Industrial Machinery Digest - January 2023

Happy new year! and welcome to 2023’s first issue of Industrial Machinery Digest. This marks our 37th year of bringing you, our readers, the industry’s most compelling information in the form of news stories, case studies, company profiles, white papers, technical articles, and more. and we don’t plan on slowing down any time soon.

now, it’s no secret that the world has been turned upside down since the global outbreak of COVID-19 in 2020, and our industry, in particular, has faced and continues to face a unique set of challenges in the wake of the pandemic. regardless, the manufacturing sector demonstrated resilience in 2022, building upon the momentum it gained after the pandemic.

So, what does this mean for the upcoming year?

according to recent industry projections by institutions like Forbes.com and Deloitte, supply chain issues like sourcing bottlenecks, global logistics backlogs, increased costs and cybersecurity threats will likely remain critical challenges for manufacturers to overcome in 2023.

This is why it’s crucial — perhaps now more than ever — for manufacturers and industry members to have an effective readiness strategy in place for the new year and beyond. It’s vital to stay vigilant and to be prepared for anything that may come your way, predicted or by surprise.

no matter where 2023 takes us, however, there is one thing that will remain constant — IMD will be here bringing you and our entire readership our industry’s most striking stories.

and, as always, I’d love to hear from you to learn about which topics you’d like to see covered here between the covers of IMD, as well as who you’d like to learn more about in our features and departments. Please do not hesitate to contact me with any questions or insight.

until next time, we hope you have a joyous January and a prosperous new year!

William Strickland

Publisher, Industrial Machinery Digest wstrickland@indmacdig.com

William C. Strickland III, Publisher william.strickland@indmacdig.com 800-366-0676 ext. 103 | Fax: 866-826-5918

Anna Claire Howard, Editor-in-Chief achoward@indmacdig.com 800-366-0676 ext. 104 | Fax: 866-826-5918

Shane Bell, Creative Director sbell@indmacdig.com

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INDUSTRY NEWS

great opportunity for better efficiency.

Dmitry Golitsyn, co-founder and CTO at aBaGy, explains: “Every single day we hear from manufacturers that they can’t find people. according to a merican Welding Society research, more than 40% of welders are over 45 years old. To address this welder shortage, we can help people who are already in the industry become more productive with new technology”.

Will welding robots replace welders? Results of polls and experiments.

robotic company aBaGy and the welder community Weld.Com, which unites thousands of welders in the uS, conducted a joint experiment. a s a result, one of the welders was able to operate a robot without special training on the same day.

austin Hargett (aka Dr. Weldz), a welder with 14 years of experience and one of the members of Weld.com, tested the aBaGy solution for robot control. He defined welding parameters and put the robot to work without any special knowledge in robotics.

“Welding machines are changing. Technology is changing. My job is a constant evolution. a s a welder, I believe that I need to learn something new every day. a nd I agree with aBaGy that robots can be a new effective tool for welders. I’m really impressed with how simple and easy it was to get the robot up and running.”, –austin Hargett said.

also, a poll was conducted among the welding community. Out of 1500 voters, 43% think robots present a

Kate Degai, CMO at a BaGy, said: “There’s a prevailing preconception that robots will replace people. This is exactly what hinders the development of robotics. It is impossible to install robots if there are no people inside the factory who are ready to work with them and feel that this helps them to increase their own efficiency. Therefore, we are open to a dialogue with the welding community”.

Seven Schools Awarded Welding Workforce Grants to Enhance Their Welding Education Programs

The aWS Foundation is dedicated to increasing the welding workforce by providing grant funding to secondary, post-secondary and welder training facilities that seek to enhance and improve their welding education programs. Grant funding of up to $25,000 per location is awarded for facilities to make improvements, invest in capital items such as welding or metalworking equipment, or purchase/upgrade computers or computer-based training systems.

The following seven schools were recently awarded the Welding Workforce Grant:

» Bend Senior High School — Bend, Or

» Bridgerland Technical College — Logan, u T

» Colonial Career and Technology Center—new Oxford, Pa

» Front range Community College—Fort Collins, CO

» Lynnes Welding Training—ramsey, Mn

» reIgnite Hope—Gardena, C a

» Wallace Community College—Dothan, aL

“a s the need for skilled welders continues to increase, helping educational facilities such as these seven locations is more important than ever,” said Monica Pfarr, Executive Director of the aWS Foundation. “We are pleased to support the expansion of their welding programs, their commitment to the welding industry and their dedication to cultivating the next generation of welding technicians and professionals.”

Welding is among the most crucial and essential skilled trades that impact everyday life, yet the number of skilled welding technicians and professionals continues to decrease. The a merican Welding Society through the aWS Foundation supports programs to ensure the growth and development of the welding industry through research and educational opportunities. In 2022, the aWS Foundation awarded more than $2.5 million in grants and scholarships to support welding education.

For more information, visit aws.org/foundation.

Wesley Maine Joins Beckhoff USA as Business Development Leader

Maine will create strategic business opportunities in the Great Lakes region, drawing on three decades of industry experience

Beckhoff automation recently added Wesley Maine to its rapidly growing team as Business Development Leader in the Great Lakes region. Maine brings deep experience in application engineering, sales and management roles across the automation industry. In this role, he will develop new sales opportunities with current customers and prospects throughout Ohio, Michigan, Indiana and Kentucky to further accelerate Beckhoff market share growth. Based out of the company’s Cincinnati-area office, he reports to Don Shanklin, regional Director –Sales and Process.

“Wes has everything you look for in a business development professional. He is an exciting addition, and we are thrilled to have him on the Beckhoff uSa team,” Shanklin said. “Wes is in a great position to leverage his deep experience in sales process, team selling and new customer development – along with enthusiasm for our market-leading automation technologies – to help us drive growth in the Great Lakes region and across the company.”

Maine spent the first 10 years of his career in manufacturing and engineering roles at Mitsubishi Electric automotive and aTS automation, Inc. He then worked as a regional sales manager for B&r Industrial automation for seven years and a sales engineer at Motor Systems, Inc. for four years. after that, Maine joined Mitsubishi Electric automation for 12 years, most recently serving as regional Sales Manager.

“a s a market-leading, family-run, global business that actively encourages employees to help shape its future, I am thrilled to join Beckhoff,” Maine said. “My 10 years of manufacturing experience and 20 years as a sales engineer provide a solid foundation for me to spearhead new technical sales activities at Beckhoff. My primary goal is to help customers think differently about automation so they can lead in their respective industries.”

Maine earned a Bachelor of Science in electrical engineering from the university of Dayton.

BWP, LiCAP, and Siemens Establish Strategic Partnership for Mass Production of Dry Electrode Manufacturing Equipment

Strategic partnership will drive cost-effective and sustainable dry electrode manufacturing towards mass production by 2023.

BW Papersystems (BWP), a division of Barry-Wehmiller, is a capital equipment manufacturer for multiple industries; and is experienced in the successful merging of technologies to develop new solutions that create value for their customers. LiC aP Technologies, Inc. (LiC aP) is a developer of cost-effective and sustainable dry electrode manufacturing solutions for lithium-ion battery and solidstate battery technologies. Siemens is a global innovator focusing on digitalization, electrification and automation for the process and manufacturing industries. Today the companies are proud to announce that they have entered a strategic partnership to manufacture and commercialize innovative dry electrode manufacturing systems for the battery cell industry.

BW Papersystems has a people-centric focus in a way that pursues business growth and creates value. BW Papersystems, LiC aP and Siemens are all companies with technology – that together – fills a product line gap, diversifies the industry, and enhances a new market. rising demand for batteries comes with a huge jump in demand for battery cell manufacturing equipment. Today most incumbent battery cell manufacturing suppliers are based in a sia, already operating at more than 95 percent capacity. Moreover, they may prioritize orders from established customers (mostly leading incumbent cell manufacturers) over those from new market entrants from Europe and the united States. a s a result, north a merican and European battery cell manufacturing companies and EV OEMs are likely to face a bottleneck in equipment supply that will place their planned start of production at risk.

The strategic partnership between BW Papersystems, LiC aP and Siemens will make the north a merican and European Gigafactories more competitive through industrialization of LiC aP’s cost-effective and sustainable activated Dry Electrode™ technology. a s a crucial manufacturing partner, Siemens will be integral in scaling production for both companies.

“For LiC aP, it was important that BW Papersystems and Siemens, as our manufacturing partners, already

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have the expertise and know-how in areas that are critical to successful commercialization of our activated Dry Electrode™ technology. This is why we partnered up with them and have no doubt they can build manufacturing equipment for our electrode manufacturing process at much greater speed compared to any other company,” says Martin Zea, VP of Operations at LiC aP.

For more information, visit bwpapersystems.com.

help identify the correct match. From there, that part can be reordered or quoted and put on record in case it is ever needed again.

Cosen Saws stands behind their products and for that reason also assure quality customer service and support for as long as you have your machine.

For more information, visit www.coensaws.coms

Datanomix and Vallen Partner to Bring Real-Time Factory Analytics to Industrial Manufacturers

Vallen adds Datanomix production monitoring software to its Metalworking Solutions Business portfolio

Datanomix, maker of the industry’s only a utomated Production Intelligence™ software platform, announced a partnership with Vallen to offer the Datanomix software solution to its wide range of manufacturing customers. Datanomix is well known for its n o Operator Input™ approach to production monitoring. The partnership enables Vallen to offer the Datanomix solution to industrial customers seeking improvements as part of Industry 4.0 and industrial automation initiatives.

Cosen Saws Support for Machine Parts

Cosen Saws is prepared with a strong stock of replacement parts at their Charlotte, n C headquarters.

Since Cosen Saws beginning in 1976, Cosen has grown and evolved to meet customer’s needs. The commitment to the needs of customers has never changed. In an effort to be proactive, the Cosen Saws parts department is constantly reviewing the parts inventory and processes to ensure that the best customer experience can be offered as well as maintaining a sufficient inventory of parts for repair. n o matter how large or small the parts order is, Cosen promises to give the attention and service each and every customerdeserves.

Cosen Saws parts department spans over 3,500 square feet. This includes a comprehensive inventory of replacement band saw parts that are always ready to ship as soon as you need them. With the importance of uptime and proper maintenance of band saw machines, Cosen does their best to keep inventory up to date for all machines including common and uncommon parts in order to make sure the parts you need for your machine are always available. This ensures the best customer experience and makes sure saws are always up and running.

Cosen Saws parts department is always available to assist you during working hours, Monday through Friday from 8:00 a M to 5:00 PM EST. They can help to figure out which parts you may need, place orders for those parts, and check on any current orders. a lso if you are unsure of which parts you need, the Cosen team will work to

“We are excited to welcome Vallen into the Datanomix Partners Program,” said John Joseph, CEO of Datanomix. “It’s clear that selling new technology to manufacturing customers requires a deep and successful history of selling value-added solutions. Vallen is a respected brand in the industrial market. They can now have conversations about adding a new layer of value by introducing our LIVE production intelligence software to the portfolio of solutions.”

a s part of the reseller program, Datanomix will train Vallen’s Metalworking customer-facing team on selling, installing, and supporting its customers, with comprehensive information on the Datanomix platform and its benefits for precision manufacturers.

“Several machine monitoring companies are selling basic utilization services to manufacturers today. We carefully evaluated the contenders and selected Datanomix for its true real-time job insights and ability to translate job performance to business impact. This aligns with Vallen’s mission of creating value for our customers,” said Chuck Delph, CEO of Vallen. “The information presented by Datanomix accelerates time to information, shortens corrective action cycles, and directly impacts decision-making at exactly the right time. a s Vallen focuses on innovation and our leadership position in metalworking solutions, we are truly excited to be offering Datanomix to our customers.”

The Datanomix solution automates the collection and analysis of manufacturing data and delivers deep insights into production performance, both in real-time and over time. Designed for growth-oriented precision manufacturers, the Datanomix platform delivers industryleading innovation of manufacturing productivity with n o Operator Input™ without burdening the end user with cumbersome analysis or data crunching.

Digital Transformation in Manufacturing: Paradigm Shift and Incumbent Paralysis

By Dr. oec. HSG Dr. phil. Jörn Lengsfeld

Digital Transformation is one of the most fundamental changes in the history of humankind. In combination with smart automation, advanced robotics and additive manufacturing it revolutionizes the principles of manufacturing. From a business perspective this is tantamount to a paradigm shift. a s success factors change dramatically, this can be a challenge for established companies. How to avoid the pitfalls of Incumbent Paralysis? and what are the implications for machinery?

Digital Transformation as a Trigger

Production is all about the product. That is already in the word. So far, so trivial. However, few things are more dangerous than triviality, intellectually speaking. Because triviality is beyond doubt. What is not being questioned, is not reconsidered. a nd not reconsidering is very risky in times of disruptive change. now, that’s where all alarm bells should be ringing. Everyone needs to keep reminding themselves that we are living in times of fundamental

change. not questioning one’s own mindset is a proven recipe for failure when facing a paradigm shift. This mental bias is well know, but that does not immunize against it. So in manufacturing everyone is well advised to ask: How could production be affected? How could the very basic certainties of manufacturing be challenged?

Traditional Paradigm of Manufacturing

Ever since the first Industrial revolution a productcentered way of thinking has been essential for success in manufacturing. Comparative competitive advantage has been determined mainly by two factors: product quality and product pricing. Particularly in mass production, this is commonsense till today. Given, a company has an innovative product, then market success is regarded to be very much a matter of perfection of production, which is necessary to elevate quality and reduce price. all other areas of business are somewhat considered as inevitable appendages in this school of thinking. Marketing? necessary, sure. needed to help the product speak for itself. Customer relations? really helpful in giving the customer a chance to understand, why the product is of superior quality and unbeatably reasonable price. and so on. Sounds like ironic hyperbole? Maybe, a bit. no offensive intended, just meant as illustration of the main point: The dominant mindset by many in manufacturing has traditionally been to put focus on perfection of production. and for good reason.

Bringing machinery into the equation, the common thinking mimics the described overall focus. The two main questions asked here are: How can machinery help with product quality? a nd how can it increase production efficiency? automation is widely regarded as an enabler of optimization. That has substantial implications for the way innovations in machinery are viewed. They are often evaluated primarily according to their ability to fit into the production process. The mindset mirrors the general attitude: In manufacturing many regard machinery as means for perfection of production.

This very mindset has proven to be extremely successful over the course of the last two centuries. a nd manufacturing has experienced a constant stream of innovations during that time. What should be different all of a sudden? never change a winning strategy, they say. So why are we talking? Paradigm shift!

Paradigm Shift and Incumbent Paralysis

Paradigm shift is the abrupt alteration in the set of overarching assumptions, which are forming the intellectual foundation of a general worldview. It is a change in the baseline believes, that are taken for granted to be true. Consequently, a paradigm shift creates a situation in which the established mindset becomes a trap. Holding on to outdated assumptions carries the risk of misjudgement and poor decisions. This risk

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affects particularly those, who owe their success to their superior understanding of the old paradigm. Often they are inclined to cling to their longheld mindset. u nderstandably, as this has been a proven success strategy for them. This is a common phenomenon: Incumbent Paralysis is the inability of established players to adapt adequately to a paradigm shift. What helps to avoid it? Well, a little self-reflection never goes amiss. The result might be: There could be a new reality on the horizon.

Digital Era Paradigm of Manufacturing

Digital Transformation is widely agreed to be tantamount to a paradigm shift. However, manufacturing is still believed by many to be immune to such digitalization induced paradigm shift. Manufacturing is all about creating physical objects. Cyberspace is thought to be completely separate from the physical world. Therefore, this is not going to change the industrial business model at its core, many say.

n evertheless, established champions get already challenged by digital innovators. The latter tend to think differently about manufacturing. Some don’t even bother to consider the traditional logic, let alone to adhere to it. They operate under a very different paradigm: Production is regarded as part of an integrated system of value generation, whose center of gravity is in the digital infosphere. u nder the new paradigm, production is conceptualized merely as a link between cyberspace and physical entisphere. Consequently, these new players are looking differently at machinery, too. It is regarded as device that functions as an interface between infosphere and entisphere, which enables the materialization of information. a device to convert information into physical objects. It is understood as a means to extend digital systems into the physical reality. This has far reaching implications. While in the traditional mindset machinery is about the optimization of the production process, the new mindset focuses on machinery as vehicle to establish a new logic of value creation, that takes an integrated approach to problem solving in a digital world.

advanced robotics, smart machinery and additive manufacturing enable new forms of production that are directly steered by information processing. With artificial intelligence, machine learning and data science becoming the mind behind the machine, this allows to reconfigure the process of production. Further, the network structure of the digital infosphere enables new forms of interaction with other relevant stakeholders in the market. Characteristic is a reconfiguration of the value architecture from linear value chains, in which manufacturers are the center, to loosely knotted nets, that are highly adaptive. Together, all of this gives rise to new success factors: Flexibility, adaptivity, decentralization, individualization, customization and network integration become key to success in the digital era.

Implications for Machinery Upgrading

Will this apply to all manufacturing? no, of course not. Some branches will be more affected than others. But that should not be an excuse not to explore the new paradigm. Such mental laziness could cost one dearly. One needs to be vigilant to assess whether the own business model is affected. Why emphasis this so much? Paradigm shift is not a new phenomenon. The disruptive potential of innovation is being discussed in management boards for decades. yet, still all to many companies fail due to Incumbent Paralysis. Service industries are facing this challenge as we speak. Industrial production is next in line to be entertained by this experience in the course of progressing digital transformation. Consider yourself warned. Better be prepared. How to do it? Start looking differently at innovations in machinery today! advanced robotics, smart factories, additive manufacturing, artificial intelligence –this is more than just the next generation of machinery. One should not go about it like in every other regular cycle of machinery update. This time a more comprehensive approach is needed: Whenever one spots a new machine one needs to assess, how it could change the value architecture if combined with digital transformation. This really seems to be key!

Digital transformation alters the structure and the functional logic of societal, economical, technological and political systems. Success is defined by the functional logic of the system in which one is operating. When a system changes, the success factors change, too. When a system’s structure is reconfigured, when it’s functional logic is altered, then it is likely that the very conditions for success will also change. What it takes to be successful will be different. Being best in class is meaningless when the discipline becomes irrelevant. Implication for manufacturing:

Perfection of production might perhaps no longer be the single highest priority when the whole business logic changes. Other success factors might gain relevance. Innovation in machinery is both in this: trigger and cure. It causes the paradigm shift and it helps to be successful under the regime of the new one. How to address the challenge? Think out of the paradigm!

ABOUT THE AUTHOR

Dr. oec. HSG Dr. phil. Jörn Lengsfeld is a German economist, management expert and communication scientist. He holds research doctorates from the university of St. Gallen (doctor oeconomiae) and the Philosophical Faculty of the university of Erfurt (doctor philosophiae). Learn more about him and his work on his website, joernlengsfeld.com, or contact him at mail@ joernlengsfeld.com.

Proactive Steps for Robot Reliability and Safety

Chris Williams is Sr. Manager, Customer Care at Yaskawa America, Inc. – Motoman Robotics Division

Advanced technologies, including high-performance robots, continue to build automation confidence and positively impact operational efficiency across the industrial landscape. To sustain a high level of productivity and associated cost savings, company leaders are implementing proactive measures to maximize robot reliability and safety – as fixing a critical asset once it breaks or addressing safety concerns after an unfortunate incident, is not a plan. Key steps manufacturers are taking include:

Implementing Life Cycle Management

While today’s robots are extremely reliable and comply with stringent safety standards, each should have a well-maintained life cycle. Whether for installation,

upkeep, continuous improvement, or retrofitting or redeployment, manufacturers should follow strict guidelines and maintenance schedules to facilitate peak performance. To better maintain the needed robot functionality, company leaders are placing greater focus on continuous improvement via data collection, and many are turning to factory automation monitoring systems that can instantly track, accumulate and visually deliver data throughout networked production environments.

Leading asset management platforms enable data-driven optimized planning for preventative and predictive maintenance, enabling proactive decision-making for more productive factories. From knowing when to order parts for future maintenance or when to change consumables for a

weld process, to tracking the velocity of product movement for optimal bin assignment during a pick and pack process, these integrated solutions provide a wide range of alarms and prompts to keep operations running smoothly. Proven edge server platforms that use a leading OPC-ua interface, such as yaskawa Cockpit™, support multiple brand devices, including robots and their peripherals, and collect information in real time to achieve this.

Measuring Robot Performance

a robot provides the greatest reliability when it is well-maintained. That said, most Tier 1 suppliers work diligently to keep their robot performance near a 99% efficiency rate, creating and executing a stringent maintenance strategy that seeks to eliminate breakdowns before they happen. While a one-size-fits-all approach to robot maintenance does not exist, completing preventative maintenance checks at regular intervals can help optimize robot performance for the utmost safety.

To minimize the deterioration of the asset and maximize robot uptime, measuring a combination of robot levels is suggested. From overall performance (where items such as path accuracy and part quality are tracked) to internal functionality (where things like grease levels, torque and cabling are monitored), there are multiple factors to consider. attention should also be given to robot controller performance.

Often a marker for when upkeep is required, checking the condition of the gear reducers is a frequent maintenance test manufacturers use. This process typically includes:

» Grease a nalysis – a routine grease analysis for each axis serves to keep iron levels in range, as a spike could be indicative of a damaged drive. The type of grease to be used should always be referenced in the robot manual.

» Manual Test – This test entails jogging the robot to reveal problem areas such as vibration and gear noise. a s with other tests, this test may be helpful in determining whether a reducer is failing or has completely malfunctioned.

» Torque a nalysis – Typically performed by the robot brand manufacturer, this test measures the torque of the motors, looking for indicators that might show inconsistencies in the robot motion. a spike in the data generated during this procedure will typically reveal any inconsistencies.

» Backlash Test – also commonly performed by the robot brand manufacturer, this procedure uses a dial indicator to determine the amount of backlash in the gear reducer. For accurate readings, the robot and dial indicator are placed in a specific location.

While these checks do not need to happen as a collective, each should be utilized, as needed, to

determine robot function. Keep in mind, maintenance intervals are based on servo hours (tracked in the robot), and it is typically performed every 6,000 servo hours. a s always, individuals should reference the robot manual for guidelines specific to the model in use.

Whether a manufacturer assumes full responsibility for any of these tests or relies on scheduled visits from the robot manufacturer, there should be a clear plan in place that designates leadership, best practices, inventory strategies and action steps for reaching specific goals. If external technicians or contractors are required to complete specific tasks, scheduling should be accomplished at least six months in advance to accommodate busy schedules.

Deploying an Inventory Strategy

Especially helpful for 24/7 operations that may not be able to completely close for a scheduled shutdown, a growing number of manufacturers are stocking spare parts on-site to avoid long lead times for parts delivery. In this instance, historical data is often relied upon to know what parts may be necessary in the future. Commonly stocked items (with average replacement intervals) include:

» Controller CPu battery – replace every three years

» Controller air filter – replace annually

» Controller fan unit – replace every three years

» Gaskets / Gasket covers – replace every three years

» Connectors – replace, as needed

» Seals – replace, as needed

» Cables – check frequently and replace, as needed

» Teach pendants – test frequently and replace, as needed

» Gear oil – replace every other year

» Grease for bearings and pertinent parts – monitor often and re-grease, as needed

Part of a smart inventory strategy is to hold an annual planning session with a customer service representative from the robot brand manufacturer. This will serve to answer any questions and address other areas of maintenance that may have been overlooked.

Facilitating Employee Training

While all manufacturers should take proper precautions for robot operation and maintenance, companies that take a DIy approach should be especially careful. In fact, it is critical for robot programmers and maintenance staff to have the proper training to do the job correctly. Courses taught at an International accreditors for Continuing Education and Training (IaCET) accredited facility, such as yaskawa academy, are ideal. These locations provide hands-on instruction in application-specific classrooms with leading technologies, ensuring robot uptime and worker safety for a better return on investment (rOI).

Supplemental training and support for robot maintenance, troubleshooting and repair can also be gained through user-friendly, yet comprehensive, web-based solutions, like robotPro®

Retrofitting Robotic Systems

The uncertainty to retrofit a robotic system is common. From downtime to cost, there is a lot to unpack. While concerns about low quality parts have been valid in the past, decision makers can gain confidence in the fact that technological advancements and safety standards have greatly improved part quality in recent years.

When smaller components, such as a power source or weld torch fail to deliver the desired quality, or something becomes a potential safety risk, the decision to retrofit is easier. When faced with the choice to add a robot to a current workcell or upgrade all together to meet throughput demands, things can get complicated. regardless, an appropriate option can usually be agreed upon over the phone with the robot supplier or integrator.

In some cases, a representative from the appropriate vendor may need to make a site visit to determine the best retooling and equipment options to meet application requirements. Likewise, if a retrofit is being considered for a safety issue or a process change, a risk assessment may be required – as the a merican n ational Standards Institute ( an SI) safety standards must be

followed and should be paramount when making any retrofitting decision.

When mulling over the decision to retrofit versus a complete upgrade, manufacturers should also consider the concept of using certified pre-owned robots. a growing trend, this option is often more affordable for small job shops and medium-size companies.

Maintaining Operational Success

Planning for repairs and retrofits is crucial to achieving long-term corporate goals, especially for suppliers with lights-out operations. From creating a monetary budget to applying the lessons learned from prior projects, a comprehensive plan with full directives should be followed. While doing this may seem excessive or unrealistic to some manufacturers, maintaining equipment and applying new technologies, when needed, can prevent costly breakdowns and unnecessary downtime.

a large part of executing a solid life cycle management program with preventative maintenance is having access to diverse support services. Whether 24/7 technical support is needed to diagnose a problem remotely, a field service technician is needed for rapid on-site support, or an emergency part is needed in the middle of the night, a committed robot supplier or integrator with skilled technicians goes a long way to maintaining safe operations and meeting production goals for maximum rOI.

Aerospace Job Shop Makes Its Own Tools for 150+ Machine Tools

Uses three anC a grinders with machine builder’s software to go from design to blank to tool in under an hour

Slabe Machine (Willoughby, Ohio) owner Brendan Slabe had an epiphany a few years ago. “a friend in Connecticut told me about a CnC machine in his shop that was simple, easy to program and set up, run and verify tools of all types. It was an anCa grinder. I mentioned it to my toolroom supervisor John Walker, who had no CnC experience but had great curiosity, being a master toolmaker. John investigated the machine to produce some very challenging variable helix endmills we were buying from an outside supplier. He came back to me a changed man as he realized that the part could be sampled on the anCa in ‘less time than it takes for a coffee break…and it’s right, the very first time.’” In just a few years, Slabe was producing all the tools used at this production job shop on its 150+ machine tools. The company operates over 300 pieces of equipment total at its facility.

“Our robotically fed anCa Tool grinders manufacture all the drills, endmills and custom carbide tools used by

all our machines and thus eliminates the inefficient and costly process of quoting and procuring tools. Our Belair Vertical Drag Hones can then selectively and precisely hone and/ or polish the edges of any tool or machine component, enabling us to be completely self-sufficient for all our tooling and grinding needs. Our Chevalier double-disc Fine grinders can grind/lap flat parts and tools down to sub-micron tolerances. The anCa FX7 is the most technologically advanced CnC tool grinder on the market today - its flexibility, spindle power and full robotic automation allow the FX7 Linear to create, reconfigure or regrind any tool with exacting precision and incredible speed, according to Brendan Slabe.

has focused on aerospace since its inception in 1939, but today also produces parts for power generation, ordnance and medical end products, often involving very hard-tomachine materials.

He further details the company’s use of the anCa grinders, which now number three on the floor at Slabe Machine. “In a phrase, it’s complexity made simple. Because anCa builds its machine almost entirely in-house, including the CnC and the software used, we can take a job and produce the tools in far less time than in the past, when we relied on outside tooling suppliers.” He cites examples such as complex flanges, helical shapes, challenging end geometries and more, where the prototype tools can be produced faster, allowing the part to be sampled and delivered to the customer in record times. This, Slabe notes, “…is a real door opener for us and anCa assistance is a big part of that process. I consider them true manufacturing partners, similar to the three machine tool dealers from whom we buy most of our high-end machines to make the parts.” Slabe

John Walker, the Slabe toolroom supervisor, says, “Our company has been doing business with anCa for about six years. We have three anCa FX7 machines making endmills for production on our 150 + machine tools, all in-house at Slabe. We make job-specific special endmills as needed, saving thousands of dollars making them ourselves. The anCa FX7 has excellent software - easy to program for specific needs, so changing programs from tool to tool is quick and easy. The anCa runs flawlessly day after day and we also run lights-out, which is outstanding about the FX7. you can set up before your shift is over and run tooling at night unattended. It has a FanuC robot loading system that loads tools, grinds them and unloads them, all day and night. The training facility at anCa in Wixom, Michigan is second to none. Those folks are very professional and courteous. Our regional Sales Manager robert Straker greets you with a smile and handshake, robert and our trainer Dan Morris are very knowledgeable and have a desire to help . Dan trained us extremely well and, when we call anCa with questions, we always get the answer we need in a timely manner, a very helpful resource for Slabe.”

concludes, “at Slabe Machine, we specialize in manufacturing a wide variety of precision components for gas turbine engine and fuel system components. Our customer base consists of the world’s largest aerospace OEM’s, to whom we supply everything from complex external components used on all commercial turbofans to internal ‘hot-section’ augmentor and turbo combustor details, used in virtually all military engines in service today. Our company was founded in aerospace and, since 1939, we’ve grown to into an industry-leading source of supply for all parts made from any grade of Inconel, Waspalloy, Titanium, Hastelloy, Stellite, Haynes or Cobalt alloys. This variety of parts requires a lot of special tools for production and having the anCa machines in the shop makes our job much easier and has taken our company to new heights in the aerospace market. a s I said, they are a true partner to us.”

Owner Brendan Slabe

Plasma Cutting and MIG Welding Cobots Yield Heavy-Duty Results for Carriere Industrial Supply

Collaborative robots from Universal Robots help heavy-equipment manufacturer reduce time and eliminate manual cleanup on curved plasma cuts by 75%; Cobots work alongside human welder to double Mig welding output

Carriere Industrial Supply (CIS) in Sudbury, Canada, produces heavy equipment for harsh mining environments; much of it—such as hauling equipment, scoops and earth movers—is used to move material from underground to the surface. Like most manufacturers, the company is adapting to a changing workforce—hiring new workers and retaining skilled talent, while strengthening its safety culture so that every employee goes home safely every day.

a utomation is an ideal approach for repeatable applications. But in a low-volume, high-mix manufacturing environment, and with many large workpieces that are difficult to move, traditional robots may not be considered.

The CIS team discovered universal robots (ur) at a trade show and was immediately struck by the sight of collaborative robots (cobots) performing tasks while people

interacted with them. Cobots from ur allow CIS to bring the robot to the work—rather than the other way around—and their easy programming empowers workers to continuously innovate to improve quality and output.

Plasma-cutting cobot empowers employees while saving 1,000 hours on a single project

The first project CIS identified for the ur application was plasma cutting of large metal parts. Manual cuts required extensive cleanup due to the accumulation of dross at the bottom of the piece along with the jagged edges that occur when workers need to reposition themselves for long cuts. reducing the cleanup time was an ideal area for improvement. Pierre Levesque, manager of innovation and technologies, says, “ using a robotic arm, we knew that we would get a more precise cut and the possibility of eliminating all of the grinding and cleanup of the joints.”

UR10e MIG welding robot is mounted on a 7th axis and placed on a mobile skid to bring the robot to large workpieces. A human welder and robotic welder work side-by-side, leap-frogging across the side of the truck body to double output.

CIS chose the ur10e, which met both its reach and payload requirements, even with the weight of the plasma cutting tool and long workpieces. and despite the size and power of the robot arm, Levesque describes it as a “very approachable robotic cell” in terms of ease of use, even for operators with no robotics experience. They can place the workpiece on the table, “teach” the robot where the part is, and run the program for a clean, precise plasma cut, even on curved parts with complex geometries.

after some innovative programming, the cell became even more approachable for operators, who were excited to make continual adjustments to improve quality and output. (See Sidebar for details on programming the plasma cutting application.) Mason Fraser, junior software engineer at CIS, initially programmed the cutting of the most complex parts from start to finish, then built a new urCap program (software handshake between the cobot arm and its peripherals accessible on the cobot’s teach pendant) that “puts the operator in the driver’s seat” with an easy-to-use interface. now the operators are fully engaged in instructing the robot on the points and speed to do the cut.

Levesque adds, “What the urCaP does is augment that operator’s ability by automatically navigating any plate geometry imperfections, and adjusting corner speed when necessary, based on the geometry and the points they provided. What you end up with at the end is the operator feeling in control, but elevating the game to make sure that the right parameters, the speeds, the material you are

cutting—all that’s covered through the urCaP. So now you have a very successful cut, reduced time, reduced risk for the operator, and it is a win-win for both the operation and the operator.”

While operators appreciate that the work is more rewarding and less physically demanding, CIS also saw significant time and cost savings. Previously, 80 percent of the plasma-cutting time was spent cleaning up the manual cut. On a single large truck body contract over the next three years, Levesque determined that the trimming process

on that project alone would be more than 50 hours for every truck. Moving to a robotic application reduced that time to 12 hours per truck, ultimately delivering 1,000 hours and a significant cost savings on this project, exceeding CIS’ expectations

Levesque further adds, “The interesting thing is to see the operators taking it even further, and applying thought on their cut process. With the ease of being able to manipulate the robot and using the free drive to position the torch in different angles, the operators were taking more care on applying bevels onto the final parts, which was quite impressive.”

Marc Sauve, process leader for steel processing at CIS who runs the plasma cutting-robot, addresses the concern that some may have about robots and jobs. “If I had a colleague who was fearful of a ur robot coming to take their job, I would put them at ease,” he says. “Every one of those robots needs an operator, so it’s just an asset to them; it’s not a tool to remove them.”

Versatility and mobility of UR cobots inspire innovation to double MIG-welding output and improve ergonomics after the success of the plasmacutting robot, CIS knew it could leverage that programming to MIG welding projects, even though that is a more difficult application. Fraser says, “The MIG-welding ur10e is doing similar profiles to what the plasmacutting robot is doing, in the sense that it is following curvatures and following profiles; It’s just welding them instead of cutting them.”

Levesque knew MIG welding would pay dividends based on the large volume of welding work the company does. The challenge was to find repeatable parts in its low-volume, high-mix environment. One application stood out: the production of truck bodies with seven large side-by-side fillet-welded ribs, spaced three to four feet apart. Levesque says, “We envisioned that the welder can be working on one of the ribs while the cobot can be doing the next rib in

coordination, and then you just index them over.” Fraser adds, “There’s a ton of welding on those, so we are trying to make this save time for the welders. They can work alongside the robot and split the work in half.”

Because of the length of the welds, the manual work raises critical ergonomic challenges to consider for welders. Fraser says, “The robot doesn’t care about ergonomics, so the operator can set up the robot and

go work on other stuff that’s more productive and easier to do. Some of the more productive work they could do is cleaning up the welds, making them look nice. The more we can free them up to do that kind of work, the better.”

The MIG welding process is applied to massive parts weighing over 15 tons on the bodies of heavy-duty mining trucks; workpieces that can’t be fixtured inside a traditional robot

Mason Fraser programs the UR plasma-cutting application, using a checker board to calibrate the vision system.

cell. That required CIS to bring the robot to the workpiece, rather than the other way around. unable to find a standard solution, the CIS team developed a custom welding skid that can be moved with a forklift to wherever the welding robot is needed. The robot is mounted on a lift to create a seventh axis to reach the entire weld on the side of a truck body. The relatively light weight of the ur cobot arm allowed CIS to develop this innovative approach.

Ease of programming, extensive UR resources, and UR+ products contribute to success

“Traditionally, in industrial robot applications, you have to do all your programming in the cell with it, at a very reduced speed, and then leave the cell and press the button, and hope for the best,” says Fraser. In contrast, the open platform and ease of programming of the ur cobots was a significant advantage. While industrial robots typically use proprietary code that requires special software for development and test, Fraser says. “ universal robots was a big, refreshing change from this because all the scripting and programmability in it was open, and it can interface with any software, any program, and any simulation tool. you’re not limited,” he explains.

a s Fraser started the project, he was able to easily find the resources he needed on the ur website. “There was the ur academy, which has great examples and tutorials on programming the robot. It actually gives you a full simulation of how a program would look and how to write it, without having to download any software. It’s all purely online, so that was extremely helpful.” Fraser and his team developed their own urCaP in-house, and says, “a lot of the tools available to us online, such as the ur+ Developer Forum, had a ton of resources and answers that I needed to get through the project. all in all, it ended up being a pretty great experience.”

Fraser also discovered the value of ur and its partner’s simulation tools

Automating Intricate Geometries for Plasma Cutting

The CIS plasma-cutting application is set up with the robot in a typical position in front of a plasma-cutting table. Operators can present the workpiece and “teach” the robot where the part is positioned relative to it, and run the plasma cut. CIS started with a standard user-frame teaching mode of three points, which worked well for many parts, but any adjustments were difficult to do quickly. Fraser and his team found a Java computer-vision library called BoofCV and leveraged that with the jMonkeyEngine 3D game-engine library. With these tools and a webcam, they were able to project and line up the part in space, similar to augmented reality, to allow the operator to know exactly where to cut every time.

Once they started cutting, the team realized that none of the parts were formed perfectly off the brake press, so they needed to develop a way to maintain a consistent cutting height above the plate. Because the ur10e has a built-in force/torque controller, they used a drag nozzle on the plasma-cutting torch to drag along the surface of the plate to maintain a consistent distance while cutting. unfortunately, the pressure generated from the torch nozzle caused it to bounce off the plate. To solve the issue, the team wrote a custom proportional–integral–derivative (PID) controller in pure ur script code, and used that to compensate for the torch height with voltage feedback. This allowed the robot to keep a steady distance off the plate for every cut.

Because the team had more than 20 years of experience with CnC machines, they knew about curve compensations and knew they needed to develop something that would follow the plate properly and would adjust for cornering. Levesque explains, “If you think about driving a car, you can’t take a corner at 90 km an hour, and the robot is no different. When you have complex geometries, we had to build some algorithms that would slow down around a corner.” The team applied that logic in a way that lets the cutting application augment the worker’s ability. “The person is in control,” Levesque says. “They give us the pathway and then we apply all those enhancements.” That allows someone with less experience to still have good-quality cuts, and guaranteed performance.

to save time and effort. The universal robot’s ur Sim is an offline simulator for the universal robot pendant. It let him test the urCaPs he developed without having to upload them to the robot and test them on the production floor. Fraser explains, “The big benefit of being able to upload to a simulator rather than the actual robot was a major reduction in cycle times. We didn’t have to go back and forth to the robot to test it; I could test everything right on my computer.”

He also discovered the ur-certified roboDK offline simulation software

on the ur+ website. roboDK is an offline simulation tool where Fraser could load 3D parts data and program an entire path. “Because of the open nature of universal robots, uploading and reading ur script into roboDK was a piece of cake, and it made testing very quick,” says Fraser.

Future projects with UR cobots

n ow that CIS has experience with ur , they have confidence for future initiatives and application, such as machine tending in manufacturing assembly. Fraser is also considering

adding vision capabilities to the MIG welding robots similar to the approach used for plasma cutting. a nother option is implementing more complex cuts with the plasmacutting robots such as coping for steel beams, or standard part cuts the robot could do quickly while minimizing disruption to production.

Levesque says, “ ur is definitely a platform we’re going to continue to work with. The ease of use and the approachability of the platform is definitely appealing for the company.”

Marc Sauve operates the plasma-cutting robot with no prior robotics experience

SME Introduces Robotics in Manufacturing Fundamentals Certification

industry-driven nationally recognized certification for students, dislocated workers, and new-to-the-industry employees

SME, a nationally recognized certifying body in manufacturing, announced today that it has developed and will offer the robotics in Manufacturing Fundamentals (rMF) credential. The new certification, focused on assessing a candidate’s comprehension of fundamental robotics concepts, may be used by those currently looking to upskill or reskill into manufacturing careers before pursuing equipmentspecific or career pathway-specific training in robotics. The credential can help individuals begin a lifelong career in an industry where there is opportunity for advancement and good-paying jobs.

The industry-recognized rMF credential was developed by SME, with two leading organizations in the robotics education area: robotics Education & Competition (rEC) Foundation and FIrST®.

“Through our extensive networks in industry, education ,and workforce, SME identified a common need for a robotics credential that demonstrates certification holders have a basic understanding of robotics concepts before starting a more advanced training program,” said Jeannine Kunz, Chief Workforce Development Officer, SME and member of the Education and Workforce advisory Committee of arM, the robotics Institute. “We worked closely with the rEC Foundation and FIrST to validate the body of knowledge to cover topics relevant for foundational robotics topics across a wide range of industries.”

The rMF credential, focused on the fundamentals of manufacturing robotics, provides a starting point for any career pathway a candidate may pursue in the field of robotics.

“The global robotics market is expected to reach $74 billion by 2026 and there is tremendous opportunity for those who want to advance their career,” Kunz said. “To keep our industry thriving, we need to help meet the high demand for advanced manufacturing and robotics talent in our country.”

With a rMF credential and the fundamental knowledge it represents, a candidate has many options available to them including:

» Entry-level employment in manufacturing jobs that involves robotics and automation

» Pursuing further education and training toward:

» robotics-specific career pathway such as a robotics technician, robotics specialist, robotics integrator, or robotics engineer

» Equipment-specific robotics training and certification

» Skilled trade in which robots may be applied such as machining or welding

» Industrial maintenance or mechatronics certification

“It is important for FIrST to recognize the high value of skills and experiences that students gain through robotics programs,” said Chris rake, Chief Operating Officer, FIrST. “The rMF credential unlocks exciting career pathways, helping us inspire young people to become leaders in robotics and advanced manufacturing, and we’re proud to join SME in developing this program.”

The rMF credential is ideal for high school and college students, dislocated workers, underemployed individuals, veterans, at-risk youth, and others who are seeking new employment in high-demand manufacturing jobs.

"The rEC Foundation is pleased to partner with SME to create the robotics in Manufacturing Fundamentals certification as a way to recognize students that are pursuing Industry 4.0 technology careers,” said Dan Mantz, CEO, rEC Foundation. “Manufacturing is evolving and today's manufacturing jobs require high tech skills. But there is a critical shortage of tech workers for these jobs so students earning this certification will have excellent career opportunities. The robotics in Manufacturing Fundamentals certification is an exciting complement to the existing rEC Foundation industry certifications in Pre-engineering and robotics that are part of our workforce development initiatives."

SME has led the manufacturing industry in providing industry-recognized certifications for over 50 years, including Lean Certification, additive Manufacturing Certification, Certified Manufacturing a ssociate (CMfga), Certified Manufacturing Technologist (CMfgT), and Certified Manufacturing Engineer (CMfgE).

Supporting Knowledge

Candidates may pursue the rMF credential on their own, work with their local training provider, or access Tooling u-SME resources to prepare for the exam.

Tooling u-SME offers an optional preparatory program of 22 online classes covering foundational manufacturing topics such as an introduction to manufacturing, applied mathematics, robotic applications, robot systems and components, robot programming concepts, and more – topics agreed upon by manufacturing experts as being relevant for foundational robotics knowledge across a wide-range of industries. Following completion of the training program, passing the certification exam validates knowledge gained.

With each class lasting approximately 60 minutes, the training program can be completed in just a few weeks (typically less than one month) or in one semester as part of an Introduction to robotics course at school, offering

short-term, but comprehensive, preparation for the certification exam.

With the prospect of over 2 million jobs expected to be left open due to a lack of trained workers, there is plenty of opportunity for career advancement.

additionally, employees are more open to the field than ever before. according to arM Institute, 77 percent of workers say that they would be happy to work alongside robotics in manufacturing if it meant having to perform fewer manual processes.

• 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.

Staying Competitive: Important Considerations When Approaching Warehouse ASRS Investments

By: Tom DiNardo

Meeting consumer demand and delighting customers are fundamental to building a competitive advantage in manufacturing and distribution. With modern advancements in supply chain and packaging technologies, companies in all verticals that may have once comfortably enjoyed their market share are facing more intense competition than ever. Industry veterans and newcomers alike are raising the stakes with competitive pricing and rapid order delivery offers.

The key to meeting demand, sustaining growth, and future-proofing warehouse and distribution center operations lies in fully embracing automation, which frequently involves implementing automatic Storage and retrieval Systems (aSrS).

The challenge of fulfilling orders is a classic Catch-22: The more orders are fulfilled, the faster expectations rise to fulfill orders. This means more products need to be consistently on hand, and in turn, more resources and capacity are needed to carry out operations and meet demand. Without support from automated warehousing solutions, there can be diminishing returns due to the limit on how quickly distribution center personnel can unload trucks, palletize and depalletize, drive forklifts, shelf and unshelf products, and get shipments out the door to fulfill customer expectations.

aSrS serve as highly versatile options and are growing in popularity and implementation. according to Business Wire, growth within north america’s aSrS market is projected at a compound annual growth rate of 9% through

2026. a s these systems represent a significant investment and can redefine end-of-line operations, several factors should be taken into consideration before determining if they are right for your operation.

First, you must have a base understanding of how an aSrS functions within a larger operation. These systems sit squarely in the intersection of logistics, robotics, and software, and use all three in conjunction to amplify the capabilities of warehouses and distribution centers. This versatility provides suitability for all types of warehouses, regardless of age, size, and floorplan.

Second, it serves to know how the benefits of an aSrS are directly derived from its components. The buildout itself consists primarily of modular shelving with high level capacities, navigated by an integrated network of powered carts and lifts that carry, store, and retrieve pallets. The software behind the automation technology drives these systems, providing customizable logistics that empower any operation. This allows the a SrS to navigate the unique logistics challenges of every respective industry and corresponding storage facilities, thereby improving inventory management, optimizing operational resources, and most importantly, meeting customer demand.

The software behind an aSrS is robust enough to serve as the primary source of logistics automation for the entire facility, but it is also adaptive and nimble enough to integrate with other third-party logistics software platforms as well. a s storage needs frequently shift within facilities to meet supply, demand, and product diversification, aSrS are designed to grow and adapt with their users by adding additional modular components onto the existing setup, or adapting software to changing business dynamics.

Beyond the machinations of the system itself, you should consider how streamlining logistics for products with varying needs can improve your ability to deliver products in their intended, ideal condition. The speed and automation of retrieval, mixed with the logistics of the operation make it naturally efficient. For example, an aSrS can automatically store the most frequently needed products, or those with the shortest shelf life, in areas for the fastest retrieval possible. Simultaneously, it can place items with a surplus at more remote areas of the facility, and automatically backfill these items from deep storage to easy picking zones as demand dictates. The algorithms that manage these decisions can be adjusted based on seasonality, portfolio changes, and other dynamics impacting product mix and priority.

The most cutting-edge innovations within aSrS allow picker carts to move at higher speeds, handle pallets with heavier loads, and operate in extremely cold environments – as low as 13 degrees below zero. Depending on your warehousing demands, these differentiating factors in a SrS functionalities should be part of the decision-making process.

a s powerful as these systems are, they can demand specialized service and ongoing upkeep. When considering the purchase of an aSrS, you should confirm that manufacturers can provide not only seamless build outs,

but also expertise in ongoing service and support from a preventative maintenance perspective. Vetting providers for expected availability to trained service professionals can help proactively minimize downtime and maximize rOI.

Beyond access to operational service and preventative maintenance, leading a SrS practitioners are equipped to collaborate with clients to make sure your exact needs are incorporated from the outset. Every facility is influenced by industry, local and global factors that should be constantly monitored for ways to further improve utility.

Companies that carefully examine all these aspects before implementing an aSrS are more likely to maximize productivity and profitability. Some have reportedly documented unprecedented growth numbers, with specific operations reporting an increase in units shipped by more than 450% after incorporating the a SrS. now is the crucial time to look to the future and to solidify your operation’s viability – and a SrS can be the key.

ABOUT THE AUTHOR

Tom Dinardo is the Vice President of Global automation at Signode. He oversees the global commercial activities for automation and Systems Integration and is responsible for automation operations in north america, Europe, a sia. Dinardo’s automation experience spans multiple industry segments, supply chain management, manufacturing, and product marketing.

SHEFFER HYDRAULIC PRODUCTS

QUALITY FEATURES… Sheffer cylinders are designed not only for exceptional performance, but for fast and easy installation and parts replacement to minimize downtime. STUDDED ROD ENDS: Sheffer’s design virtually eliminates breakage by outing stress away from a common weak point. SEPARATE ROD BEARING: On most Sheffer cylinders, the hydrodynamic “flooded bearing” greatly reduces wear and extends part life. SLIPPER PISTON SEAL AND BEARING: Standard on all hydraulic cylinders. Teflon surfaces provide excellent lubrication, reduce heat and friction. FOUR FULL WRENCH FLATS: Designed to avoid damage to the rod surface during installation or replacement. CHAMFERED TUBE ENDS: When replacing seals, the chamfer compresses the seal into the piston, minimizes seal damage.

HYDRAULIC CYLINDERS… The Hydraulic line consists of three series. The MH and HH models feature interchangeable dimensions with ANSI, NFPA, and JIC. MH: Medium-Duty, Bores to 8’’, 800 to 2,000 PSI, 20 standard mountings. HH: Heavy-Duty, Bores to 24’’, 3,000 working PSI, 22 standard mountings. UH: Ultra High Pressure, Bores to 14’’, 5,000 PSI, 8 standard mountings.

PNEUMATIC CYLINDERS… The Pneumatic line consists of four series. The MA and A models feature interchangeable dimensions with ANSI, NFPA, and JIC. MA: Medium-Duty, Bores to 8’’, 200 PSI, 14 standard mountings. A: Heavy-Duty, Bores to 14’’, 250 PSI, 20 standard mountings. AA: Light-Duty Aluminum, Bores to 2.5’’, 200 PSI, universal mount, kits available. C20: Cast Iron, Bores to 10’’, 200 PSI, 5 standard mountings.

Protecting VFDs from Overheating

an easy way to calculate cooling requirements

By Jon LaPorta, Pfannenberg USA

Variable frequency drives are a hot topic. advancements in VFD technology and reductions in price are driving rapid market adoption. Dramatic energy savings can deliver a payback period measured in months, and VFDs enable precise motor control in many industrial process applications.

But VFDs are also hot in the literal sense: the advanced electronics pack more semiconductor components into a smaller form factor resulting in more intense heat generation. Elevated temperatures degrade performance, impair operational reliability and shorten service life. a variety of cooling methods have proven effective, including passive air cooling with fans and heat exchangers, and active cooling with air conditioning and water cooling. unfortunately, determining the cooling load can be a bit confusing. Calculations are needlessly complicated by a mismatch of systems of measurement. — Imperial units (HP, BTu, CFM) mixed with Metric units (Watt) — and the conversion gets lost in translation. Therefore, at Pfannenberg we have developed simple rule-of-thumb guides for selecting and sizing VFD cooling solutions.

Protective enclosures cause overheating

The basic challenge of VFD cooling comes from the fact that VFDs usually need to be placed in an enclosure to protect them from the immediate environment, and paradoxically, these enclosures trap heat which necessitates protection from overheating.

Basic nEMa 12 type enclosures are often specified to protect against common hazards such as settling dust, dripping water and condensation of non-corrosive liquids. Increasingly, advanced technologies in new VFDs such as fiber optics require enclosures with more enhanced levels of protection.

and with the wide scale adoption of VFD technology, many applications require enclosures specially designed for challenging environments, from weather and impact resistant outdoor enclosures to tightly-sealed stainless steel enclosures for food production facilities that must withstand hosedown cleaning. a s an enclosure becomes more sealed it naturally starts to hold in more heat, due to the decrease in passive dissipation, thus creating a larger cooling challenge.

The size of the enclosure also matters a great deal. Typical enclosure dimensions have been dramatically

scaled down in recent years, to fit in tighter spaces and to economize on the cost of the enclosure. In a large box — imagine a space the size of a room — the difference in temperature between the floor area and the ceiling area causes a slight airflow called natural convection. The smaller the space, the less objects are able to benefit from this cooling effect. Without adequate airflow, a phenomenon known as “hot spots” is more likely to develop on the surface and in the interior of VFDs, wreaking havoc on sensitive electronics.

The smaller form factor of VFDs and their enclosures contribute to overheating in another way: a smaller box means that less surface area on the exterior is available to transmit heat to the surrounding air. all of these factors necessitate effective and reliable cooling solutions.

Rapid Adoption of VFDs

But first, let's step back from the box and consider the big picture. The energy efficiency of VFDs is not just good for individual businesses, it is also key to addressing climate change.

Worldwide, about a quarter of all electrical energy is used to supply motors in industrial applications. In the u.S., an estimated 40 million motors consume 60-65% of all electrical energy. Three quarters of these motors are variable-torque fan, pump and compressor loads, the types of applications ripe for the energy efficiency afforded by VFDs.

Today, only about 3% of aC motors are currently controlled by VFDs, but about 30-40% of new motors installed each year have a VFD. according to a 2021 report by research Dive, the global variable frequency drive market is estimated to grow at nearly 5% annually to $25 billion in 2027.

The energy savings are dramatic. VFDs reduce energy consumption by enabling electric motors to operate at less than full speed. Basic aC induction motors are designed to run at a constant speed, but in actual use, speed requirements fluctuate, with full speed typically employed only about 10% of the time. The inherent inefficiency is obvious, analogous to running a car engine with the tachometer showing the engine constantly at its maximum speed.

The energy savings can be calculated using the Laws of affinity: the electrical power drawn is proportional to the cube of the rotational speed. Therefore, slowing a pump or fan to 75% speed reduces energy consumption by nearly 60%, and 50% speed saves almost 90%.

From these efficiency gains, it is necessary to subtract the relatively minimal energy waste of about 3% due to heat loss from the VFD. This heat loss from the VFD is important to quantify, not for its financial impact, which is minimal compared to the overall efficiency gains of utilizing the technology, but rather for the danger that overheating poses to the VFD electronics if the heat trapped in the enclosure is allowed to exceed acceptable temperature limits.

When to choose passive cooling and when to choose active

There are two different types of cooling, the first being passive cooling and the second being active cooling, both types utilize The Second Law of Thermodynamics which in simple terms is that energy goes from a higher source to a lower source. Passive cooling utilizes the natural path of heat transfer with the heat going from the higher temperature source to the lower temperature source. a good example of this is filterfans, filterfans move the colder ambient air into and through an enclosure where that air absorbs heat until it is exhausted and the heat dissipates into the environment.

active cooling requires a source of energy to be put into the system in order to create a path for heat to transfer. This is commonly done with the use of a vapor compression cycle, a vapor compression cycle has four major parts, a compressor, a condenser, a throttling device, and an evaporator. The cycle starts with the compressor where energy is put into the system, refrigerant enters the compressor under low pressure and low temperature where it is compressed which causes the refrigerant to leave the compressor under high pressure and high temperature. next the refrigerant travels through the condenser where heat is removed causing the refrigerant to become a saturated or subcooled liquid. Then the refrigerant passes through a throttling device where its pressure and temperature drop. Finally, the refrigerant passes through

the evaporator where heat is absorbed turning it into lower pressure and low temperature gas, where the cycle can then repeat.

Deciding when to use passive and when to use active is fairly simple. If your ambient temperature is lower than your target enclosure temperature or you have a source of passively chilled water, then a passive cooling unit can be used which is desirable for energy savings. Passive cooling uses significantly less energy than active cooling, as the passive cooling does not require energy to be put into the system to allow a path for heat transfer. If your ambient temperature is higher than your target enclosure temperature or you do not have a source of passively chilled water, then an active unit has to be used.

Simple way to calculate cooling requirements

Here is a simple way to calculate cooling requirements for both active cooling and passive cooling methods.

Active Cooling Rule of Thumb

VFDs are typically sized in horsepower (HP) and cooling systems are measured in British Thermal units (BTu, or BTu/h for BTu hours). But how do you convert from HP to BTu/h?

Here is the rule of thumb for air condition and water cooling:

In other words, for a 100 HP VFD drive, 7500 BTu/h of cooling is required. This rule of thumb is derived as follows:

» 3% of the electrical energy in a VFD is converted to heat

» 1 HP = 746 watts

» 746 watts x 3% heat loss = 22 watts of heat loss per 1 HP

» 1 watt = 3.4 Btu/h

» 22 watts x 3.4 BTu/h = 75 BTu/h per 1 HP

Passive Cooling Rule of Thumb

For passive cooling solutions, such as the Pfannenberg Datawind Filterfan®, the rule of thumb is 4 CFM is required for every 1 HP to maintain 10°C above ambient in the enclosure

In other words, for a 100 HP drive, 100 CFM is required. This rule of thumb is derived from the following equation 1 CFM = 1.82 x watts of heat loss / Δ Temp (°C) These rule of thumb guides provide a general guide for selecting a cooling method and for sizing the cooling load requirements. For more precise calculations that account for ambient temperature and humidity and other critical considerations, we provide Pfannenberg Sizing Software at no charge.

By simplifying the calculation of cooling requirements, we hope that the adoption of VFD technology will continue to grow rapidly, and that users will benefit from maximum

The Future of 3D Printing –Six Factors to Consider

Max Siebert, CEO & Co-Founder of Replique

Recent times have shown those in manufacturing and the supply chain that 3D printing – or additive manufacturing (aM) – is becoming a serious and mature manufacturing technology, not only for prototypes but also for small and medium sized series. Here are six key trends which are having a major impact on the 3D printing industry and those using the technology.

1. The New Era: Bigger, Faster and Cheaper

3D printing/aM technologies are developing quickly, and they are getting bigger, faster, and cheaper. rising demand for specialized materials to fulfil the required properties of end-parts will continue to drive forward developments in the range and types of options available. The key for the new generation of printers, especially industrial-grade solutions, is their ability to handle a greater range of advanced materials, as this opens the door for businesses to benefit from aM where they previously could not.

although machine costs remain high, increased print speed is pushing the price of parts down. a s more and more businesses switch to 3D printing, these advancements will accelerate. With processes such as dual extrusion, the versatility of 3D printing is growing, and we see uptake of 3D printing in a wider range of industries. another trend likely to significantly drive development is printing without the use of support structures, which again broadens the range of applications aM can offer. In our eyes the potential for cost and time savings is high.

2. AM as an Integrated Supply Chain Approach

To maximise benefit, manufacturers not only need a large range of printers, but also materials, and importantly, connections with other industry professionals. Furthermore, interoperability between different systems is becoming important to maximise the potential of 3D printing. automation in production and post-processing as well as an integrated usability will continue to be an important trend in the coming years.

aM can provide a whole new supply chain approach, as part of a holistic and secure platform where the individual steps are combined into one process, from concept to materials, digital inventory, production, and delivery. a s manufacturers strive towards Industry 4.0, services offering a fully automated, yet secure, platform will drive this change forward.

that lead to a greater product for the end-customers. In 3D printing this has proven to be a main enabler to scale industrial production. However, we now see the need for a more holistic collaboration. Standards have to be developed together, printer and post-processing systems should be able to work together; and collected production data could lead to improved printers and materials.

From our own perspective, close collaborations are essential to achieving the best solution. an ecosystem where service providers, material producers and print farms worldwide are connected is the next step to building a better service. Only with close collaborations and permanent exchange can we offer customers the best solutions.

4. Security and Quality Assurance as Part of AM Industrialization

3D printing continues to transform todays industries, with companies adopting the technology for more and more of their needs, thereby giving rise to a more integrated production environment. However, for industrial production, companies have to be assured that their 3D printed parts will meet necessary quality requirements. Moreover, data ownership will play a crucial role. Intellectual property needs to stay in the right hands. We believe that data management will be a huge topic moving forward.

3. From Individual Partnerships to an Ecosystem Partnerships

can create mutual benefits and synergies

From our own perspective, in terms of quality assurance, we carefully select production partners, check their capability and ensure repeatable fit-for-purpose parts. Further steps are required to ensure design data is kept in the right hands. In addition, we enforce manufacturing parameters by encrypting the data, so the parts can only be produced in the requested amount and material. By

5. Creating a Resilient Supply Chain

yes, we know, this issue has been discussed several times and it was one of the main issues in 2020 and 2021, yet we feel that supply chain disruptions will continue to rock the boat. COVID-19, geopolitical issues like cross border trade disputes, or even something as unforeseen as a ship getting stuck in the Suez Canal have shown the vulnerability of supply chains.

3D printing has already been used in the past as a solution to those problems and we predict use of it will increase. With the decentralization of supply chains and the on-demand production close to the consumer location, the technology enables shorter, stronger and more resilient supply chains.

Physical inventory is the weak point in any supply chain and the fact that parts can be housed digitally rather than in a physical warehouse, eliminates both storage and transportation costs. With a digital warehouse, once a part is ordered, it can be automatically sent to the best fitting, most appropriate production partner based on location, capabilities and capacity. Parts can be produced anywhere. at any time – reducing CO₂ in logistics and improving supply chain resiliency.

6. Driving Sustainability Forward

Demands of end-customers, official regulations and even moral duty, are making sustainable production and supply chains increasingly necessary. This trend is also present in 3D printing, which can – in the right use case – reduce waste during production. By specifically designing a part for 3D printing, it can drastically decrease the weight of the end part, therefore reducing the material needed for production. Moreover, as mentioned above, when using 3D printing as part of an on-demand and decentralised digital warehouse, it could reduce the number of parts in inventory and associated waste, as well as CO₂ emissions during transport. Looking ahead, we envisage a growing usage of 3D printing as part of companies’ sustainability strategy. To further improve sustainability of the technology, the energy consumption during production has to be reduced, and we are already seeing huge improvements in this area. Moreover, we see a growth of sustainable 3D printing materials such as recycled, reusable, and biodegradable plastics.

ABOUT THE AUTHOR

Max Siebert is CEO & Co-Founder of Ba SF-owned, replique, which offers an industrial 3D printing platform that enables OEMs to provide parts on-demand anytime and anywhere to their customers through a global, decentralized and secured 3D printing network.

PRODUCT SHOWCASE

ANCACrete polymer concrete base: a proven ANCA strength

CnC grinders, reducing vibration and increasing the overall rigidity of the machine.

Since 1991 we have been using the polymer base technology which forms the stable foundation base of all anC a machines. Customers often ask us to explain the benefits of polymer concrete and we explain that polymer concrete by its very nature has a high thermal mass, so our bases are good at absorbing a lot of heat.

It all begins with a solid base... and a secret recipe. What do tool and cutter grinders and buildings have in common? The importance of having a solid foundation.

a n essential component of achieving good accuracy and repeatability when grinding a cutting tool is the base. Having a stable foundation for a machine is paramount to achieving stable production. a s part of anC a’s commitment to vertical integration, in the late 1980s Pat McCluskey decided to replace the bases that were then outsourced with an anC a designed and manufactured base.

McCluskey’s research was conducted primarily in Europe in conjunction with a achen university who had carried out some research in polymer concrete in machine tool applications. He worked with German and local consultants to develop anC a’s recipe for concrete base manufacture. The base molding technology they developed has since been an important part of the rigid anC a bases.

The first base was poured in late 1989. Further pouring and testing followed until everyone was fully satisfied. now called anC acrete, this technology would provide the best possible foundation for precision

That means that throughout the production processes, their growth and contraction are very controlled and it takes a long time which means that the process is very, very stable. The second main part of polymer concrete is that when we designed the mix over 20 years ago, it was made to mimic the expansion thermal coefficients of cast iron very closely. This means that as our machines heat up and cool down, we can control the expansion and contraction of the machine – which in turn, gives us control over the production processes to make sure that the machine aligns to how we want it to react.

Between the large thermal mass, the very closely linked thermal expansion coefficient to cast iron and also the vibration absorbing characteristics, anC acrete significantly contributes to the overall rigidity of the machine. For our customers this translates into highly accurate tools with a superior surface finish.

This is the first in a series looking at the range of anC a technology that we have developed and refined over

Industrial Machinery Digest's Monthly Product Showcase features the latest from some of the manufacturing industry's top suppliers.

the years so that we can offer the best in class to the market. at anC a we have fully embraced the benefits of vertical integration and are the only tool and cutter grinding machine company in the world that designs and manufactures the complete machine, including building the CnC, precision motors and spindles, and of course our anC acrete polymer concrete bases, in-house.

This means customers enjoy the benefits of a manufacturer that understands their product completely, stands behind the quality of every element, and is uniquely positioned to custom design both hardware and software to suit individual needs.

Optimising installation space and performance with thread-tapping screws

When it comes to fastening lightweight metals, the focus is on optimising installation space and on performance and cost optimisation.

When it comes to fastening lightweight metals, as well as a fastening needing to be reliable, the focus is on optimising installation space and on performance and cost optimisation. against this background a crucial point is the load-bearing capacity of the fastening.

It is precisely for such applications that a rnold umformtechnik GmbH & Co. KG has developed Powertite. – a round thread-tapping screw with a trilobular tapping zone. This means that at the deformation point the screw has a slightly triangular cross-section (rounded edges) to reduce the tapping torque. The length of the tapping zone at 3 x p (p=thread pitch) is optimised for the installation space, allowing the forming energy created by the thread-tapping process to be distributed over several thread turns and giving optimal setting and centring of the screw. The round load-bearing cross-section has a defined overlap, the external diameter of the screw is always greater than the nominal diameter. This ensures a greater overlap of the screw’s thread edges and tapped nut thread. The

combination of the trilobular shape in the tapping zone and the round cross-section in the load-bearing section achieves a significant improvement in thread-tapping screw fastenings. This is because firstly, the tapping torques are low and secondly, because the load capacity of the tapped nut thread is considerably greater.

Major savings potential

There are many examples of applications for the thread-tapping Powertite screw. For example, applications in which maximum preload forces need to be achieved with plastically stressed assembly. a nd Powertite is also suitable for components into which only very short penetration depths can be made and high hole tolerances are necessary. Furthermore, in many cases it is possible to reduce weight by reducing the length of the screw and optimising the weight of the head.

Two specific examples illustrate how even a tiny screw can be a climate protector within a specific product. Since June 2022, a Powertite M7x40 has been implemented in a load transmission unit, currently still used in combination with combustion engines. With 13 screws in each transmission unit and a requirement

for some 6 million screws per annum, by using Powertite in this unit alone there is a saving of around 19,400 kg in weight and a reduction in CO2 by 33.1 tonnes each year.

The saving is even greater in an e-motor transmission unit where 33 screws are used for each unit. Of the 50,000 vehicles planned each year, it is forecast that 30,000 will each be fitted with two e-motor transmission units. Projected over all 50,000 vehicles and the 80,000 transmissions needed the total number of screws required is around 2.64 million a year. Simply by using Powertite it is possible to achieve a weight-saving of some 8,519 kg and a carbon reduction of 33.1 tonnes each year in the manufacture of these vehicles.

Enhanced threadtapping technology according to a rnold umformtechnik, Powertite, with its perfect geometric fit, increases load-bearing capacity in the tapped nut thread by over 20 percent compared to screws with trilobular load-bearing cross-section. That creates a series of technical and commercial benefits: standardscompliant tapping torques, plastically stressed assembly even into conical cast core holes in al-Gd, a preload force similar to metric fastenings, and the possibility of larger core

hole tolerances to optimise lightweight metals casting. a s well, assembly reliability is very good, and it can also be used in steel, aluminium and other lightweight metals. Furthermore, it is possible to make the screw fastening repeatedly and they can be replaced by metric screws if needed for servicing.

The main focus of Powertite applications lies on electromobility. This is especially true for lightweight metals, but it also applies when combined with cast components.

The product, which has already been patented, was launched on the market in October.

a s always, potential customers can access the complex product knowledge held by the Forchtenbergbased (south-west Germany) fastener manufacturer, as well as a full understanding of the product’s performance in the various applications and sectors. This is supplemented by the relevant calculation tools and wide-ranging manufacturing expertise. Together with its development partners in the vehicle manufacturing sector a rnold umformtechnik has developed a completely new manufacturing process especially for Powertite.

“We have long sought to use our experience in the additive sector to fuel digital manufacturing as a whole,” says a ndre Wegner, CEO of authentise. “additive has key advantages that make it a fertile sandbox, such as more data, less legacy, and focus on lot size 1. That ability to manage agile operations is increasingly in demand as the world moves to address recent supply chain failures. That is why we’ve chosen this point to release Flows and Flows a M.”

Keith Perrin, VP of agile Manufacturing at authentise and formerly an executive managing Hexagon nexus, autodesk Fusion360, and Siemens Teamcenter added: “Since I joined the team 8 months ago it’s become increasingly clear that authentise has a ‘special sauce’ when it comes to handling production operations that require a high degree of flexibility. I know from experience that this is a big gap in the market, now more than ever. authentise’s ability to integrate machine data, 3rd party software tools, and human operations, into a contextual process is critical to meeting that need. The success we’ve seen with some of the world's most advanced agile engineering operations speak for themselves. I’m excited to bring this capability to other enterprises looking to deliver more flexible engineering, production and supply chains.”

authentise Flows a M (https://www.authentise.com/ flows-am) is available today. authentise Flows (www. authentise.com/flows) will be generally available in 2023. a n early adopter programme is now open for customers with a particular interest in driving agile operations into their engineering and manufacturing operations and realising near triple digit productivity improvements.

Authentise announces Flows & FlowsAM rebranded data-driven workflow management suite now available for additive and agile production environments. authentise (www.authentise.com), the leader in data-driven engineering & manufacturing workflow tools, today released its rebranded workflow management suite for both additive and non-additive applications.

Flows is the product of a decade of experience building data-driven solutions for the world’s most agile operations at Boeing, Danfoss, and ricoh, among others. Boeing’s time studies claimed that the system delivers up to 94% time savings and a 3x rOI within 8 months. Formerly known as the advanced Manufacturing Execution System (“aMES”), Flows incorporates many tools that stretch beyond the capabilities of a traditional Manufacturing Execution System, including real-time quoting, machine-data driven status updates, material genealogy, supplier management and more. These features are already used to manage post processing such as heat treatment, machining and more. With this release, authentise is announcing general availability of Flows a M for operations primarily centred around additive manufacturing, and Flows for those that are not.

Beckhoff Elevates XPlanar Functionality with Bumper ID and New Mover Variants

The adaptive automation system’s expanded features and mover variety further boost traceability and flexibility for wide-ranging applications

Beckhoff has once again created new possibilities in adaptive automation by expanding the functionality of the XPlanar “flying motion” system. now, on top of XPlanar’s impressive, field-proven capabilities, the solution can handle more products with even more flexibility through new mover identification, movers for two lanes of traffic on one tile, rectangular movers and mover coupling for higher payloads.

XPlanar now provides greater traceability through ID technology integrated into the mover bumper. The ID functionality enables unique identification of XPlanar movers by reading the mover’s individual serial number. The ID bumper is easy to mount or retrofit on movers already in the field, and it requires no additional hardware. This solution makes it possible to seamlessly track movers and the products they carry – even after system shutdown and restart. The bumper ID also eliminates the need for homing at system startup with appropriate programming. among the new XPlanar mover variants, the aPM4221 is now the second smallest model in the aPM4xxx family.

It supports payloads up to 1 kg and is ideal for handling small and medium-sized products with 140 mm center-to-center spacing. With dimensions of 127 x 127 mm, the aPM4221 allows two lanes of traffic to flow simultaneously across one row of XPlanar tiles. This enables a complete production cycle, including recirculation, with minimal footprint. The same applies to the aPM4230 rectangular mover, which measures 115 x 155 mm, for payloads of up to 0.8 kg.

a third new variant is the a MP4350 rectangular mover, which measures 155 x 235 mm and supports payloads of up to 3 kg. By adding a second row of tiles to the XPlanar base, the aPM4350 rectangular mover enables up to three lanes of transport for longer products, further increasing adaptive automation capabilities.

The aPM4550 XPlanar mover is the largest version (235 x 235 mm) and can transport payloads up to 4.2 kg, making it the

perfect device for handling larger, heavier products. More elaborate workpiece carriers and attached tooling can also help meet specific application requirements.

However, XPlanar can transport and position payloads weighing far

more than 4.2 kg. using a simple adapter, several movers can be mechanically fixed together and the payload increases linearly. Coupling four aPM4550 movers would result in a new maximum payload of approximately 14.8 kg.

Electro Magnetic Filter for Ceramics Producer

Model HIF225-50 Electro Magnetic Filter

a leading German ceramic manufacturer is cleaning ceramic glaze with a high-intensity Electro Magnetic Filter designed and manufactured by Bunting. The successful removal of fine magnetics reduces finished product rejects and increases surface brightness.

The Electro Magnetic Filter provides one of the most effective methods of removing problematic fine iron and paramagnetic minerals from ceramic slips and glazes. The separation efficiency of the technology is significantly better than permanent magnetic separators such as Liquid Pipeline Separators and Tube Magnet configurations. Electro Magnetic Filters consist of an electromagnetic coil positioned around a central hollow core containing a magnetic (400 series) stainless-steel matrix of various designs. The highly efficient computer designed coil generates a high intensity magnetic field that intensifies on the points of the matrix creating the magnetic force needed to separate paramagnetic particles from the slurry. The rectangular steel casing enclosing the magnetic coil intensifies the magnetic field into the hollow centre of the coil. Valves, mounted on the top and bottom

of the Electro Magnetic Filter, close and open in a controlled timed sequence for product feed and discharge, as well as matrix cleaning using water and air.

In operation, ceramic glaze or slip feeds up through central canister packed with magnetic stainless-steel matrix. The magnetic field of the Electro Magnetic Filter intensifies on the sharp points of the matrix, enabling the capture of fine magnetic particles such as free iron and magnetic minerals.

This ceramics project in Germany required a large model HIF225-50 Electro Magnetic Filter, which generates a background magnetic field of approximately 6,500 gauss inside the central canister. The points of the matrix enhance the background magnetic field by up to four-times, with the 6,500 gauss models generating peak fields above 2-Tesla.

The ceramic glaze feeds up through the Electro Magnetic Filter for a period of approximately 60 minutes. On an automatic operation cycle, managed by a separate control panel, the valves system then stops the feed, diverting the glaze back into the feed tank, whilst the system goes through a cleaning cycle. This involves discharging the captured magnetics from the canister and cleaning of the matrix, which lasts for approximately two-minutes. The control enables adjustment of the sequence times to suit the processing of a wide variety of ceramic glazes. In this project, the HIF225-50 handles between 3-5 tons per hour of glaze with 64% solids. “If fine iron and magnetic minerals are not removed from ceramic glaze, they cause surface defects and discoloration,” explained Phil Tree, Bunting’s European Sales Manager. “In this project, we are working with one of the world’s leading ceramics manufacturers. They understand the necessity and benefits of automatically removing all magnetics, which is only possible with an Electro Magnetic Filter.”

For further information, visit our website: www.bunting-redditch.com.

CERATIZIT MaxiMill 491

Features New Insert Size for Added Flexibility

For maximum productivity and machining application versatility, CEraTIZIT offers a wide range of tooling systems within its expansive Indexable Milling line of products that includes the company’s new MaxiMill 491. With eight usable cutting edges per newly expanded 9-mm insert size, a precise 90°profile and a durable nickel-coated tool body, the MaxiMill 491 system is extremely well suited for all shoulder and full-slot milling applications.

The MaxiMill 491 system provides exceptional ease of use, allowing users to quickly exchange inserts while the tool remains in the machine. This capability significantly reduces machine downtime while the precision-ground inserts deliver stable and smooth cutting thanks to CEraTIZIT’s state-of-the-art Dragonskin coating technology. Plus, the Dragonskin coating gives the inserts added strength for even the most demanding of machining conditions.

Configured with a positive insert geometry, the MaxiMill 491 ensures excellent surface quality and dramatically increases tool life. The tool’s eight usable insert cutting edges also provide a low price per edge for cost effectiveness.

CEraTIZIT initially launched the MaxiMill 491 in a 12-mm size with a nominal diameter range from 32 to 160 mm and a corner radius of 0.8 mm. The company extended the range with the addition of 1.2-mm, 1.6-mm and 2.0-mm corner radii. The new 9-mm insert size now brings even greater flexibility for all applications.

With this smaller size, more inserts can be mounted in the tools for even longer tool life and higher chip removal rates. The new size also reduces power consumption, making the MaxiMill 491 effective for use with lower power machine tools.

For more information visit www. CuttingTools.CEraTIZIT.com

AM Coating: Innovative coatings for brake disks

A high-speed process to protect against corrosion

and wear

How can the protective layer be applied to the brake disk more quickly and more effectively? a nd how can it be made to stay on for longer? “The solution is intelligent coatings, as can be applied to brake disks using our a M coating system” says Dr. Géza Koscsák - the Head of additive Manufacturing at the CHIrOn Group. He has played a prominent role in developing the new system and reaching the decision to opt for the high-speed deposition welding process in his previous job as Head of advanced Development.

Innovative and productive process

Compared with the conventional LMD process, powder particles travel a longer distance before they are applied during high-speed laser material deposition. This means that they absorb more energy and melt in the laser beam, which enables a significantly faster coating speed. This process also has a clear advantage in comparison to thermal coating using high-velocity oxygen fuel spraying.

a M coating's quicker speed and shorter process are two advantages with respect to the future Euro 7 standard, believes Dr. Koscsák. “When the standard comes – and it certainly will come – a production volume of 10 million brake disks annually will need to be managed, for the European vehicle brands alone. With a cycle time for conventional brake disks of around 30 seconds per disk, it's clear that the coating process needs to keep up” he adds.

In line with market requirements: a M Coating available in two versions

» a M Coating TWIn is specifically designed for series production. The system works with two lasers for front and rear coating and the brake disks are transferred automatically.

» a M Coating SInGLE is the ideal choice if you would like to test materials and material combinations in parallel with or before series production, to develop the application process or to manufacture small series. upon request, the team of experts at the CHIrOn Group can provide support during process development, either at the customer premises or in Tuttlingen. “We could install a base machine here,” says Dr. Koscsák, outlining a potential scenario, "where the customer's specialists can learn the process, run tests and set up the parameters with us ready for series production. Or, for a continuous and even more productive process, we can integrate a grinding machine and perfectly coordinate both systems."

Top-quality, firmly bonded application

Of course, productivity is not enough on its own – the quality of the coatings needs to be right too. What

about crack formation and durability? Project Manager

Ernest Frombach says “We use high-speed laser material deposition to achieve improved adhesion through the firmly bonded connection. The layers are also thinner, down to tenths of a millimeter. This uses less material, and our powder management enables us to achieve a high degree of powder utilization. The powder and hard material layers are applied directly one after the other. By applying the first layer, the brake disk is tempered as it were, and we consistently achieve the best application quality for every brake disk without pores or cracks forming.”

More about the Chiron process at: www.chiron-group.com/ expertises/additive-manufacturing

AI-Powered, HD Mode for 3D Scanners

Exact Metrology: a Division of In-Place Machining Company and a comprehensive 3D metrology service provider and hardware sales company, has increased the capability of their a rtec 3D handheld scanners with the new HD mode. This a rtificial Intelligence-powered scanning technology provides ultra-sharp, clean and detail-rich scans for a rtec Leo and a rtec Eva.

Powered by a rtec 3D‘s aI neural engine, users can obtain sharp 3D scans with a resolution of up to 0.2 mm. Trained on hundreds of thousands of carefully selected samples, the engine’s neural network detects familiar patterns, surface details and shapes. This allows the 3D scanner to reconstruct a higher number of polygons per frame, resulting in 3D data that’s both denser and higher quality. now, the desired HD density can be selected from a standard 1X density up to 36X for Eva (~3 mln polygons per frame) and 64X for Leo (~5 mln polygons per frame). HD mode makes it possible to capture smaller, thinner elements with the 3D scanner while also considerably reducing noise. With these a rtec scanners, fine edges can be captured in high definition, faithful to their original shape. It’s easy to capture hard-to-reach areas

as the scans are reconstructed with every detail, giving users complete surface geometry.

Handheld Eva and Leo scanners can easily scan dark or shiny surfaces in high resolution and capture the full range of their geometries, without additional steps. using the artec aI engine, little to no noise in the raw scan data results in cleaner processed data and also saves time when producing the final 3D model. Once difficult to capture, now short hair, even separate strands, are fully within reach when scanning with HD mode. Furthermore, these scanners can capture a broad range of objects flawlessly and in high detail: from smaller, intricate parts such as thin pipes or valve handles, to larger objects with multiple high-detail sections, including car engines and skeletons. a perfect fit for reverse engineering and quality control due to clean, comprehensive data, scans can be easily fitted with primitive shapes and exported to the most popular CaD solutions for development.

full finger, variable flow trigger able to produce varying force upon a target simply by pulling the trigger. The VariBlast is available with a standard, 12" or 20" extension which can also be outfitted with type 316 stainless steel or PEEK thermoplastic air nozzles for non-marring applications.

The 1/4 nPT VariBlast Precision Safety air Gun has a convenient hanger loop built into it. The air gun body is made of high impact acetal thermoplastic. The airflow that exits the nozzle can’t be blocked, assuring safe operation and meeting required OSHa standards 1910.242(b). a quiet 75 dBa noise level is well below the limits of the OSHa noise exposure standard 29 CFr 1910.95(a).

a variety of other Super air nozzles with different force and flow values are available. all of EX aIr’s Safety air Gun product lines are CE compliant and use engineered air nozzles for high performance and safety. all are available with extension pipes and Chip Shields. Price starts at $88.00.

For more information, visit: www.exair.co/153-pten

Graco Launches QUANTM Pump

processing, water treatment, paint manufacturing, food and beverage, pharmaceutical and more.

“The QuanTM pump isn’t a new twist on old technology. It’s an entirely innovative design that changes how pumps perform in factories and other installations around the world,” said Dan Purkat, Senior Product Marketing Manager. “We’re excited to have created an advanced, extremely efficient design that is lightweight and provides significantly lower lifetime costs than other pump technologies. The pump modernizes operations by greatly reducing energy cost. This empowers industrial manufacturers to protect and grow margins and measurably contribute to energy savings, compliance and environmental stewardship efforts.”

VariBlast Precision Safety Air Gun is the People’s Choice

EX aIr’s VariBlast® Precision Safety air Gun has won the 2022 People’s Choice award from Professional Tool and Equipment news (PTEn). These safety air guns provide a focused blast of air capable of handling tough jobs with remarkable strength while minimizing air consumption and noise. This OSHa safe air gun employs an engineered,

The new electricoperated double diaphragm pump for industrial and hygienic applications is a big leap forward in pump innovation Graco Inc. (nySE: GGG), a leading manufacturer of fluid handling equipment, announces the release of the Company’s next generation electric-operated double diaphragm pump, QuanTM™. The QuanTM pump features a revolutionary new electric motor design that is up to 8X more efficient than a standard pneumatic pump.

The innovative QuanTM pump is suitable for nearly any fluid transfer application and offers a wide range of materials of construction to support multiple industrial and hygienic applications, including chemical

The breakthrough electric QuanTM pump is designed to be a highly reliable drop-in replacement for current pneumatic pumps or greenfield construction. This pump is built for harsh industrial or hygienic environments, yet its innovative and efficient design is lightweight and easy to maintain. With built-in controls and no gearbox, the pump also fits seamlessly into most fluid transfer applications.

“Our new QuanTM pump is the perfect solution for upgrading your less-efficient air operated pumps,” said Jeffrey Shaffer, Senior Product Marketing Manager. “The same great self-priming, stalling, seal-less design with smooth, steady flow is a must-have for in-process applications, filling systems and hygienic applications. The powerful new FluxCoreTM motors and drives deliver up to eight times more continuous torque at low speeds than conventional motors, and the plug-and-play installation allows you to easily replace existing pumps without additional investment or infrastructure rework.”

For more information, visit: www.graco.com.

actek Manufacturing and Engineering Inc. — www.actekmfg.com 35

aTTCO, Inc. DBa Syclone aTTCO Service — www.skyhookmfr.com 5

attica Hydraulic Exchange — www.hydraulex.com 19

Betenbender Manufacturing, Inc — www.betenbender.com 3

Carell Corporation — www.carellcorp.com 17

Clamprite — www.clamprite.com 37

COLE TuVE— www.coletuve.com 49

Denver Breaker & Supply — www.denverbreaker.com 47

Dynabrade, Inc. — www.dynabrade.com BC

Eagle Bending Machines — www.eaglebendingmachines.com 17

EnM Co — www.enmco.com 49

Essex Structural Steel Co. — www.essexstructuralsteel.com 48

Formdrill uSa Inc. — www.formdrill-usa.com 25

H&K Equipment, Inc. — www.hkequipment.com 48

HMI div of Betenbender Manufacturing — www.betenbender.com 31

HyPnEuMaT, Inc. — www.hypneumat.com 29

IMDauctions.com — www.imdauctions.com 48, 49

Industrial Magnetics — www.magnetics.com 43

Kanetec uSa Corp — www.kanetec.com 47

KHK Gears — www.khkgears.us IBC

Lenzkes Clamping Tools, Inc. — www.lenzkesusa.com IFC

L&L Special Furnace Co., Inc. — www.llfurnace.com 49

MacMillin Hydraulic Engineering Corporation — www.macmhydraulic.com 33

northwest Machine Tool Expo — www.machinetoolexpos.com 11

Pro-Line — www.1proline.com 49

radwell International, Inc. — www.radwell.com FC, 7

royal Products — www.mistcollectors.com 49

Schweiss Doors — www.schweissdoors.com 49

Standard Direct — www.Standard-Direct.com 47

Stor-Loc — www.storloc.com 21, 23

Tormach — www.tormach.com 13

Trim-Lok — www.trimlok.com 39

watco — www.watcofloors.com 36

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