-code reader has many features. A storage device is, for example, directly integrated onto which the complete configuration is stored. If a device should need to be replaced, the storage device can simply be inserted in the new device which is immediately configured.

Expensive downtimes are minimised. O2I50x series Furthermore, the internal storage device can be used to configure the same application on different devices.

To communicate with the higher-level applications, the multi-code reader has an Ethernet interface which does not only allow communication via TCP/IP but also via Ethernet/IP. It has a stable and industrially compatible diecast housing and can be easily installed. The connection is designed as a 5-pole M12 connector, which has the advantage that the pin connection is standardised, and no individual wiring is necessary. Y cables are now available as accessories via which the voltage is supplied, and an external trigger is connected.

Schunk Intec India | Bengaluru

ifm electronic India | Kolhapur

Email: info@in.schunk.com | Tel: +91-80-405-38999

E-mail: info.india@ifm.com | Tel: +91-231-2672770

A&D India | Aug-Sep 2019

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TECHNOLOGY | NEWS

New smart probes with additional features Testo smart probes are smart & compact measuring instruments which can be connected to the smartphone or tablet via Bluetooth, and intuitively operated via App. They proved out to be a great development in the HVACR segment making on-site measurement and data sharing as simple as a click on your smartphone. The company has introduced 3 new smart probes in its basket— testo 605i (thermo-hygrometer), testo 549i (highpressure measuring instrument) & testo 115i (clamp thermometer). These innovative, pocket-sized pro measuring instruments carry additional advantages with excellent innovative features & designs.

In addition to the cooling & heating performance of these probes they are capable enough to conduct functional testing of refrigeration & heating systems. For example, for an air-conditioned ambience, there is no need to measure the ambient parameters & duct outlet parameters separately. Instead, they can be measured at the same time even if the vent is placed outside the room. This feature is possible due to the increased bluetooth range of these probes. Mould detection can be carried out using the testo 605i & infrared thermometer testo 805i.

Smart sets New designs & improved operations In order to facilitate refrigeration, air conditioning and The new testo 605i has thinner probe tip which is ventilation contractors with all the measuring ideal for smaller measurement apertures and instruments necessary for their daily jobs, the openings to measure humidity & temperature. It also Testo 605i, Testo 549i & testo 115i company offers tailor-made sets which are better, has a stable magnetic holder given at the back for focused & kits including testo Smart Case for heating, secure attachment. Not only that, it has a bendable probe feature which makes VAC, RAC, HVAC applications. Respective technicians can conduct their on-field measurement more comfortable at the outlets, vents or at any other difficult to measurement tasks and record & share the data by using the smart phone. access locations. The new testo 549i pressure measuring probe is redesigned Multiple probes are available in these kits at special prices, which enables safe & its connection is angled at 45° for easy mounting. The new smart probes storage and comfortable transportation of instruments. They are suitable for all have an extended bluetooth range of up to 100 metres. important temperature, humidity, pressure and flow velocity measurements.

Testo India | Pune Email: info@testo.in | Tel: +91-20-25920000

Intelligent UPS system

Safe sensor technology

Phoenix Contact recently introduced an intelligent UPS system to ensure the superior system availability, which is Qunit DC UPS. An uninterruptible power supply (UPS) is a device that allows a load to keep running for some time when the primary power source is lost. IQ technology is the key to an intelligent power supply solution.

The UPS monitors and optimises the energy storage, avoid Intelligent management with IQ technology interruption when working with the intelligent UPS for non-stop power. The data cable allows the user to integrate the UPS module into the application. The user can, therefore, benefit from all the advantages of IQ technology and be kept informed of the state of their UPS solution. Also, buffer times are optimally utilised. The advantages of the new system include, flexible adaption of Qunit UPS behaviour to individual requirement, monitoring and data recording, knowing the state of charge and remain run time of the energy storage, being warned about failure at an early stage and having the time to prevent them, maximising the service life of the energy storage and transfering all the relevant information to the computer and higher–level controller.

Pilz portfolio recently expanded with the introduction of the safe sensor technology range PSEN, which is a safe complete solution for protection zone monitoring. It comprises of the safe radar system, with up to six radar sensors and one control unit, depending on the application. Add to that the configurable safe small controller PNOZmulti 2, which is responsible for safety in the solution.

The solution can be used up to SIL 2, PL d, PSEN range Category 2. The layout for a protection zone is flexible: Each sensor has a maximum range of 4m and can be configured with a narrow or wide coverage area, 50º horizontal and 15º vertical or 110° horizontal & 30° vertical, respectively. The Inxpect Safety software configurator enables the user to select the sensors and their configuration. An additional warning zone can be configured here as an option. This saves time, plus the machine can be put into service more quickly. This complete solution provides safe, economical monitoring even in the must rugged environments – in extreme production environments, such as, dust in woodworking for example – or with complex plant structures. Benefits of the safe radar system solution include high plant or machine productivity, despite the most rugged environment.

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Phoenix Contact India | New Delhi

Pilz India | Pune

Email: response@phoenixcontact.co.in | +91-11-30262700

Email: info@pilz.in | Tel: +91-20-49221100

A&D India | Aug-Sep 2019

NEWS | TECHNOLOGY

Comprehensive image processing in PC-based control system Beckhoff recently incorporated comprehensive image processing capabilities into its PC-based control system with the help of TwinCAT Vision, which is a software that unites a comprehensive range of machine functionality – PLC, motion control, robotics, high-end measurement technology, IoT, HMI and now machine vision – all in an end-to-end engineering and control platform.

The software opens up vast innovation potential in machine building – for instance, through consistent real-time synchronisation with other automation tasks or support of advanced trackand-trace solutions.

The software also provides the required image processing capabilities in the form of PLC functionality on a universal, end-to-end software TwinCAT Vision platform, complete with a specially developed library of image processing functions and function blocks that can be called up directly from the TwinCAT PLC. The flexible runtime system in TwinCAT is capable of executing these functions and function blocks in real-time.

Integration at this level simplifies engineering significantly, so that PLC programmers can create machine vision applications themselves without support from outside experts.

Works in existing environment The GigE Vision compliant cameras of almost any kind can be added easily – even in parallel – via standard camera interfaces and configured in TwinCAT engineering. The cameras can also be calibrated directly, either in the engineering environment or mid-process in the runtime system. With the new software, there is no need for specialised tools or programming languages when coding the image processing logic, because the machine vision applications are created in the PLC, using familiar PLC programming languages.

Direct communication solution With stand-alone machine vision solutions, communication between image processing & control applications can be complex and difficult to manage.

External factors, such as, the operating system may also have an impact on the processing time and data transmission speed. This software not only avoids communication problems of this kind, but also allows the image processing & control components to communicate with one another directly. Because the image processing operates at the same real-time level as the PLC, response times are shorter and machines can run faster and more efficiently, as a result.

Beckhoff Automation | Pune Email: info@beckhoff.co.in | Tel: +91-20-6706 4800

Motion control software

Cables for the rail industry

B&R recently added new functions to its mapp Motion software package, that makes it possible to represent the actual structure of a complex machine intuitively in the configuration. The various subsystems of a machine can simply be linked together. The movements of robots can be easily synchronised with gantry systems or tool tables with no additional programming. The “Frame hierarchy” mapp Motion function can be used to represent the actual structure of a machine. Each coordinate system can be assigned a name that identifies it within the application. This ensures clearly organised, easily readable code – even in complex applications. While, the “Programmed moving frame” function couples a coordinate system to an axis and defines an additional degree of freedom. This allows optimised movements and better utilisation of robot dynamics. The function incorporates the movement of the gantry system into the path calculations of the robot. Only one controller is necessary for the machine, robot and other moving components. Plus, the coordinated path planning allows optimal utilisation of the dynamic limits of the individual components. It also guarantees that all specified process parameters are adhered to, such as the relative speed between tool and workpiece.

LAPP recently added several new cables and system products to its range of products for the rail sector. As a result of shortening of delivery times around the world, from up to three months to less than a week, the users can reduce inventories and respond to new requirements even faster. Most of the new cables are now also available off-the-shelf. The new range comprises of: ÖLFLEX CLASSIC 110H SF – This control cable, with its Class 6 New range of power and control cables conductors, is extremely flexible, allowing for installation in tight spaces. Further variants include the shielded ÖLFLEX CLASSIC 115 CH SF and ÖLFLEX CLASSIC 115 CH SF (TP). ÖLFLEX TRAIN HT150 – This single-core silicon cable is designed for use at high temperatures and can withstand up to 150°C. ÖLFLEX TRAIN 340 and ÖLFLEX TRAIN 345C – These cables are available in cross-sections of 0.5 mm2 to 50 mm2 and with between two and 40 cores.

The company also offers the complete range of data connection technology and is constantly expanding its range of connectors and system products, such as cable glands, cable inlets and cable protection systems as well as labelling solutions and tools.

B&R Industrial Automation | Pune

Lapp India | Bengaluru

Email: office.in@br-automation.com | Tel: +91-20-4147 8999

Email: info@lappindia.com | Tel: +91-80-47405222

A&D India | Aug-Sep 2019

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H I G H L I G H T S | C O M PA N Y I N D E X | I M P R I N T

Highlights – Oct-Nov 2019 IMPRINT

Automation & Drives

Publisher / Chief Editor ShekharManufacturing Jitkar Efficient

shekhar.jitkar@publish-industry.net Features Writer Juili Eklahare juili.eklahare@publish-industry.net Anvita Pillai Sub-editor & Correspondent anvita.pillai@publish-industry.net Content Developer (Online & Print) Namrata Singhania namrata.singhania@publish-industry.net

» Food & beverage processing The food & beverage industry is the second largest industry in terms of production. The networth of the industry is estimated to be 12% of the world’s GDP. The industry is making a fast-paced move towards adopting the latest technologies to help increase operational efficiencies and customer order fulfilment as well as to increase throughput and quality. The forthcoming edition explores the latest technology adoptions, automation solutions and more.

» Sensors & encoders In Industry 4.0, sensors & encoders will enable extensive analysis, automatically adapt to changes, provide real-time condition monitoring and remotely solve complex tasks within a larger manufacturing network. The upcoming issue takes a look at how user-specific applications can be more easily be developed and quickly implemented in Industry 4.0.

» Robotics & handling The dire need to increase manufacturing agility whilst reducing production costs have given rise to industrial robotics and handling. With the industry accelerating towards Industry 4.0, the worldwide sales of industrial robots are set to increase at least 15%. The following edition will investigate the key factors driving the expansion of the robot usage in industrial processes, types of industrial robots, leading robotic operating systems and more.

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COMPANY INDEX Name . . . . . . . . . . . . . . . . . . . . . . . . . Page ARC Advisory Group . . . . . . . . . . . . . . . . . . 58 B&R Industrial Automation .Cover, 6, 7, 10, 30, 63 Balluff Automation India . . . . . . . . . . . . . . . . 14 Beckhoff Automation . . . . . . . . . . . . . . . . 1, 63 C4i4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Contrinex Automation . . . . . . . . . . . . . . . . . 25 Delta India . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Detect Technologies . . . . . . . . . . . . . . . . . . 18 Emerson . . . . . . . . . . . . . . . . . . . . . . . . . . 10 HMS Industrial Networks . . . . . . . . . . . . . . . 51 Hummel Connector Systems . . . . . . Back Cover ifm electronic India . . . . . . . . . . . . . . . . 45, 61 igus . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 61 IMTMA . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Innovista Sensors India . . . . . . . . . . . . . . . . . 9

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Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Katlax Enterprises . . . . . . . . . . . . . . . . . 17, 37 Kubler Automation . . . . . . . . . . . . . . . . . . . 41 Lapp India . . . . . . . . . Back Inside Cover, 38, 63 Maxon Precision Motor India . .Front Inside Cover Mitsubishi Electric . . . . . . . . . . . . . . . . . 13, 53 MurrElectronik India . . . . . . . . . . . . . . . . . . 43 Mettler Toledo . . . . . . . . . . . . . . . . . . . . . . 19 Nord Drivesystems . . . . . . . . . . . . . . . . 55, 61 Phoenix Contact . . . . . . . . . . . . . . . . . . 35, 62 Phoenix Mecano . . . . . . . . . . . . . . . . . . . . . 57 Pilz India . . . . . . . . . . . . . . . . . . . . 16, 27, 62 QuEST Global . . . . . . . . . . . . . . . . . . . . . . . 34 Rexel India . . . . . . . . . . . . . . . . . . . . . . . . 15 Rittal India . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Rockwell Automation . . . . . . . . . . . . . . . . . . 12

Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Schmersal Group . . . . . . . . . . . . . . . . . . . . 28 Schunk Intec India . . . . . . . . . . . . . . . . . . . 61 Sectigo . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Seebo . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 SEW-EURODRIVE India . . . . . . . . . . . . . . . . 21 Sick India . . . . . . . . . . . . . . . . . . . . . . . 8, 47 Siemens . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SMC Pneumatics . . . . . . . . . . . . . . . . . . . . 49 Tata Consultancy Services . . . . . . . . . . . . . . 22 Testo India . . . . . . . . . . . . . . . . . . . . . . . . . 62 Titan Engineering & Automations . . . . . . . . . . 39 VDMA Robotics + Automation . . . . . . . . . . . 52 VDW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Yokogawa Electric Corporation . . . . . . . . . . . 42

Board of Directors Kilian Müller (CEO – Worldwide) Hanno Hardt (Head – Marketing & Business Development) Frank Wiegand (COO – Worldwide) Shekhar Jitkar (Publisher / Chief Editor) Subscription Cover Price: `100 Annual Subscription Price: `600 AandD.india@publish-industry.net Tel: +91-7410006435/36 Printing Vikram Printers Pvt. Ltd., Parvati Industrial Estate, Pune-Satara Road, Pune - 411009, Maharashtra, INDIA Copyright/Reprinting The publishing company holds all publishing and usage rights. The reprinting, duplication and online publication of the magazine contents is only allowed with written permission from the publishing company.

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A&D India | Aug-Sep 19

RNI NO. MAHENG/2010/34602