IndustrialMachineryDigest.com | January 2022
North America’s Manufacturing Resource for Industry Professionals Since 1986
» Manufacturing Showcase: Hypneumat » Talking Shop: Greg Groth » Is Manufacturing Making Progress? » On TRAK to Industry 4.0 » Heat-Treating Gears Improves Surface Durability » Machine Tools Learn to Improve Thanks to AI » Configuration Lifecycle Management for Sustainability
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Table of Contents
COLUMNS
10
BUSINESS 4.0 Configuration Lifecycle Management for Sustainability By: Henrik Hulgaard, CTO, Configit
14
TALKING SHOP Greg Groth, Division Manager – Exact Metrology
20 FEATURES
20
16
MANUFACTURING SHOWCASE Hypneumat By Loyd McIntosh
22
24
INDUSTRIAL FABRICATION & AUTOMATION
16
WORKFORCE DEVELOPMENT Is Manufacturing Making Progress?
By: Robin Cave, National Applications Engineer, Mazak Corporation
Exploring the Current State of the Workforce Skills Gap By: Michael Womack
28
44
NEW TECH
32 PROCESS
Advanced rotary surface grinders enable efficient, precise resurfacing of the build plate, improving productivity and quality By: Del Williams
36
SURPLUS BUYING AND SELLING
On TRAK to Industry 4.0 TRAK Machine Tools brings digitalization to job shops
SAFETY & MAINTENANCE Machine Tools Learn to Improve Thanks to AI
DEPARTMENTS
INDUSTRY INSIGHTS Heat-Treating Gears Improves Surface Durability
By: Brian Dengel, KHK Gears USA, Inc.
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EDITORIAL DIRECTIONS INDUSTRY NEWS PRODUCT SHOWCASE ON EXHIBIT MODEX
49 CLASSIFIEDS 50 ADVERTISER INDEX
ON THE COVER Radwell International stocks and sells New and Surplus Industrial Automation, MRO, Pneumatic, Motion, Electronic, Hydraulic, HVAC and Electrical Control Equipment for plant floor and facilities maintenance machinery. Learn more at www.Radwell.com
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Editorial Directions Welcome to the new Industrial Machinery Digest. The issue might look a little different, but our coverto-cover editorial coverage of the manufacturing industry is still here for you each month. 2022 is shaping up to be an interesting year, and our team is excited for the opportunity to highlight the latest from leading manufacturers and suppliers to improve your business. The manufacturing industry made huge strides last year. Investment in new technology was at an all-time high. According to the Association for Manufacturing Technology (AMT), at the time of writing, the total orders were up to $4.7 billion. Business owners are making significant investments, and not just in terms of capital equipment, but also their future. Technology that was once often regarded as science fiction, such as Artificial Intelligence (AI), is becoming more commonly implemented, even in small-to-medium shops. The capabilities of artificial intelligence can range in broad to specific applications. Utilizing advanced sensors and complexed programming, these systems are created to perform tasks such as quality control, maintenance monitoring, and even sometimes logistics. Data taken from thermal or vibrational sensors can help determine tool life, while machine vision systems help determine part accuracy or detect irregularities before moving on to finishing. In some use cases, you could think of AI as another set of eyes providing you with valuable insight on your already costly equipment. Now that technology can go even further and implemented into your workforce through wearable devices ranging from smart glasses to apps on a mobile phone or tablet. Artificial Intelligence can be used for augmented reality for training or diagnostic purposes, and aide managers and team leads in uncovering productivity issues. The data taken from these devices can be analyzed and highlight the choke points that may result from shift change overs or other issues. Don’t forget to check out the new expanded, and enhanced, Product Showcase. Each month, you can find IMD’s top products and technology for manufacturing professionals. Want to learn more about a featured product? Scan the included QR code with any mobile device’s camera and you can read more on IndustrialMachineryDigest.com.
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Fab, Form, Finish – Fabricating & Heat Treating in House Fabricators across the country are searching for ways to expand their current capabilities and are looking to bring services they may have previously outsourced back in-house. Special focus includes finishing, plating, and heat treatment equipment that can be quickly brought online to meet their production needs.
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Industry News
INDUSTRY NEWS Industrial Machinery Digest's Industry News features the latest news and press releases from some of the industries top companies. WANT TO BE FEATURED? Send your press releases to editorial@indmacdig.com
Trim-Lok, Inc. Announces Major Midwest Expansion
at the 2021 AME International Conference along with Bob Chapman (also Hall of Fame) and Joe Fisher (Lifetime Achievement Award).
To better serve Trim-Lok’s existing customer base and support the growth that they have experienced during their 50 years in business, including over 6 years in Elkhart, Indiana, Trim-Lok announces a major expansion in the Midwest. They have entered into an agreement to occupy a new, state-of-the-art facility on the Eastern border of the City of Elkhart, Indiana. This new facility will be 150,000 square feet of manufacturing and warehousing space and add an additional 5,500 square feet of office space with the latest technologies to support all facets of their business. Trim-Lok’s expansion will create many additional jobs, including manufacturing and warehouse jobs, as well as office positions to support the significant investment they are making into equipment to increase manufacturing capacity and implement new capabilities.
ANCA Launches its Own Television Show – The ANCA Academy Each month, the ANCA Academy show will cover a different technical topic from set up through to grinding. The educational videos will help ANCA machine users understand new applications and features. Hugh Ingham, ANCA Mechanical Engineer hosts the new show and said: “I love working at ANCA because we design and apply really interesting and effective technology. It is important that we make sure we are helping our customers and those interested in getting into cutting tool grinding produce the best possible product faster, more accurately and at the lowest possible cost. The first episode will explain a PCA adaptor, how they work and how you can set your machine up for long and stable batch runs.”
Harry Moser Inducted to Association for Manufacturing Excellence Hall of Fame The Association for Manufacturing Excellence (AME) inducted Harry Moser, president of the Reshoring Initiative®, into the AME Hall of Fame during the 2021 AME International Conference. The AME Hall of Fame recognizes industry thought leaders and influencers who support the values, principles and practices found within leading enterprise excellence organizations. The nomination criteria include the significance of an individual's contributions to the growth of enterprise excellence within the lean, continuous improvement community. Moser joins 34 previously inducted Hall of Fame members including Jean Cunningham, George Koenigsaecker, John Shook, James Womack and Robert “Doc” Hall. Moser was honored
BIG KAISER Changes Name to BIG DAISHOWA BIG KAISER Precision Tooling Inc. is excited to share important news concerning the name of its company. BIG KAISER Precision Tooling Inc. will change its name to BIG DAISHOWA Inc., effective January 1, 2022. “BIG DAISHOWA is a global leader of tooling systems, and we have been a member of the BIG DAISHOWA group of companies for many years,” said Jack Burley, President & COO. “The name change is a natural evolution in this relationship. Being known as BIG DAISHOWA in North
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America will strengthen our corporate presence on a global scale."
Platinum Tooling President Celebrates Four Generations and 100 Years in Metal Cutting
machine tool industry has been and continues to be an extremely vital part of our country’s continued success. My son Luke and I are proud to be 3rd and 4th generation professionals involved in this exciting industry.”
KYZEN’s Senior Chemist Wins Women’s Excellence in Metal Forming and Fabricating Award 2021
In a world where machine shops are struggling to stay open and maintain their business and in a day when “going into dad’s business” is not what it once was, Platinum Tooling is an exception to the rule. Located in Prospect Heights, Illinois, the company is set to reach an important milestone. In 2022, company President Preben Hansen and his family will celebrate 100 years working in metal cutting and four generations of Hansen men in the industry. Reflecting on 100 years as a family in the manufacturing industry, Preben Hansen says, “The
The Precision Metal Forming Association (PMA) recognizes 40 women in leadership positions that represent commitment to their company and industry, but also to help support and inspire those that may be interested in a similar career path. Haley Reid has been employed with KYZEN for nine years after interning with the company for a year. During her time, she has worked very closely with the founder of KYZEN, Kyle Doyel, to research and develop chemistries in both the electronics and metal finishing industry. Recently, she even developed the newest MICRONOX product MICRONOX MX2120, a
multi-metal safe power module cleaner, that premiered this month.
SME and CESMII Join Forces to Accelerate Smart Manufacturing Adoption “The past decade has revealed an unprecedented flattening and even decline in our manufacturing productivity by worker,” said Robert Willig, CEO, SME. “Together, CESMII and SME will optimize our strengths and resources to accelerate the transformation and democratization of the smart manufacturing ecosystem and jumpstart productivity.” Willig said the collaboration will help bring clarity amongst oftenconflicting voices offering guidance about the way forward. Without recreating the wheel, CESMII and SME will strategically combine their rich networks and resources to advance smart manufacturing adoption and address the “digital divide” by connecting manufacturers to technical knowledge.
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Business 4.0
Henrik Hulgaard CTO, Configit ABOUT THE AUTHOR Henrik Hulgaard is the CTO and co-founder of Configit, the global leader in Configuration Lifecycle Management (CLM) solutions and a supplier of business-critical software for the configuration of complex products. He holds a doctorate in computer science from the University of Washington and is an associate professor of computer science. He has published more than 25 articles internationally.
Configuration Lifecycle Management for Sustainability As buyers consider the carbon footprint of products, Configuration Lifecycle Management can help them make the right choice.
W
hen today’s consumers are evaluating their options, they’re figuring sustainability and the product’s carbon footprint into the evaluation process. A report by IBM and the National Retail Federation found that 8 in 10 respondents indicated sustainability mattered to them; 6 in 10 said they’d be willing to change their shopping habits to reduce environmental impact. This means having the least expensive product is no longer an adequate differentiator – and many companies are now taking notice. Sustainability is quickly becoming a competitive differentiator.
Green Regulations in Manufacturing The Center for Energy and Climate Solutions notes that the manufacturing industry accounts for about 30% of greenhouse gas emissions, including indirect emissions resulting from the sector’s electricity consumption. The
10 | IMD JANUARY 2022
EPA defines sustainable manufacturing as “the creation of manufactured products through economically sound processes that minimize negative environmental impacts while conserving energy and natural resources. It also enhances employee, community and product safety.” In the European Union, the Sustainable Finance Disclosure Regulation (SFDR) went into effect earlier this year. The idea behind this law is to unify transparency rules for financial market participants and financial advisers about integrating sustainability risks and negative impacts in their processes. Companies that fall within the purview of the SFDR must provide sustainability‐ related information about their financial products. This means investors who put capital into Europe or marketing investments in Europe will be subject to Environment Social Governance (ESG) disclosure obligations. The
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regulation precedes the new EU Taxonomy for sustainable activities, which will provide a clear definition of sustainability and require investments promoted as environmentally friendly to be clear on their green objectives. The intent behind this taxonomy, which takes effect in 2022, is to promote larger investment in green projects. The U.S. and the UK are considering similar regulations, as the EU directives will apply to companies in these regions operating in the EU area. Though these regulations mainly target the financial industry, they will impact every other sector as regulations like these redirect funds towards more sustainable projects and companies. And this could be just the first of many industries to see sustainability regulation within the next few years.
Environmental Impact in Product Manufacturing There are several other factors to consider when it comes to product – and specifically, configurable product – manufacturing. For example, how do you help your customers find the right product with the smallest footprint that still meets their requirements? How do you find that balance between performance, price and sustainability? A good example is what‘s happening in the car market. More and more consumers are placing greater emphasis on emissions standards. These decisions aren’t always cut and dry. Here’s an example: Imagine you’re a pump manufacturer. In the long run, it’s more important that your customers pick the right pump for their situation than pick it based on the energy footprint of manufacturing the pump. That said, environmental impact is taking on increased importance for buyers overall and product manufacturers need to understand their role in this. Customers are looking for transparency, and as a product manufacturer, you can provide this by helping customers understand how to configure your product(s) so that the environmental impact is as low as possible.
The Role of Configuration Lifecycle Management To help your buyers make more environmentally friendly choices, consider the aid rendered by Configuration Lifecycle Management. It can give buyers insights on how to make the best trade-offs between performance, price and environmental impact. Here’s the
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opportunity for companies to turn this into a competitive differentiator: each product component or choice can be correlated to a carbon footprint cost. This is similar to the energy efficiency ratings that the ENERGY STAR program calculates for consumer products. Configuration Lifecycle Management takes that concept in-house and giving each of the different options a rating. Consumers can then see how the different product configuration options stack up and use this information to make a purchasing decision. But it goes beyond this. By using a configurator, it’s possible for the consumer to specify upfront what energy rating they want, for example, and then have the configurator engine guide them toward a set of choices that are guaranteed to be within the overall constraint.
Sustainable Configuration These days, a product’s total cost involves more than the price tag a buyer sees. Product teams have the opportunity to create a differentiator by highlighting the sustainability of their products. Configuration Lifecycle Management enables your customers to compare options and find the product that aligns with both their business and sustainability goals. It can help lead to purchasing decisions that serve the environment as well as your customers. ABOUT CONFIGIT Since its founding, Configit continues to grow, developing products and solutions to address digital transformation, Internet of Things, and the increasing proliferation of software consumer products. Through cooperation with clients and partners, Configit takes pride in helping organizations with complex configuration problems, as well as helping to shape the future of configuration software. For more information, www.configit.com
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Talking Shop
Understanding your hardware and its limits and capabilities are the recipe to successful workflows.
FEATURING:
TALKING SHOP WITH: Greg Groth — Division Manager – Exact Metrology How would you describe your company’s primary business? We are a service and sales oriented business, with both offerings being complimentary to each other. Our expert service and education helps customers transition into being able to provide their own internal capabilities with hardware and software that we proudly support.
For many manufacturers, reverse engineering can relate to several different processes. In what ways does Exact Metrology specialize in reverse engineering? Our goal is to accurately digitally duplicate whatever a customer presents to us. We have a variety of data acquisition tools to capture items of all sizes and shapes. Secondarily, a considerable toolbox of software to process the data accurately.
What are some common reasons for reverse engineering? One common reason is salvaging legacy components that were never digitally captured. Imagine a 75-year-old car part that may be of only few in existence. Those were never pushed
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through a CAD package, or maybe even never captured through drawings. Another solution is adaptability. To mate something or accurately bolt on a component requires an accurate starting point. Capturing the existing condition of an amputee, allows for proper fitment of a prosthetic, this reduces injury or additional soreness. Starting with the right “actual” is paramount.
Are there many misconceptions about reverse engineering? Yes. Accuracy requirements get blurred into the capabilities of the scanning hardware used. There is an inevitable stack-up of tolerances that occur.
IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986
Manufacturing defects, like shrink and flash are typically worked out of the final deliverable but would initial fail the ‘rule’ established by the accuracy requirements of the final model. Simply, if there was a sink mark of .010” on a plastic part, that would never need to be replicated in the final design, but if a +/-.005” final deviation tolerance allowance is established, that correction would violate that baseline request.
on its size. CT’s common use is internals, or complex small assemblies. Long Range expands the reach of the smaller portable CMM and Structured light. With, project dependent, can all be used in collaboration to create an end result data set. It is not uncommon that we utilize several of these technologies in tandem to get a complete, accurate digital copy.
What factors should be considered before someone begins the process of reverse engineering?
Is validation important, and in what ways can manufacturers validate the data taken from their scans?
We have a basic rule here, and that is “What are you doing with it?” Although that may seem a bit intrusive, it answers a lot of questions. The simple answer to that question sets a path of hardware and software to be used. It also can dramatically change the timing of the project, which can be dramatically financially impactful to our customers. Our goal is to educate those customers on the front end.
Yes. Garbage in, garbage out. Most hardware suppliers have stop gaps or validation procedures in place to check their hardware to maintain that it is still within factory specifications. We routinely, using the hardware guidelines, validate our hardware pre and post job. This allows us to track accuracy shifts and mitigate any problems in process, not after completion.
In general, what are the different use cases for Structured Light, Portable CMM/Scanning Arms, Long Range Scanners, and CT (X-Ray) scanning machines?
Is it possible to identify areas of weakness or potential reliability issues that may not have been recognized previously?
There are a lot of variables at play here. One driving factor may be pure accuracy requirements. There are also crossovers here, with Structured Light/Portable CMM/CT all being capable of scanning the same part, depending
Yes, education is critical. Understanding your hardware and its limits and capabilities are the recipe to successful workflows. For more information, visit www.exactmetrology.com
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Robin Cave National Applications Engineer Mazak Corporation ABOUT THE AUTHOR Robin Cave is an application engineer at MAZAK Corporation. He has worked with the company for over 38 years. To learn more about MAZAK and their line of machine tools and controls, visit www.MazakUSA.com.
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Machine Tools Learn to Improve Thanks to AI
A
rtificial intelligence (AI) and machine learning can analyze performance data and deliver optimization results that exceed what human beings can accomplish. For data giant Google, AI reduced server-farm cooling costs by an average of 30% after only a few months of use, with even greater optimization potential as the system continued to acquire performance data. Similarly, AI can reduce manufacturing setup time, enhance efficiency and workpiece quality, and boost productivity for better profits, helping shops progress past old-fashioned trial and error. Until the advent of AI and machine learning in manufacturing technology, the old saying "If at first you don't succeed, try, try again" described how shops attempted to make good production results repeatable. Because the machines could not provide first-hand insights into their performance, engineers identified good parts and doubled back to the production floor to ask operators how they achieved that level of quality. But even with operator notes, many shops failed to replicate success from day to day, and the large, growing volume of data generated through
machine analytics provided too much information for timely processing. Now, with smart CNCs and AI systems, machines can provide essential data about how they operate when they make a good part, and process all that information automatically to improve future results through machine learning. In an AI-equipped CNC, the controller
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can collect data about everything from axis thrust levels to spindle temperature and RPM, coolant behavior and more, providing a far more detailed picture of each production task than any operator's notes could capture. All this information can facilitate faster setups and shorter cycle times, improve surface finishes and boost machining accuracy, all while making overall machine operation easier. But at the rapid pace of a busy production environment, humans cannot collect and analyze the exhaustive data required to recreate a successful production task at scale. To achieve these data-driven improvements, Mazak developed the MAZATROL SmoothAi CNC – the industry's first dedicated CNC designed specifically for 5-axis machining and Multi-Tasking – and gave this new control the artificial intelligence to manage production project data, CAD/CAM software and machine behavior. This enormous volume of information includes programs, tool and coordinate data, and all the parameters required for machining. To process all this information automatically, the MAZATROL SmoothAi CNC includes the Mazak SMOOTH Project Manager, which provides an AI-managed set of analytics. Its advanced processing helps reduce the time required for data to flow into and out of a machine network, which in turn, speeds setup. With the SMOOTH Project Manager in charge, the system can communicate the machine's configuration, condition and behavior to CAD/CAM software, virtually eliminating manual input and the errors it can cause. These advanced capabilities help flatten the learning curve for new machine operators just as they enable less-experienced employees to succeed at more-advanced production tasks. Along with the information necessary to produce good parts, analytics also help eliminate machine crashes and production-quality hazards. On MAZATROL SmoothAi CNC-equipped Mazak machines, Ai Thermal Shield automatically adjusts temperature compensation to maintain precision as environmental temperatures change. As thermal compensation reports accumulate, artificial intelligence uses the long-term data to optimize compensation even further. The optional MAZATROL SMOOTH AI Spindle then monitors milling vibration and automatically adjusts spindle speed to minimize chatter and maintain excellent surface finishes. AI enhances advanced processes as well as production of individual workpieces. Automated and lights-out machining have become essential in many shops, but these processes can fail unless tools, workpieces, fixturing and programming are available before production starts. On MAZATROL SmoothAi CNC-equipped systems with advanced robotic automation for high-mix, low-volume production, dedicated management software makes it easy to set up robots and verify all production resources before the cut begins. The same system also validates tool condition against the length of the automated production cycle, ensuring that sufficient tool life remains to complete the production process without an interruption. If any of these parameters fail the pre-check, alarms alert operators
18 | IMD JANUARY 2022
to correct problems before errors can endanger part production or even damage equipment. Shops with stored MAZATROL programs from machines equipped with previous-generation Mazak CNCs can use Smooth CAM Ai File Manager to convert these programs for use on new machines with MAZATROL SmoothAi CNCs. That conversion process can work in both directions, making many programs backward compatible directly through a shop's production network and ensuring that shops make the fullest use of all their machines. In short, every aspect of production, planning and error prevention can benefit from AI's ability to foresee how past experience predicts future performance, manage machine behavior and share moment-by-moment updates on machine condition with CAD/CAM software and automation. Instead of "try, try again," AI and machine learning make great results repeatable without guesswork. From start to finish, these developments can revolutionize metal cutting in all industries for shops of all sizes. For more information, visit www.MazakUSA.com
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Manufacturing Showcase
Hypneumat
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By Loyd McIntosh
or almost 80 years, Hypneumat, Inc. has been a leader and innovator in the drilling and tapping industry. Hypneumat, Inc. was established in the 1940s by Earl Putrow, a self-taught inventor from northern Wisconsin, who created the world’s first high-speed, automatic drilling and tapping unit. Putrow named his invention the Hypneumat, a clever combination of the words hydraulic, pneumatic, and automatic. Less than a year later Putrow established a company bearing the name of his invention, Hypneumat, Inc. Now under the leadership of President John Weber - the fifth owner in the company’s history - Hypneumat develops solutions for industrial automation along three product lines; Hypneumat, Commander, and SNOW. The Hypneumat brand includes a line of automatic high-speed drilling and tapping units, machines, and controls. Under the Commander brand, the company manufactures multiple spindle heads, and, under the SNOW brand, an array of replacement parts, clutch-type tapping heads, and fixtures. Over the last eight decades, Hypneumat has developed a reputation as a leading supplier of automatic drilling and tapping units, which can be found in most major manufacturing industries throughout the world, everything from aerospace, to automotive, food as well as transportation. “We have over 10,000 customers worldwide,” Weber says. "Hypnemaut continues to build on the foundation of the
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same basic units, either powering and automating the process of drilling or tapping with the mechanism of a piston in a cylinder either pneumatically or hydraulically,” adds Weber. "We've also developed units with more sophisticated options utilizing Servo motors with ball screw rail units." After spending 25 years in the foundry and machining industry with a tier-one automotive supplier based in Wisconsin, including a little more than a decade in a top leadership position, Weber decided to strike out in a different direction. He spent almost two years looking for an existing business to purchase before learning that Hypneumat was for sale in 2011. A former customer of Hypneumat, Weber was familiar with its solid reputation within the drilling and tapping industry. It also didn't hurt that Weber's daily commute was more than reasonable as well. "It's less than 20 minutes from where I live, and I'm very familiar with the product, so it was kind of a win-win," says Weber. Hypneumat currently has 19 employees, three of whom have been with the company more than 50 years, as well as some brilliant new minds that have come on board in recent years. The combination of team members with decades of knowledge to build upon with an eagerness to investigate new, innovative ideas makes Hypneumat stand
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out among its peers according to Weber. "We have a long tradition of stability, and it's a good place to work. That's what caught my eye when I decided to buy the company some ten years ago.” Weber believes one of the traits that differentiates Hypneumat from the competition is the company's flexibility. "One thing that makes us stand out, in my opinion, above and beyond our competitors is we will customize our units to just about any configuration a customer wants. I am not aware of anyone building a feed unit that has 26 inches of stroke," says Weber. “We will build units with stroke lengths from three-anda-half inches to 26 inches. We offer many motor sizes, we’ll put just about any spindle-nose type that our customers need, and can include mounting for vertical up, vertical down, or horizontal operation, you name it,” adds Weber. “Our competitors build good products, but they don’t tend to customize quite to the extent that we do.” Having worked in high-end manufacturing for most of his career, Weber understands first-hand how changes to one piece of equipment in one area of the plant can have a ripple effect on the entire operation. For that reason, he is a firm believer in developing custom solutions that fit into the client’s production model. The Hypneumat team, Weber says, is adept at working together internally and with the client’s project team to develop innovative approaches to problem-solving. "We'll collaborate internally with customer input to come up with multiple solutions to tackle the unique challenges of the project," says Weber. "For example, the food industry. You've got to use the appropriate types of lubricants that are food-grade as well as stainless steel components to comply. "We work closely with the customer and collaborate internally to confirm we haven't missed anything or to discover someone has come up with an idea to build a better mousetrap," adds Weber. "We'll jump on it and make proposals to the customer that would make sense for their situation." For example, a customer of Hypneumat’s approached Weber and his team about a year ago with a problem. The client expressed a need for a new builder/supplier of its
swaging machines. The client reached out to Hypneumat for a new design to meet the company’s specific needs. "We came up with a machine that would automatically apply adhesive, hydraulically swage all types of abrasive wheels to hubs with a Hypneumat unit, and auto unloads the assembled part into a bin,” explains Weber. “We designed and built the machine for them, and we are now their exclusive builder of those types of machines." Over the years, Hypneumat has embraced automation to manufacture and deliver products faster and at a lower cost than many of the competitors. An ISO 9001 registered company, Hypneumat has made significant investments into new automated systems allowing them to shorten production times, improve quality, and keep costs as low as possible. “Over the last few years we purchased several five-axis, multiple spindle turning machines that can really speed up and automate the manufacturing process for many of the components that we build in-house,” explains Weber. “We can have one person run numerous machines now without too much fanfare. We have the capability to make common components in large quantities very quickly. This allows us to be more efficient, keeping your costs under control." Hypneumat products are very durable, with many units built decades ago and still in operation and in good working order around the world. “That’s a testament to the company in and of itself.” To learn more about Hypneumat, visit the company’s website at www.hypneumat.com.
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IMD | 21
Industrial Fabrication & Automation
4 Spot Welding Robotic Solutions to Avoid Wasting Your Cycle Time and Shop Space By: Josh Leath, Senior Product Manager, Yaskawa Motoman
F
ast cycle times, efficient floorspace utilization and user-friendly production tools are all necessary for spot welding success. When it comes to the latter, there are several solutions that help manufacturers maximize the benefits that robotic automation can bring to the resistance welding process. With that in mind, here are some spot welding robotic technology “must haves”:
High-Performance Robots Quick axis speeds and acceleration capabilities are key to reducing air-cut time and achieving faster cycle times. Spot welding robots like Yaskawa’s SP-series family of robots are ideal to meeting production and reliability goals, while GP-series robots can be used for existing pedestal welders.
Space-Saving Tools Floorspace utilization can often make or break competitive edge. Highly flexible seven-axis robots such as the SP100B are specifically designed to maximize floorspace and reach into tight spaces. An expanded range of motion and reduced interference design work together to expertly accommodate high-density workcells. Similarly, six-axis robots like the SP80 or SP165 also offer slim profiles to facilitate product line layout flexibility. Pre-engineered workcells, like those based on our ArcWorld® series, are also helping manufacturers solve floorspace dilemmas. Robust robots, positioners and process equipment are easily combined with the proper safeguarding on a space-efficient base. Automotive, agriculture, construction manufacturers and more find that these workcells offer a more affordable way to save on cycle time and resources.
Robust Positioners A wide range of servo positioners exists to provide the speed and reliability needed to get jobs done quickly with the utmost accuracy. From single-axis positioners to threemotor trunnion positioners, and more, a variety of durable options exists to facilitate peak performance. Manufactured to the same exacting standards as our robots, Yaskawa positioners are built to perform for the toughest applications. A patented MotoMount™ fixture mounting system allows positioners to be lagged directly to the floor, increasing positioner life and improving weld repeatability. It also simplifies tooling for faster and easier changeover. Multi-tasking software facilitates coordinated motion control between all multi-axis positioners, robots and base axes from a single primary controller and programming pendant.
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Servo Guns Leading spot gun manufacturers like OBARA and ARO work hard to provide their customers with the lightest, most efficient and versatile welding equipment for any material or part size. More energy efficient than pneumatic guns driven with compressed air, today’s servo spot welding guns help: » Minimize electrode wear, resulting in increased uptime » Provide consistent clamping force, improving quality » Eliminate “squeeze time” wait for an air-gun to close, resulting in reduced cycle time
Comprehensive spot welding packages bring all of this to fruition and typically include: Robust software: spot guns integrated with Advanced Robot Motion (A.R.M.®) control software maximize performance by providing easy calibration for X- or
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C-type spot guns. They also automate offset for gun arm deflection and tip wear compensation. Furthermore, stepped pressure files allow the spot gun pressure to be varied during the weld cycle, as well as during a tip dress cycle. Integrated spot gun harness: the spot welding harness improves throughput by eliminating downtime due to robot harness issues and simplified programming. Product launch times can be reduced via simulation and offline programming, versus editing programs to avoid cable interference. New hollow-arm robots increase these benefits even more, and they are equipped with the proper sized wiring for aluminum spot guns. Efficient servo spot guns: spot gun manufacturers keep packing greater spot gun capability into a smaller system. Transformer sizes have been greatly reduced by using mid-frequency inverters for DC welding. And, higher frequency inverter switching (1,800 to 2,000 Hz) help reduce gun size and weight. Spot timer digital interface: digital interfaces for spot timers, such as the ones offered by Medar® and Nadex®, allow programming from the robot teach pendant. For the Medar MedWeld 6000 timer, the ability to program and monitor information is also provided with up to to 255 weld programs supported (for each timer). Likewise, up to four timers can be networked with a multiple robot controller.
Overall, all of these technologies work together to provide feature-rich operation that yields transformative results. To learn more on how these items can positively impact your shop floor, contact our experts today! For more information, visit www.motoman.com
ABOUT THE AUTHOR: Josh Leath is Sr. Product Manager for Welding Robots at Yaskawa Motoman. After spending over a decade as a Product and Brand Manager for tools and test equipment lines, Josh joined the Yaskawa team in 2017. With nearly 15 years of experience, he works extensively with end users to breed solutions that ensure customers are equipped with the tools and knowledge they need to succeed.
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IMD | 23
Workforce Development
Is Manufacturing Making Progress? Exploring the Current State of the Workforce Skills Gap By: Michael Womack
E
mployment challenges have been capitalizing headlines since the pandemic caused one of the most turbulent job markets in recent history. Manufacturing businesses had a whole different experience with the pandemic since the workforce challenge is not a new concept for them. US manufacturers had to step up to overcome global delays for critical products. These businesses began retooling or were being approached by customers they’ve never worked with in the past because foreign suppliers couldn’t meet deadlines. However, the workforce challenge is an issue manufacturing businesses understand extremely well. For decades manufacturers have struggled to attract and retain new talent. The skills gap continues to cause massive disruptions for these businesses but for the first time, real workforce solutions are here.
Understanding the Manufacturing Skills Gap to Bridge the Skills Chasm 'Skills Gap’ was the name given to the massive separation between baby boomers that have an unmatched wealth of manufacturing experience and the rest of the public that has little to no hands-on experience with the industry or industrial processes. Manufacturing businesses have struggled to find new employees with the proper training and education to make them productive members of their teams. In 2011, the average age of a high-skilled manufacturing worker was 561. Fast forward 10 years later and these individuals are approaching retirement age. With more manufacturers retiring, the Skills Gap has turned into the Skills Chasm. The Bureau of Labor Statistics reported in December of 2022 that there are over 424,000 manufacturing job openings2. Open positions are common. Businesses
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can’t seem to find applicants that have any experience, certifications, education, or training that will allow them to safely step into manufacturing roles. As schools stepped away from developing these skills and media pushed college as the only path toward a career, interest faded and the talent dried up. A 2021 study conducted by Deloitte and the Manufacturing Institute (MI) paints a troubling picture. The study explained that 2.1 million manufacturing positions will be unfilled by 20233. It is expected that these open positions come with a hefty price tag. Deloitte and MI expect this inability to fill manufacturing jobs could cost the U.S. a loss of upwards of $1 trillion in GDP. Cheap labor outside the United States allowed the nation to feel comfortable about the erosion of skilled tradespeople. Expectations that this was the new face of manufacturing caused schools to eliminate shop classes and any encouragement from parents or mentors to pursue industrial careers seized almost entirely. Millennials were a lost generation to manufacturing but this is not the end. Workforce solutions are presenting themselves. Workforce development, professional growth opportunities, and incredible hands-on manufacturing training technology are beginning to bridge the disruptive skills gap.
Setting the Stage for Modern Manufacturing When most people think about the industry, they imagine an outdated picture of what manufacturing looked like decades ago. No safety procedures, no digital technologies, no respect for the career, but the world is changing. Modern manufacturing looks extraordinarily different than it did in the early 1900s. Even businesses that work mainly by hand, creating massive metal structures or classic textile operations take safety extremely seriously. Most utilize
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incredible digital technologies that connect the shop floor with their ERPs and supply chain partners. Along with progress inside shops, public perception is changing. A newfound respect for industrial careers is beginning to form. People are starting to pay attention to the high school graduate that developed a skill and put it to work. Students that followed today’s conventional path of college directly after high school struggle to find a job that will pay the bills while young manufacturing professionals are thriving. The general public may assume that these careers are low-paying. This could not be farther from the truth. New Jersey Manufacturing Extension Program (NJMEP) produces the ‘Manufacturing Industry Report’ each year which compiles data from highly reputable sources including the Bureau of Labor Statistics. In 2020, the average annual compensation for a manufacturing employee was over $94,000. The industry also provides highly competitive benefits package when compared to service careers. Along with competitive pay and benefits, job security is leaps and bounds beyond most industries. During the COVID-19 pandemic when most organizations were laying off millions, many manufacturers were looking for more people to help offset the shortage of foreign-produced goods. These businesses need people and when the individuals they hire have skills that are incredibly hard to come by, they are respected and nurtured since they are a critical asset to that company.
Higher education is a goal of many. People often assume that once a person finds a job after High School instead of going directly to college it will mean the possibility of getting a diploma is out of the question. This isn’t true. There is no “right” path. Seeking trade skills and employment after High School is a fantastic way to begin a journey toward higher education. Manufacturing businesses often provide tuition reimbursement or will even pay for relevant credentials. Individuals that work in an industrial setting are potentially even better set up to succeed in a higher education environment. People that work, gain life experience, and earn a living before going to college have a high chance of taking
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IMD | 25
education more seriously. Additionally, these individuals might even be able to graduate without any student debt by combining tuition reimbursement and having the funds to pay for their education. Choosing a career doesn’t mean a person has to stop improving themselves.
Manufacturing Employment Solutions and Current Progress Manufacturing Extension Programs are located throughout the nation. There is at least one MEP center in every state including Puerto Rico. Each act independently but with workforce challenges cited as a primary issue among manufacturers, many provide workforce development and recruiting opportunities for local manufacturers. In New Jersey, NJMEP has a strong workforce focus. Their workforce division, the Pro-Action Education NetworkTM works to address the skills gap from all levels; high school curriculum and engagement, USDOL Registered Apprenticeships, educating the manufacturing industry on retention best-practices, and low barrier-toentry hands-on training. Progress is being made. The average age of an employed factory worker dropped dramatically to 37, from 56 in just 10 years4. Working together will be the only way to continue this trend and steadily reverse the skills gap. Local high schools, community colleges, local workforce programs, state and federal governments, manufacturers,
MEP centers, close collaboration is proving itself beneficial. Pre-Apprenticeship programs start in high schools. Funded through the NJ DOL’s Pre-Apprentice in Career Education (PACE) grant, a program was created that brings together manufacturing workforce programs like NJMEP, and local high schools to develop and deliver industryrelevant curriculum to students all over New Jersey. These students are educated on manufacturing safety, industrial processes, and can get hands-on with the most advanced training equipment available. NJMEP works closely with manufacturers, providing training and consulting services. This connection to both a pool of young adults with manufacturing skills and ‘MADE in New Jersey’ manufacturing business leaders directly and actively refills the talent pool, steadily closing the skills gap. US DOL Registered Apprenticeship programs are structured curriculum delivered to incumbent workers; individuals that have been employed by a manufacturer for at
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least 90 days. An apprenticeship can take on many different forms but the core concept is the delivery of hands-on training hours, coupled with substantial and highly structured classroom course material. Apprentices must pass a series of tests and are held to a higher responsibility standard as they are being upskilled. Participants pass through safety, manufacturing process, quality, and maintenance training all the while working with a mentor to hone a skill for a specific manufacturing operation. This employee is given the opportunities to advance their career, develop professionally, and the manufacturer gains a loyal, productive employee. Apprenticeship programs are a proven model but just now regaining popularity in the United States. The effectiveness of US DOL Registered apprenticeship programs improves exponentially when coupled with the Pre-Apprenticeship program developed by New Jersey’s MEP. Collaborative partnerships are the only way to make progress and continue closing the manufacturing skills gap. An investment of time and energy is required by all parties to succeed. Private businesses, academia, governments, organizations of all kinds need to work together and break down the stigma while building up communities. NJMEP’s example is just one of many opportunities all over the nation. Connecting with local partners, workforce networks, high schools, and nationwide communities will foster a stronger pool of highly qualified, highly productive manufacturing professionals. Having this refreshed workforce allows the
entire nation to benefit by ensuring it does not miss out on that estimated $1 trillion lost GDP because of the current state of the skills chasm. ABOUT THE AUTHOR: Michael Womack is the Marketing and Communications for the New Jersey Manufacturing Extension Partnership (NJMEP). NJMEP provides consulting, education, and training to New Jersey Manufacturers. He began his career in 2015 as a Social Media Manager for an advertising agency with a client base of manufacturers and logistics companies across the United States. Later, he worked for a manufacturer in Fairfield New Jersey in the marketing department until his current role at NJMEP. Passionate about education and manufacturing, he works to shine a light on today’s advanced manufacturing industry, breaking down the stigma associated with the industry, working to ensure U.S. manufacturers bridge the skills gap in order to maintain global competitiveness.
SOURCES: 1. https://www.shrm.org/hr-today/trends-and-forecasting/research-andsurveys/Documents/4-13%20Skills%20Gap%20Briefing.pdf 2. https://www.bls.gov/news.release/pdf/jolts.pdf 3. https://www.nam.org/2-1-million-manufacturing-jobs-could-go-unfilledby-2030-13743/?stream=workforce 4. https://www.zippia.com/factory-worker-jobs/demographics
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IMD | 27
New Technology
On TRAK to Industry 4.0 TRAK Machine Tools brings digitalization to job shops
J
ob shop owners know digitalization is coming. Now, they have a familiar and trusted machine tool partner to help them meet the challenge. “There’s the closing scene in the first ‘Terminator’ movie,” says TRAK Machine Tools owner Steve Pinto. “Sarah Connor is escaping because she knows that Skynet is coming. She’s in Mexico, and a young boy points to the horizon speaking in Spanish that a storm is coming. And she looks off and she says, ‘I know.’” Job shops are facing the digital adoption challenge across two fronts—toolroom and production. “The transition across the business will be difficult for job shops,” Pinto says. “Especially owners that do not have teams of engineers and IT specialists to help them evaluate and integrate new, digitally enabled machining operations.”
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As a first step to help shops on the toolroom side, TRAK developed a line of machining centers, powered by the company’s popular ProtoTRAK® CNC. Now the company is introducing an all-new line of production-level machines empowered by the Siemens SINUMERIK ONE “digital twin” CNC platform.
The Transition to Digitalization Tom Copeland is TRAK Chief Technology Officer. During his 40 years with the company, he has seen how job shops can fall behind during technology transitions. “Most shops are still at step one, getting started with what I call the dashboard era,” Copeland explains. “They are basically connecting machines to software applications, then monitoring those machines from a managerial dashboard. The benefits of this first step are to sort out connectivity
IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986
As TRAK Vice President of Engineering, Leo Gammaitoni stresses the importance of making technology easily adaptable.
and security issues along with preparing the organization to make data driven decisions. But then shops need to take the next step. They need to implement software that connects machine tools and shop floor personnel. This provides the targeted information that enables an organization to implement new business models. Together with Siemens, we can help our customers take that next step.” According to Copeland, Siemens is the right technology partner at the right time, and the reason can be summed up in one word: automation. “Automation can mean any kind of mechanism that enables a process to go from part-to-part,” Copeland says. “The Siemens SINUMERIK ONE platform enables TRAK and our job shop customers to cross over into that level of automation. We do not need to build our own platforms with all of the related IT and software development. The Siemens platform is already there with their Control to MindSphere® connectivity and their support for common machine protocols like OPC-UA and MTConnect. Also, with the SINUMERIK ONE software development kit and their MindSphere API, TRAK is able to add new features that are targeted at specific markets without us having to write complex software from scratch.
Uplifting Toolrooms and Production
TRAK Chief Technology Officer Tom Copeland says job shops can now make the transition to digitalization because it is adaptable at the operator level. Production-level machines at TRAK enable this by leveraging the Siemens SINUMERIK ONE CNC platform.
Leo Gammaitoni is TRAK Engineering Manager. He sees the company’s relationship with Siemens as perfectly aligned with TRAK in the delivery of digitally evolved production machines that are easy to adapt at the operator level. “The Siemens control has long been the closest to what we’re doing in terms of conversational CNC, the ease of use, the ease of programming,” Gammaitoni says. “Our ProtoTRAK controls and machines serve prototyping and low-volume production. But machine shops also need that ease of use on production equipment, and Siemens was the No. 1 choice to partner with to do just that.” Central to the digitalization strategy at TRAK is the adoption of the SINUMERIK ONE control’s “digital twin”. INDUSTRIAL MACHINERY DIGEST.COM
IMD | 29
advantage of that greater rigidity,” Gammaitoni says. “This was This software module, called Create MyVirtual Machine, also made possible by the Siemens control, which is capable enables machine motion to be visualized and exactly of moving faster and cutting at higher speed rates.” measured on a 3D plane. The digital twin workspace moves machine design, operation, maintenance, and operator training far beyond the limitations of current A New Set of Digital Tools simulation software. Chris Britton feels privileged to have collaborated with the “Using Create MyVirtual Machine, I can see the entire leadership team at TRAK Machine Tools for over 15 years. As machine in exact 3D before the machine is even built,” the Siemens account manager, he has closely participated in Gammaitoni says. “I can customize the machine, make the adoption of digital CNC technology at TRAK. changes, and see what happens. I can trace a tool path and be “It was never about selling features and functions,” confident that it’s 100 percent accurate.” Britton says. “When we talked about the SINUMERIK ONE Gammaitoni and TRAK plan to collaborate with Siemens to leverage the SINUMERIK ONE CNC platform to create other leaps forward in production-level machining. The integration of more powerful yet intuitive CNC opens the way to building production machines with much faster spindle speeds, improved surface finishes, faster setups, and parts completion. All of which contribute to faster time-to-market. For example, by exploring within the SINUMERIK ONE CNC digital twin environment, Gammaitoni and his engineers proved that the motion of their new production machines could evolve from traditional linear ball guides to linear roller guides. “We’ve gone to a more rigid A shared vision: Former TRAK Machine Tools owner Rich Leonhard (left) and current owner Steve Pinto production machine because (right) see the Siemens SINUMERIK ONE control platform as the company’s way forward in the development we proved within the digital twin of digitally enhanced production machines. Siemens account manager Chris Britton (middle) has been a environment that we could take collaborative partner in the journey.
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platform and the path to digitalization, we didn’t say, here’s this incremental improvement in hardware with more features. We talked about a digitally enabled platform for job shop business evolution and the software tools to take you there.” Within the Siemens digital twin design environment of SINUMERIK ONE, a numerically exact 3D tool path accounts for all related forces, including tool type and speed, part material, part shape, and machine rigidity. Create MyVirtual Machine software enables the machine design engineer to see in 3D exactly how the machine will perform before actually building the machine. Run MyVirtual Machine enables a job shop to use virtual 3D to dramatically cut part production time, train machine operators, and improve shop-wide processes. ShopMill and ShopTurn software visually guide the simple and efficient setup of a production-level machine.
Owning the Challenge Having found the right technology partner in Siemens, the company that pioneered the ProtoTRAK control for toolrooms everywhere is helping those customers confidently take the next step into digitally enabled production.
“Prototyping and production are different operations requiring different technology solutions,” Pinto says. “TRAK can now offer machine technology solutions across both sides of a customer’s business.” True to its beginnings, TRAK leadership is seeing to it that the company continues to earn the trust of customers by helping machine shops survive and thrive. Whether you call wvit digitalization, IoT, or Industry 4.0, the way forward for TRAK starts with trust.
FOR MORE INFORMATION, CONTACT: John Meyer Marketing Communications Manager Siemens Industry, Inc. cnc.marketing.us@siemens.com
A Legacy of Engineering Innovation TRAK Machine Tools will always trace its success back to its down-to-earth beginnings. Starting out as a job shop in 1951, TRAK Machine Tools was founded by a former Lockheed engineer, Dr. Fred Jenks. Under the name Southwestern Industries, the shop performed contract work for the aerospace industry, but it wasn’t long before its engineering mindset led to the acquisition and perfection of a mechanical marvel called the Trav-A-Dial. “The Trav-A-Dial is an all-mechanical device that supplements the Vernier dials on a manual machine with precision measurement,” explains Steve Pinto, TRAK owner and CEO. “It was wonderfully well-designed, worked beautifully, and we sold over 100,000 of them.” Most important, the popularity of the Trav-A-Dial established an early connection with toolroom machinists across the country, Pinto says. That connection was strengthened as the company went on to develop digital readouts based on the same gauge-wheel technology. Pinto was the company’s service manager at the time, and he recalls spending many hours visiting customer shops, getting to know people, learning their challenges. Top of mind was the migration of manual production machines to CNC machines. It was a growing challenge that all shops faced, including Southwest Industries. What toolroom machinists needed was a retrofit CNC that would naturally build on their familiarity with the digital readouts pioneered by Southwest Industries. Pinto credits Rich Leonhard, the company’s owner and leader at the time, for inventing what would become the
ProtoTRAK—the first retrofit CNC for manual machine tools. A control that would soon prove to be the toolroom machinist’s best friend. Leonhard, an engineer, especially understood the toolroom machinist’s need for a CNC that was not only more efficient, but also easy for a toolroom operator to use. “We worked hard to not make the ProtoTRAK look like a computer on a stick,” Leonhard recalls. “The people who needed it were skilled but not computer literate. In fact, many were computer-phobic. They didn’t want any part of G-codes.” The original ProtoTRAK CNC looked like an advanced digital readout. Kept simple, the control was built to speak the language of the machinist, not the language of a computer coder. Leonhard emphasizes that the new control did not require G-codes or M-codes, P-codes or F-codes. It featured a simple menu. It asked you what piece of geometry you wanted to create, and you answered using numbers, doing what you knew how to do. Then you just let the control figure out where to move the table. “That was the essence of the ProtoTRAK CNC when we introduced it in 1984,” Leonhard says. “It still is today. It’s the reason why over 50,000 of the systems have been installed across the U.S. and the world. More importantly, it’s the reason why we are on a first-name basis with thousands of machine shops. People we know personally, who can trust us to help them make the move to adaptable, operator-oriented digitalization.”
Process
Almost any operator can use an advanced rotary surface grinder like DCM Tech’s to enter virtually any requirement into a touch screen using simple controls, including a touchscreen Human Machine Interface (HMI).
Streamlining Metal Additive Manufacturing with Better Build Plate Resurfacing
Advanced rotary surface grinders enable efficient, precise resurfacing of the build plate, improving productivity and quality By: Del Williams
I
ndustries like aerospace and automotive are increasingly relying on metal Additive Manufacturing (AM) to expeditiously create weight-saving components with complex geometries, different material properties, and minimal setup times. To construct each part, advanced 3D printers melt, or partially melt, ultra-fine layers of metal powder on build plates. After each metal part is finished, it is cut from the build plate. However, one production bottleneck in AM is that any residual metal must be entirely removed before the build plate can be re-used. This requires precisely resurfacing the build plate so that is completely flat, level, and correctly textured prior to printing the next part. Unfortunately, traditional methods of accomplishing this task have significant drawbacks and have become a production bottleneck.
32 | IMD JANUARY 2022
Enter advanced precision rotary surface grinders, which have long been used in metalworking and glass grinding to create perfectly flat, parallel surfaces. The equipment is ideally suited to the AM process and quickly and accurately removes any residual metal from the build plate surface, restoring it to precise dimensions. The most advanced units even offer automation that allows minimally experienced operators to set them up and then attend to other tasks. This comprehensive approach is helping to exponentially speed build plate resurfacing, boost AM production, and improve quality. “With advanced rotary surface grinders, our AM build plate resurfacing process is significantly more efficient, precise, and flexible. Incorporating the units in our process will help us handle high expected growth in the AM market,” says Doug Hedges, Chief Technology Officer of Deerfield
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DCM Tech’s industrial surface grinders are designed with advanced sensors and controls that maintain very tight tolerances, removing material down to within one ten-thousandth of an inch of the final thickness, eliminating variability, and improving quality and productivity.
Beach, FL based Beehive3D, Inc., an additive manufacturing provider for industries such as aerospace, defense, and turbine technologies. The AM contact manufacturer currently has five U.S. locations and is expanding nationally. According to Hedges, it is critical in Beehive3D’s laser powder bed fusion process to resurface the build plate to precise process tolerances prior to re-use. “Not only do you have remnants of metal on the build plate, but also portions of the build plate can become bowed or distorted so it needs to be resurfaced after each use to keep it flat and parallel,” says Hedges.
Since the metal part is essentially “welded” to the build plate, it is typically cut off with electrical discharge machining (EDM) wire or a bandsaw. However, both approaches involve removing a thin layer of the build plate surface, gradually reducing its thickness until it is no longer usable. Most of the cuts are not entirely flat or level, either. The alternative is to cut close to the part, but this leaves material that must be removed later. With EDM and bandsaws, the process can take hours and hard materials like Inconel tend to strain-harden, increasing the difficulty further. Some shops even address the issue with a CNC
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IMD | 33
milling machine, but this can also take hours and limit the availability of the equipment for actual production. Exceptionally hard AM materials like Inconel and titanium further lengthen the required milling time. A more efficient alternative utilizes advanced precision rotary surface grinders to remove unwanted residual material with a large rotary grinding wheel surface. “The goal is to remove just the residual AM part material and as little of the building plate as possible while providing necessary resurfacing of the build plate,” says Erik Lawson, Engineering Manager at Winona, MN-based DCM Tech, a designer and builder of industrial rotary surface grinders. Today, surface grinders are designed with much more advanced sensors and controls that automatically maintain very tight tolerances, removing material down to within one ten-thousandth of an inch of the final thickness. The equipment can achieve tighter dimensional tolerances, flatness, parallelism, and surface finish on build plates in much less time than other methods. The process eliminates variability among resurfaced build plates in addition to increasing production and quality, batch after batch. More advanced units such as DCM Tech’s IG series offer variable speed grinding with automation and controls that allow virtually any operator to successfully manage a unit. These units can control the initial contact between the abrasive wheel and the build plate, which in the past had to be finessed by the operator. Advanced sensor technology detects vibration and can automatically fine-tune not only the pressure of the spindle motor but how quickly it moves the wheel down onto the build plate. When the machine senses the abrasive wheel has contacted the build plate, it automatically begins the grind cycle. The most advanced units offer simple controls including a touchscreen Human Machine Interface (HMI) that even unsophisticated operators can use to make any necessary adjustments without programming. The HMI controls allow operators to enter virtually any requirement into a touch screen. This capability enhances processing flexibility, so it is easy to adjust any grinding factor to prevent an issue from reoccurring. For routine processes, the use of a variety of grind “recipes” with sets of parameters for different AM construction builds can further speed production, enhance quality, and aid in quick changeover. “Different grind recipes can be set for different customers, material types, or construction builds so complex programming or data does not need to be entered at the start of each job. A new recipe can be created for job variations, such as a different finish for a specific AM material,” explains Lawson. One aspect that expedites production is the operator’s ability to accommodate grinding of extremely hard residual material like Inconel or titanium from build plates. This typically involves working with an expert vendor that can tailor the surface grinder’s abrasives to accommodate different types of metals and alloys, as well as the materials used for the build plate.
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It is critical to resurface the build plate to precise process tolerances prior to re-use, since there are not only remnants of metal on the build plate, but also portions of the build plate can become bowed or distorted, so it needs to be resurfaced after each use to keep it flat and parallel.
Advanced precision rotary surface grinders like those from DCM Tech create perfectly flat, parallel surfaces for the metal AM process, quickly and accurately removing residual metal from the build plate surface and restoring it to precise dimensions.
Beehive3D currently uses DCM Tech IG series rotary surface grinders at some of its locations and plans to add more in the future. Chief Technology Officer Hedges finds value in working with an expert vendor that can tailor the rotary surface grinder to Beehive3D’s specific needs. “Using the proper abrasives and feed rates can reduce finishing time and facilitate an efficient, repeatable process. Working with an expert in abrasive use like DCM Tech gives us the flexibility we need to efficiently remove a range of metal remnants such as aluminum, titanium, and Inconel from the build plates,” says Hedges. Also important is the ability to alter the parameters through the grind cycle to handle both the printed metal or alloy and the material used for the build plate. The material
characteristics of the printed part residue and the build plate are very different, so the rotary grinder must appropriately adjust to each on contact. Once the grinder cuts through the residual part material and reaches the actual plate, the grinding abrasive must work completely differently. The rotary grinders automatically make that transition. The advanced unit’s grind recipes can also be set to accommodate required build plate textures. This eliminates the need to “roughen up” a build plate in a separate process so the AM part will properly adhere to the surface during buildout. “Instead of trying to tailor a build plate finish by running it through a mill or an abrasive blaster, after grinding with an IG machine there is no reason to take it to a secondary operation,” says Hedges. “An operator can simply clean it with alcohol or a solvent, let it dry, and it is ready to use again in the AM process.” According to Hedges, the automation provided by advanced rotary grinders allows operators to set up the machine and then attend to other tasks. The machine does not need to be constantly monitored because it has built-in load monitoring. “Unlike older style machines, the advanced rotary grinders do not need constant operator input or oversight. This allows the operator to multitask and minimizes the risk of error,” says Hedges. Automation also eliminates the need for operators to manually dress abrasives on the grinding wheel to renew a
good abrasive surface. Without automation, over time the wheel can become clogged with residue from the AM material. When operators manually dress abrasives, on most machines they hold a tool under the grinding wheel abrasive. The tool applies abrasion and knocks off all used or clogged abrasives until the grinding wheel has a nice new abrasive surface. Operators frequently need to repeat the process, sometimes as often as every 10 minutes depending on the materials ground, which can be labor intensive and decrease productivity. “Advanced rotary grinders with an auto dress option free operators from needing to do it manually, making operation easier and less time consuming,” says Hedges. “The option can be particularly helpful with hard materials like Inconel, which can require more frequent dressing of abrasives.” As metal AM production ramps up, manufacturers that take advantage of sophisticated, automated rotary surface grinders to efficiently remove excess part materials and resurface build plates will outperform those using slower, less precise conventional methods. For more information: call (800) 533-5339; email info@dcm-tech.com; visit www.dcm-tech.com; or write to DCM Tech at 4455 Theurer Blvd, Winona, MN 55987.
ABOUT THE AUTHOR: Del Williams is a technical writer based in Torrance, California.
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IMD | 35
Industry Insight
Induction hardening
Heat-Treating Gears Improves Surface Durability
Flame hardening, induction hardening,carburizing and laser hardening are among the common, effective methods. By: Brian Dengel, KHK Gears USA, Inc.
A
common question asked of gear manufacturers by their potential customer is, “Is this gear strong enough for my application?” Without qualifiers, this question is ambiguous at best. The world record for deadlift is 536 kilograms (1,181 pounds). Does this make the record holder strong enough? Could he hold this weight for 10 minutes? How about for an hour? A gear needs to be able to withstand the applied torque of the desired service life of the gear. As such, the bending strength AND the surface durability need to be considered in order to answer the heretofore mentioned strength question. All metals have a bending strength that is significantly stronger than their surface durability or bearing strength. To improve that surface durability and thereby improve the life of a gear, the gear can be heat-treated. There are several methods for heat-treating a gear.
36 | IMD JANUARY 2022
Flame hardening is a common method for heat-treating gear teeth. It involves using a torch to heat specific areas of a gear, typically the gear teeth, to improve the surface durability. When applied manually, this method is prone to unsatisfactory results as the time spent heating each area will be different, the distance from which the flame is applied will vary and these two variations will cause different surface hardness across the gear. Even when the process is automated to remove these variations, the gear will still experience some dimensional distortion that will typically reduce the gear quality by one grade. Induction hardening is another common heat-treating method for gearing. In this process, the gear is surrounded by a coil. The coil is energized, thus creating alternating magnetic fields. These fields in turn generate eddy currents which heat the gear. This method is a fairly accurate way to
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harden all of the gear teeth to the same hardness and depth. However, it takes some skill and practice to determine the time that each individual gear configuration needs to obtain the desired hardness for a specific material. One of the drawbacks with induction hardening is that the areas immediately next to the gear teeth are also partially hardened. This limits the rework of areas near the teeth, after heat treating. A third method for heat-treating gearing is to carburize the gear. Carburization is the process of placing the gear into an oven with added carbon and heating the oven to several hundred degrees Celsius for an extended period of time. This process allows the added carbon to penetrate into the molecular structure of the gear. This added carbon causes a skin of hardened material (also known as a case) to form on the outermost layer of the gear. This case makes the gear unable to be re-machined after heattreating unless carbide tooling or wire EDM methods are employed. As such, it is desirable to perform all machining operations prior to carburization. Similar to induction hardening, great skill is needed to obtain the desired results when carburizing. The newest method of heat-treating is laser hardening. This method, as the name suggests, uses light energy to rapidly heat small sections of a gear. It has several
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Laser hardening
advantages over all other methods of heat treating. The first advantage is that it can be used in very small areas and does not affect nearby areas. Additionally, since it is operated by a CNC, the amount of energy applied to each section is identical and the hardness depth can be limited. Since the pulse of light is applied very quickly, the gear does not have an opportunity to heat up and therefore, there is no degradation in gear quality. All heat-treating methods increase the surface durability, but some also reduce the bending strength as the material becomes brittle after heat-treating. Some examples of the benefits of heat treating are as follows: » A: Module 2, 15 tooth, 1045 carbon steel spur gear with a 20mm face width, has an allowable bending strength torque of 29.6 Nm and a surface durability of 1.48 Nm. When induction hardened to HRc 45-55, the allowable bending strength torque remains at 29.6 Nm but the surface durability increases to 10.5 Nm. This is a 9x increase in surface durability. » B: Module 2, 25 tooth, 1045 carbon steel spur gear with a 20mm face width, has an allowable bending strength torque of 63.3 Nm and a surface durability of 4.64 Nm. When induction hardened to HRc 45-55, the allowable bending strength torque decreases to 52.7 Nm, but the surface durability increases to 27.0 Nm. This is a 5.8x increase in surface durability and a 16 percent decrease in bending strength. » C: Module 2, 40 tooth, 1045 carbon steel spur gear with a 20mm face width, has an allowable bending strength torque of 118 Nm and a surface durability of 12.5 Nm. When induction hardened to HRc 45-55, the allowable bending strength torque decreases to 98.3 Nm, but the surface durability increases to 72.1 Nm. This is a 5.7x increase in surface durability and a 17 percent decrease in bending strength. » D: Module 2, 1045 carbon steel gear rack with a 20mm face width, has an allowable bending strength of 3830 N and a surface durability of 775 N. When induction hardened to HRc 45-55, the allowable bending strength torque decreases to 3480 N, but
38 | IMD JANUARY 2022
the surface durability increases to 2000 N. This is a 2.5x increase in surface durability and a 9 percent decrease in bending strength. However, if laser hardened to HRc 55-65, the bending strength remains 3830 N and the surface durability increases to 1730 N. This is a 2.2x increase in surface durability without any of the distortion or decrease in bending strength that occurs with other methods. These are some of the many ways that you can heat-treat a gear to improve the surface durability. Each method has its advantages and disadvantages, but laser hardening is the most economical method for small batch hardening. For more information, visit www.khkgears.us
ABOUT KHK USA INC. KHK USA, based in Mineola, New York, is a wholly owned subsidiary of Kohara Gear Industry. KHK USA is a factory direct, full-service distributor of KHK gears with a large selection of product available off-the-shelf to meet your gearing needs. On staff application engineers assist customers with a wide selection of gears for their design and can produce customer gear quotations.
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Product Showcase
PRODUCT SHOWCASE Industrial Machinery Digest's Monthly Product Showcase features the latest from some of the manufacturing industry's top suppliers. Cracking the Code: Connecting IMD Readers with More Information To learn more about each product, scan the included Quick Response (QR) code with your mobile device. These special barcodes have been designed to allow our readers to quickly and easily discover more information available on IndustrialMachineryDigest.com. WANT TO BE FEATURED? Send your latest product information to editorial@indmacdig.com
New ABB OmniCore Robot Controllers Offer Faster, Scalable, More Energy Efficient Manufacturing To meet the demand for faster, more efficient production, ABB is adding two new members to its OmniCore™ controller family. Available for a range of robots across ABB’s portfolio, the new E10 and V250XT controllers offer best-in-class motion control, as well as 20 percent energy savings and futureproofing through built-in digital connectivity and 1000+ additional functions to meet changing requirements. These two new controllers extend the possibilities for enhanced robot control in a variety of industries, from electronics assembly to automotive, logistics, and general manufacturing. “The growing demands of the industry for quicker, more diverse production and greater responsiveness to changing market conditions calls for solution that bring new levels of speed…
ATI Industrial Automation's new QC-29 Robotic Tool Changer Unlocks Productivity for Smaller Robots The QC-29 Robotic Tool Changer brings the powerful and rugged technology of ATI’s Heavy Duty Tool Changers to robots in the 25 - 35kg payload class. The QC-29 is the first standard ATI Tool Changer designed…
40 | IMD JANUARY 2022
EMUGE-FRANKEN USA Expands TOP-Cut VAR High Performance End Mills Line TOP-Cut VAR end mills feature unique flute and profile geometries optimized for long tool life and superior performance in both roughing and finishing applications. Variable helix angle flutes provide extensive vibration dampening…
ESAB Marathon Pac™ Ultra Bulk Package Holds 22 Percent More Welding Wire In A Stronger Package ESAB Welding & Cutting Products has introduced Marathon Pac™ Ultra, a new 1,100-lb. bulk welding wire drum, that features a robust outer box and reinforced corners for stabilizing the inner drum to prevent wire movement…
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NEW PRODUCT: 1/4 NPT Hollow Cone Liquid Nozzle for Cooling and Washing
FANUC America’s New Mobile Apps for CNC Product and Maintenance Support
EXAIR’s new 1/4 NPT HollowStream™ liquid atomizing spray nozzle provides a hollow cone spray pattern for pressurized liquids. They are applied to solve cooling, cleaning, foam breaking, rinsing and dust suppression applications for industry…
The CNC Comparison and the CNC Functions Catalog are two newly created apps designed to help easily evaluate the vast array of FANUC CNC products available. The FANUC CNC Comparison App is a convenient way to compare and contrast…
AXYZ Introduces New METALWORKER Router for High Performance Metal Cutting
Brass Pie Jaws Hold Delicate Materials Securely Without Marring or Distortion
Hypertherm Announces Release of Production Manager for ProNest CAD/CAM Nesting Software Production Manager seamlessly integrates with Hypertherm’s EDGE Connect® CNC, to automatically capture machine data without the need for operator intervention. In addition, it displays…
New Seco High Feed Square Cut Size 14 Milling Systems To Tackle Difficult-To-Machine ISO P, M, And S Materials
AXYZ Tailored Router Solutions ™ is excited to announce the addition of the all-new METALWORKER Router to their inventory of industrial grade CNC machines. Fabricators looking to process nonferrous metals…
Dillon Manufacturing presents brass pie jaws which firmly grip delicate workpieces without marring or distortion. Maximum contact area from the full grip jaws provides a solid gripping surface which yields more friction for drive with reduced part…
Walter Expands Its Accure-Tec Vibration Dampening Boring Bar Line
The Esco Mini-MILLHOG Pipe Beveling Tool Self-Centering and Chatter-Free
New Norton Quantum Prime Grain Revolutionizes Grinding Wheel Performance
The standard A2201 is an offset adaptor for reduced radial forces, greater stability and provides more space between the boring bar and the bore wall for improved chip removal with very deep bores. With the A3001 and the A2201 Walter has…
The Esco Mini-MILLHOG ® is a compact, portable pneumatic I.D. clamping tube and pipe beveling tool with a working weight of 27.5 lbs. that squares itself when mounting and provides high torque with low RPM. Featuring smooth…
Norton Quantum Prime Wheels have several important advantages including a new micro-fracturing grain that has unparalleled sharpness and cutting efficiency which reduces power draw and cycle times, while increasing material removal rates…
Seco Tools has launched a new High Feed cutter and insert series in size 14. Increase tool life and maximize the value of every edge with this new series in stainless steels, titanium, and superalloys milling applications. The…
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IMD | 41
On Exhibit - westec
ON EXHIBIT Industrial Machinery Digest's On Exhibit features the latest news and press releases from companies exhibiting at the leading trade shows across North America. WANT TO BE FEATURED? Send your press releases to editorial@indmacdig.com
MARCH 28-31, 2022 Atlanta's Georgia World Congress Center When the largest manufacturing and supply chain trade event of 2022, MODEX, returns to Atlanta on March 28 it will include over 900 exhibits from leading solution providers and a comprehensive Educational Conference of over 150 sessions focusing on best-inclass solutions for manufacturing and supply chain operations. MODEX 2022 exhibits will represent all segments of the material handling, logistics and transportation industry, from traditional, manual equipment to computerized, automated systems and smart, connected supply chain technologies.
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BOOTH: B7747
BOOTH: B5227
The new AME-OP is a stand-on electric powered model that combines the advantages of a narrow aisle articulated forklift and an order picker for versatile operation in warehousing applications. Entries were judged on their combination of innovation, customer benefit and technical excellence, all of which qualities apply to the AME-OP. According to the editor of IP, Daniel…
The TwinCAT automation software suite from Beckhoff has reached its 25th anniversary in the market. Ubiquitous in automation today, TwinCAT has served as a powerful resource for engineers since 1996 – a quarter of a century. In addition, the underlying PC-based control technology from Beckhoff has been going strong since 1986, marking 35 years in the industry…
B6848
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With five levels of gravity flow conveyor to hold small bins of hardware and supplies, each lane features side guides to hold the bins securely in place. The gravity flow ensures first-in/first-out (FIFO) material usage, while the 4° angle of the flow lanes help the containers flow, keeping them toward the front for picking ease. The cart enhances the user’s ability to see the parts they…
Oil and gas, chemical and manufacturing workers are often required to use powered air-purifying respirators (PAPRs) to protect them from inhaling harmful dust, vapors and gas. With the PA900 Series Headgear, Honeywell designers delivered a solution that allows users to perform their jobs, breathe…
German Industry Award for the Aisle Master AME-OP
Creform Flow Rack – is it a Flow Rack or is it a Cart? It’s Both.
42 | IMD NOVEMBER 2021
TwinCAT Automation Software from Beckhoff Turns 25
New Honeywell Headgear Combines Innovative Face and Respiratory Protection for Enhanced Worker Safety
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C3785
B5014
As a response to the rising demand for fast, flexible and compact industrial robots, Kawasaki developed two 6-axis vertically articulated robots with a maximum payload capacity of 7 kg and different reach. The RS007N and RS007L models are some of the newest additions to the company general-purpose R series line…
Machines function optimally when the drives are perfectly adapted to the power train. This ensures that a high-quality product is produced at the highest machine cycle rate with a minimum production error rate. To achieve this, the control loop in the inverter is set to be machine specific. Until now, a drive expert would need several hours to complete this task during the commissioning phase…
B2012
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Signode’s StorFast Automated Storage and Retrieval System (ASRS) is an innovative cart-based solution consisting of powered carts and lifts that automatically move pallets in and out of storage positions in the warehouse. The newly enhanced cart-based StorFast system operates at twice the speed with improved control for acceleration and deceleration…
The SK2000 features a fully welded tubular upright, giving the racks superior impact resistance over open-back style uprights and is ideal for a wide range of warehouse applications and markets including food and beverage, retail, agriculture, and automotive. Because the SK2000 is roll-form steel, it is cost-effective for small storage applications, and has the strength and durability…
Kawasaki RS007N/L Robots Offer Flexibility, Low Payload and High Speeds Applications
Optimize a Drive in 60 Seconds
Signode To Highlight Storefast Technology at MODEX 2022
Steel King SK2000® Closed-Tube Roll Form Rack Systems
C-FRAME PRESSES MADE IN THE USA!
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FILTRATION… The range of filter
• Heavy Gauge Steel Design • Press Bed bolted on, not welded, to prevent distortion. • Large press bed to accommodate a variety of tooling other than just punching. • Pump, motor, valve and reservoir are all easily accessible for maintenance. • Large rectangular tubes used at base of machine to give safe, instant portability.
solutions implemented at Argo-Hytos extends from fixed-position industrial plants to highly mobile applications, primarily tailored to individual customer requirements. As a result of their vast experience with custom applications over a wide variety of sectors, Argo-Hytos offers a comprehensive range of innovation standard solutions: Suction Filters; Return and Return-Suction Filters; Pressure/ High Pressure Filters; Filling and Ventilating Filters; Filter Accessories; Sensor Technology.
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IMD | 43
Surplus buying and selling
Electric Boilers Suddenly in Vogue Again
With zero emissions, economical electric steam and hot water boilers deliver maximum thermal output in minimum spatial footprint By: Del Williams
F
or EU and U.S. industry, process heating and steam production are significant sources of energy use, and at many industrial sites boilers can account for up to 60% of energy costs. Process heating is usually from steam, which is used to increase the temperature in a process vessel. Due to the threat of global warming as well as international commitments to the Paris Accord on Climate Change, industrial processors in Europe and North America are tasked with significantly reducing their environmental footprint in record time. In response, last year the 27-nation European Union (EU) agreed to cut greenhouse gas carbon emissions by 55% by 2030 compared to 1990 levels. According to a recent report that has tracked the EU's power sector since 2015, renewables surpassed fossil fuels last year (38% to 37%), indicating that industry is already pivoting away from carbon emissions. Even the U.S., which recently rejoined the Paris Agreement, has targets for American businesses to achieve a carbon pollution-free power sector by 2035 and a net-zero economy by 2050. While the interest of industry in electric boilers for process heating and steam production has waxed and waned in the last century, suddenly it is in vogue again. Whether to honor Environmental Social and Governance (ESG) goals, meet regulatory commitments, or take advantage of government credits and incentives, a growing number of industrial facilities are installing new or retrofit high-voltage electrode boilers that are compact, economical, and produce no emissions. This is, in part, due to technological advances in electric boiler design that increase the output to a level that rivals even large gas or oil-fired boilers. When process heating is used to raise process vessel temperature, electric-powered alternatives are sure to be a critical piece of the puzzle in meeting future emission reduction goals.
Transitioning from High-Emission Gas and Oil-Fired Boilers In industrial processing, besides the notorious greenhouse gasses carbon dioxide (CO2) and methane (CH4), natural gas-fired boilers and furnaces emit dangerous nitrogen oxides (NOx), carbon monoxide (CO), and nitrous oxide (N2O), as well as volatile organic compounds (VOCs), sulfur dioxide (SO2), and particulate matter (PM).
44 | IMD JANUARY 2022
However, many industrial process engineers familiar with gas-fired boilers mistakenly believe that electric boilers cannot match the output of the traditional, fossil fuel burning units. Due to considerable advances in electric boiler technology, that is far from the case. Today, such technology can match the capacity of large gas or oil-fired boilers in a much smaller footprint. Electric boilers utilize the conductive and resistive properties of water to carry electric current and generate steam. An A.C. current flows from an electrode of one phase to ground using the water as a conductor. Since chemicals in the water provide conductivity, the current flow generates heat directly in the water itself. The more current (amps) that flows, the more heat (BTUs) is generated, and the more steam produced. Crucially, almost 100% of the electrical energy is converted into heat with no stack or heat transfer losses. As an example, the electrodes of the CEJS High Voltage Electrode Steam Boiler by Acme, a Canada-based manufacturer of industrial and commercial boilers, are vertically mounted around the inside of the pressure vessel. This enables the unit to produce maximum amounts of steam in a minimum amount of floor space, with boiler capacity from 6MW to 52MW. The boiler operates at existing distribution voltages, 4.16 to 25 KV with up to 99.9% efficiency, and can produce up to 170,000 pounds of steam per hour. With pressure ratings from 105 psig to 500 psig, the boilers are designed to ASME Section 1, and are certified, registered pressure vessels at the location of the boiler. “There is an entire generation of industrial process engineers that grew up with oil and gas-fired boilers almost
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exclusively,” says Robert Presser, Vice President of Acme Engineering, which, along with North American facilities, builds in Europe to European standards and has a network of CE-compliant fabricators for the pressure vessel, as well as partners in France and the UK for local equipment assembly. “As a result of preconceived notions, most view electric boilers as small underpowered units, like a hot water heater,” adds Presser. “So, we frequently have to educate engineers that there is electric boiler technology that can match the capacity of large gas or oil-fired boilers available.” According to Presser, high-capacity electric boilers are well suited to heat process water. The electric boilers have several advantages compared to oil or gas-fired boilers, including superior safety, ease of installation, faster start-up and shut down time, and quiet operation. Electric boilers do not have a high minimum operating level to make them immediately available. “Electric boilers do not need an operator because if anything goes wrong, the breaker trips, preventing further escalation of the issue,” says Presser. “With gas burning boilers, however, any gas leak can increase the risk of an explosion. So, gas units must usually be continually monitored or periodically inspected.” He notes that state and municipal safety guidelines vary depending on boiler type and the expected frequency of inspection. With electric boilers, the energy input as well as adjustment is also precise and virtually immediate. In
contrast, increasing or decreasing the temperature in a gas fired boiler is a slower process because it takes time for the heat in the boiler to rise or dissipate before reaching the targeted output. The electric units are also exceptionally quiet compared to fuel fired boilers. “Unlike gas-powered burners that throttle like turbine engines almost continually, electric boilers keep operational noise levels down,” says Presser. “Because the loudest boiler component is a circulating pump motor, it is easy to have a conversation next to one without having to raise your voice.” As the EU and U.S. resolve to dramatically cut their greenhouse gases to combat climate change, the urgency for industry to similarly reduce their carbon emissions for process heating will only grow. In this battle to protect the environment before the global climate hits an irreversible tipping point, industry along with the government must do their part. Fortunately, advanced, zero-emission electric boiler technology can be a readily implementable part of the solution. For more info, contact Robert Presser at Acme Engineering at e-mail: rpresser@acmeprod.com; phone: 888 880-5323; or web: https://acmeprod.com/high-voltage-electrode-steam-boiler/
ABOUT THE AUTHOR: Del Williams is a Technical Writer who lives in Torrance, California.
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IMD | 45
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Advertiser Index Accudyne Products USA — www.ezpullerusa.com ........................................................................ 9 Actek Manufacturing and Engineering Inc. — www.actekmfg.com ......................................... 37 ATTCO, Inc. DBA Syclone ATTCO Service — www.skyhookmfr.com ...................................... 13 Attica Hydraulic Exchange — www.ahx1.com ............................................................................... 27 Betenbender Manufacturing, Inc — www.betenbender.com .................................................... 19 Carell Corporation — www.carellcorp.com ................................................................................... 15
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Clamprite — www.clamprite.com ....................................................................................................45 Denver Breaker & Supply — www.denverbreaker.com ............................................................... 47 Design-2-Part Shows — www.d2p.com ......................................................................................... 47 DHM Associates, Inc. — www.dhmassociates.com .....................................................................49 Dynabrade, Inc. — www.dynabrade.com ...................................................................................... BC Eagle Bending Machines — www.eaglebendingmachines.com ................................................ 15 ENM Co — www.enmco.com ...........................................................................................................49 Essex Structural Steel Co. — www.essexstructuralsteel.com .....................................................48 Formdrill USA Inc. — www.formdrill-usa.com .............................................................................. 33 H&K Equipment, Inc. — www.hkequipment.com .........................................................................48 HMI div of Betenbender Manufacturing — www.betenbender.com ........................................43 HyPneuMat Inc. — www.hypneumat.com ....................................................................................... 9 IMDauctions.com — www.imdauctions.com ................................................................................ 47 IMTS | International Manufacturing Technology Show — www.imts.com ............................ IBC Industrial Magnetics, Inc. — www.magnetics.com ....................................................................... 23 Kanetec USA Corp — www.kanetec.com .......................................................................................48 KHK Gears — www.khkgears.us .......................................................................................................... 7 Lenzkes Clamping Tools, Inc. — www.lenzkesusa.com ................................................................ 2 L&L Special Furnace Co., Inc. — www.llfurnace.com ..................................................................49 MacMillin Hydraulic Engineering Corporation — www.macmhydraulic.com ........................43 Pro-Line — www.1proline.com .........................................................................................................49 Radwell International, Inc. — www.Radwell.com .................................................................... FC, 3 Royal Products — www.mistcollectors.com ..................................................................................49 Scotchman Industries, Inc. — www.scotchman.com ...................................................................11 Select Equipment Company — www.selectequipment.net .......................................................46 Standard Direct — www.Standard-Direct.com .............................................................................48 Stor-Loc — www.storloc.com ...........................................................................................................17 Tormach — www.tormach.com ....................................................................................................... 35 TRAK Machine Tools — www.TrakMT.com ....................................................................................... 5 Trim-Lok — www.trimlok.com .......................................................................................................... 25
50 | IMD JANUARY 2022
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