Industrial Machinery Digest - April 2020

» Technical Skill Assessments: A Tool for Managers, Machinists, and More » Why Use a CT Scanner for an Industrial Job? » Demand Outpacing Production » The New EMAG Systems

Manufacturing Showcase: IndustrialMachineryDigest.com

April 2020

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Table of Contents

COLUMNS

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By: Nick Boliek

18

14

FEATURES

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WORKFORCE DEVELOPMENT

Technical Skill Assessments: A Tool for Managers, Machinists, and More

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By: Tony Glockler, CEO and Cofounder of SolidProfessor

24

NEW TECH Why Use a CT Scanner for an Industrial Job? By: Dean Solberg, Co-Founder, Exact Metrology

32

SAFETY & MAINTENANCE Protective Systems for Press Brake Applications Fiessler AKAS 3-P Safety System from Press Brake Safety Has New Features to Ensure Employee Safety and Maintain Production

DEPARTMENTS

28 PROCESS

Demand Outpacing Production True Precision Machining implements OB7 on wire EDM machine, doubling machine output and meeting deadlines early for their high-technology customers in the medical, aerospace and communications industries.

TALKING SHOP Lisa Donnelly Vice President of Marketing Soft Robotics

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MANUFACTURING SHOWCASE Suhner

By Russ Willcutt

BUSINESS 4.0 Responding to the Pandemic The National Association of Manufacturers Provides Policy Actions in Response to COVID-19

6 8 36

EDITORIAL DIRECTIONS INDUSTRY NEWS

ADVANCED MANUFACTURING

SOLUTIONS

INDUSTRY INSIGHTS The New EMAG Systems: EMAG provides complete turnkey solutions from a single source

40 PRODUCT SHOWCASE 46 SURPLUS BUYING AND SELLING 49 CLASSIFIEDS 50 ADVERTISER INDEX

ON THE COVER

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Editorial Directions SERVING AMERICAN MANUFACTURERS FOR OVER

It’s hard to concentrate on anything these days with the coronavirus as a constant backdrop. Every industry faces specific challenges in facing down this global pandemic, and we have no way of predicting what news each new day will bring. Travel has been disrupted, employees are being encouraged to work from home – not possible for everyone in manufacturing – schools are being shut down, hospitals are being overrun, restaurants are hurting, and entire states are being told to go into lockdown. This may be with us for quite a while, and many believe the post-virus world will be fundamentally and significantly changed from what we’ve known in the past.

That’s why it’s time for industry professionals to take a very close look at the technologies that are now available that can mitigate physical exposure and help you continue cutting chips. And here I’m talking about everything from conference calls, bringing people together while avoiding unnecessary contact, to the Internet of Things (IoT), linking machine tools within a facility and beyond to ensure accurate, streamlined production and the gathering of system data that can be harnessed in myriad ways to help maintain and optimize efficient process flow. Robots, cobots, AI, and automation (see FANUC “Talking Shop” interview in the March issue) are enhancing worker safety, further bridging the gap between man and machine and resulting in new definitions of that partnership in the manufacturing environment. In the most recent issue of IMD we produced a feature for our “Manufacturing Showcase” department describing a new technology developed by Help Lightning that provides “Remote Expertise” to machine tool operators who connect with OEM engineers and technicians via smart devices – your phone, or a tablet, for instance – so they can discuss challenges without the need for a site visit. As an example, when machine repairs or maintenance procedures are necessary, the machine operator can connect directly with the OEM expert using their smart devices, aiming the camera at the target area and allowing interaction, complete with hands superimposed over the problem part or area and the ability to sketch diagrams and exchange graphics for a quick and satisfying solution. Cincinnati, Inc., contributed to this article by describing their experience as an early adopter. Again, this provides yet another means of avoiding physical exposure while getting the production line back up and running.

These are just a few examples of the technologies increasingly available to manufacturers that make more sense now than ever before. Learning how to use them could help maintain smooth production even while facing unexpected crises, such as the coronavirus pandemic. So stay safe, work smart, and take advantage of our commitment to bringing you information about leading-edge technologies that will enhance your operations.

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Industry News Epson Robots Names Automation Engineering an Authorized Service Center

WD-40® Brand Partners with Habitat for Humanity to Give Back to Communities

As part of an initiative to increase technical support in the Midwest US, Epson Robots, the #1 SCARA robot manufacturer in the world, today announced it is expanding its relationship with Air Automation Engineering ( AAE), a leading automation solutions provider. The partnership establishes AAE as an official Authorized Epson Service Center and will expand beyond selling Epson Robots, automation products and integrated solutions to include maintenance and repair of the broad installed base of Epson robots, helping to ensure fast repair turnaround times throughout the Upper Midwest. The partnership with Air Automation Engineering involves all Epson Robots automation products, including the large lineup of SCARA and 6-Axis robots and the lineup of integrated solutions. The company has helped Epson Robots introduce award-winning robot-based automation solutions throughout the Upper Midwest, including Iowa, North Dakota, South Dakota, Minnesota, Nebraska, and Wisconsin.

“We’re pleased to expand our relationship with Epson Robots and help our joint customers in the Upper Midwest,” said Paul Wood, general manager, Air Automation Engineering. “Our team of long-term professionals focus on providing the best repair and support services so our customers benefit from a high return on investment.”

As part of WD-40 Company’s ongoing effort to make things better than they are today, WD-40® Brand will donate 50 cents to Habitat for Humanity® for every 12 oz. can of WD-40® Smart Straw® sold at participating Lowe’s Home Improvement stores between now and April 30, 2020. WD-40 Brand will donate up to $50,000 to Habitat for Humanity International to assist the organization in its mission to bring people together to build homes, communities and hope.

“Our company values doing the right thing and creating positive lasting memories by developing products that help people get their jobs done right,” said Erin Bala, director of brand management and innovation at WD-40 Company. “Supporting Habitat for Humanity’s vision of ‘a world where everyone has a decent place to live’ allows us to live our values and give back in a meaningful way.”

"We are excited to partner with WD-40 Brand on a national scale. Their support of San Diego Habitat has enabled critical work to address the affordable housing crisis locally, and now with their national partnership, the impact of their support will be even fartherreaching.” said Colleen Finn Ridenhour, chief development officer of Habitat for Humanity International. “We are incredibly grateful for their commitment to Habitat and to the families in need of a decent place to call home.”

In addition to its partnership with Habitat for Humanity International, WD-40 Company has provided local support to San Diego Habitat for Humanity by volunteering for home builds. Last year, WD-40 Company associates laced up their work boots and spent a day in the Logan Heights neighborhood of San Diego, building a Habitat home alongside its future homeowner.

KISSsoft Launches New Website With the launch of its new website, KISSsoft focuses its strategy on digitizing the customer section and presenting a clearly structured and easy-to-use information and download platform.

KISSsoft.com offers revised content, additional services and functions, a clear structure as well as a slick new appearance.

With eight language versions, KISSsoft strengthens its global presence and makes it easier for customers to communicate in their own language. The “MyKISSsoft” customer portal integrated into the website lays the foundation for sustained use and puts the customer at the center of attention. Customers can now decide for themselves what kind of information they would like to receive and in which particular way. With the user-friendly and intuitive navigation, one can quickly achieve the desired aim in just a few clicks. KISSsoft presents the entire product and service portfolio in a clearly arranged form and reports on current topics such as engineering, software development, technical product descriptions, and much more.

CONNECT WITH US ONLINE Visit our website or connect with IMD on social media! www.IndustrialMachineryDigest.com

Wildeck Names Dan Lorenz President Dan Lorenz joined Wildeck in August, 2018 as the Vice President of Operations. Prior to joining Wildeck, he held senior leadership positions in Wisconsin manufacturing stalwarts such as Superior Die Set, Fisher Barton and Wacker Neuson.

“After an exhaustive search involving both internal and external candidates, it became apparent that Dan was the leader Wildeck needs to accelerate our growth journey,” commented Keith Pignolet, Executive Chairman of Wildeck, “his commitment to our customers and our mission to make their projects run smoothly is unwavering.”

A search for Lorenz’s successor as Vice President of Operations is underway. In the interim, Dan will continue to oversee all facets of operations.

UNITED GRINDING North America Partners with Dynamic Machine UNITED GRINDING North America Inc. announced it has entered into a partnership with Dynamic Machine of Detroit, a Troy,

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Michigan-based CNC equipment dealership. For those UNITED GRINDING North America customers in the Michigan territory, the partnership will further strengthen grinding machine sales, service and application support. With over 200 years of combined machine tool and manufacturing experience, Dynamic Machine will provide Michigan manufacturers with a local advanced technical center for UNITED GRINDING-brand machine demonstrations, test cuts, turnkey projects and training. The dealership also offers machine retrofits and upgrades as well as engineering services. According to Dynamic Machine co-owners Vince Meleto and Greg Sandler, the company’s reputation for excellence is one based on years of close customer relationships and thousands of machine tool installations. As such, they will offer UNITED GRINDING North America’s customers that same level of attention and expertise.

Fives Joins Woman in Manufacturing Association® (WiM) as a Corporate Member Fives, an industrial engineering group with nearly 8,700 employees across the world, has joined the Women in Manufacturing® Association (WiM) as a corporate member, signaling the company’s commitment to the success and growth of women in the manufacturing industry. WiM is the only national trade association dedicated to year-round support for women who have chosen a career in the manufacturing sector. It offers tools, training and thought leadership to help companies identify and advance women leaders in the industry. Fives highlighted its’ membership with WiM during the grand opening ceremony of its North American headquarters for Fives Intralogistics Corporation in Louisville, KY, February 12, 2020, aligning with its new brand signature statement “Industry can do it" and a workforce comprised of ~45 percent female engineers and management roles.

MC Machinery Announces New Regional S S Sales Representative

Machinery’s long-standing success by expanding our customer base in Northern Ohio,” Barbeck said.

Vecna Robotics Expands Partnership with UniCarriers Americas Vecna Robotics, a leading automation provider in the materials handling space, today announced an expansion of their partnership with UniCarriers® Americas, part of the Mitsubishi Logisnext family companies - the third largest forklift manufacturer in the world. Through this partnership, UniCarriers will manufacture and promote their best-in-class pallet jacks running Vecna Robotics’ Pivotal™ automation software. With UniCarriers’ manufacturing capabilities, this alliance enables Vecna Robotics to satisfy soaring demand for automation solutions amongst their customer base, including the largest retailers, 3PLs and manufacturers in North America. UniCarriers’ Marengo, IL operation employs sophisticated manufacturing equipment, a team of more than 350 highly skilled professionals, and a half a million square foot manufacturing facility. Vecna Robotics is also working with UCA to leverage UniCarriers’ Authorized Dealer network of 125 Dealers throughout the Americas. Through this support network, customers can expect rapid response times in the field, further improving the already best-in-class uptime offered by Vecna Robotics autonomous mobile robots (AMRs).

OVENS & FURNACES

MC Machinery Systems is excited to welcome Craig Barbeck to the MC Machinery team as a Regional Sales Representative for the Northern Ohio Territory. Barbeck will support the sales team with a focus on laser and press brake products. Barbeck’s strong technical and engineering background provides him with a unique insight into the needs of MC Machinery customers. With over 15-years of experience in the fabrication industry and machine tool sales, Barbeck will utilize his industry expertise to increase sales support and boost customer satisfaction. Barbeck previously served customers in Eastern Ohio, Pennsylvania, Upstate New York, Maryland, and Texas. He currently resides in the Greater Cleveland Area.

“I’m honored to accept a position alongside the well-respected 5 MC Machinery team,” Barbeck said. “I look forward to upholding MC

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Business 4.0

Responding to the Pandemic The National Association of Manufacturers Provides Policy Actions in Response to COVID-19 By: Nick Boliek

B

efore I began writing for Industrial Machinery Digest, I worked for a decade in the medical diagnostic industry. It was primarily second or third shift positions, allowing me to pursue aspirations of journalism during normal business hours.

I had worked my way up from a simple specimen preparation technician, who processes and handles specimens, to a lab assistant running the tests that impacted patients’ daily lives. During that time, there was never any outbreak as devastating as the novel coronavirus, COVID-19.

At the time of this writing, no guidelines have been officially put in place to assist manufacturing and fabricating businesses.

This crisis will be turning to the manufacturing sector for solutions.

Automakers are already evaluating efforts to produce ventilators, and other equipment in response to the pandemic. General Motors, for example, announced that it would be working with

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Seattle’s Ventec Life Systems to support the increased production of respiratory care products.

A recent National Association of Manufacturers survey indicated that 78.3 percent of manufacturers anticipate financial impact. Over half surveyed were anticipating an impact in operations, and more than 35 percent were already facing supply disruptions. NAM has laid out policy actions as a response to the COVID-19 pandemic. These guidelines have been presented to Congress and other federal agencies to protect, and further underline the importance manufacturers will be in the days ahead.

“Manufacturers have a greater purpose than profits,” says Mike Lamach, NAM Board Chair and Chairman and CEO of Trane Technologies plc. “We are also about protecting our people, and our communities.”

First and foremost, NAM’s COVID-19 Policy Action Plan Recommendations ask Congress to recognize manufacturers’ critical role in response to the pandemic with, at least, $1.4 trillion in interest-free loans for a federal Manufacturing Resiliency Fund.

To ensure the supply of products, manufacturers are to be deemed essential businesses and protected as such. NAM is also trying to protect manufacturing business owners from insolvency with efforts to have the IRS delay all scheduled tax payments for 90 days.

It should be noted that the U.S. Small Business Administration is currently working with state governments to provide low interest loans for businesses suffering from loss of revenue due to COVID-19. The Economic Injury Disaster Loan Program can provide working capital of up to $2 million to help maintain standard operations. The SBA has also provided guidance backed by the CDC on how to avoid stigma and workplace discrimination that may be associated with virus.

In terms of providing a safe workplace, NAM guidelines also call for clear CDC guidance for cleaning and disinfecting plant and production facilities. With clear rules in place, manufacturers can make more confident decisions, to ensure the safety of workers, even if that requires full plant shutdowns due to community quarantine.

“Already, manufacturers are grappling with disruptions to their businesses due to the COVID-19 outbreak, with many anticipating financial and operational consequences. The federal government can take steps to further equip manufacturers to deal with COVID-19 by implementing the NAM’s ‘COVID-19 Policy Action Plan Recommendations,’” said NAM President and CEO Jay Timmons.

“Across the country, manufacturers are stepping up to keep their employees and their communities safe and healthy, and working closely with elected officials, we can ensure the resilience not only of our companies but also our country.”

These measures and others included in NAM’s Policy Action Plan could even be used to allow for further investment in upgrading and improving our nation’s transportation, water, energy, and digital infrastructure systems by supporting NAM’s “Building to Win” strategy.

now mid-May. This is the time for businesses to work smarter not harder. The manufacturing sector has been facing a labor shortage and has already made efforts in closing the ever-growing skills gap. Automation solutions, such as collaborative robots, could become even more important to meet production demands.

Other technologies including artificial intelligence and remote assistance applications with Artificial Reality (AR) support could allow businesses to connect more easily for training and service of key production machinery.

None of that will matter, however, if we do not all do our part in eliminating the spread of this pandemic. How we respond to this crisis determines how fast we can truly recover. It is imperative that we all take measures to ensure the health and safety of our coworkers, friends, family, and ourselves.

ABOUT NATIONAL ASSOCIATION OF MANUFACTURERS The National Association of Manufacturers (NAM) works for the success of the more than 12.8 million men and women who make things in America. Representing 14,000 member companies—from small businesses to global leaders—in every industrial sector, the National Association of Manufacturers (NAM) is the nation’s most effective resource and most influential advocate for the values for manufacturers

The Manufacturing Landscape Going Forward

across the country.

It is far too early to act like we are on the road to recovery. Currently, there more than 33,000 confirmed cases in the United States, with many sources saying the peak for this viral epidemic being

For more information and to view the full COVID-19 Policy Action Plan Recommendations, visit www.nam.org

Limit the Spread of Germs and Prevent Infection » Avoid close contact with people who are sick. » When you are sick, keep your distance from others to protect them from getting sick too. » Cover your mouth and nose with a tissue when coughing or sneezing. It may prevent those around you from getting sick. » Washing your hands often will help protect you from germs. » Avoid touching your eyes, nose or mouth. » Practice other good health habits. Get plenty of sleep, be physically active, manage your stress, drink plenty of fluids, and eat nutritious food.

Guidelines are from Department of Homeland Security

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Talking Shop Our soft fingers eliminate pinch points, providing what we feel is the safest gripper available for collaborative robots, where safety is of paramount importance.

FEATURING:

TALKING SHOP WITH: Lisa Donnelly — Vice President of Marketing, Soft Robotics So how did this gripping technology come into being?

A chemist at Harvard University, Dr. George Whitesides, was intrigued by the skill and agility with which octopi used their tentacles to manipulate a wide variety of objects of different sizes and material consistencies, automatically adjusting its grip pressure and tentacle configuration. He was able to partner with the Department of Defense to develop the technology. Our CEO, Carl Vause, learned of this work and immediately saw how valuable it would be for manufacturing and packaging applications. So it was agreed that Soft Robotics would be formed and stand as the go-tomarket representative for this gripper technology.

What were the first markets to understand this product’s potential?

Automotive was the first industry to realize the potential of traditional automation since they have so many consistent processes and products that are readily automated. Traditional gripper design works well with consistent part geometries, but it didn’t translate to industries where there is natural variation in products or a very high mix of low-volume SKUs. Having to change a gripper each time the SKU changes is time-consuming and costly. The Soft Robotics gripper enables the automation of industries that have products with variation, that are delicate in nature, or have stringent surface finish requirements. Developing relationships with companies such as FANUC and ABB, who also became investors, has been valuable, and that list has grown much longer over time. This allowed us access to their global trade channels in a wide variety of markets.

Are your grippers compatible with different types and makes of robots and cobots?

We describe ourselves as being “robot agnostic” so that the grippers can be paired with virtually any type or brand of robot. Because of our relationship with companies like FANUC and Universal Robots, we’ve developed specific control systems that integrate with their platforms to allow gripper manipulation directly from the teach pendant. Plus,

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our grippers can be configured to match just about any OEM’s robotic arm. Our mGrip adaptable system includes both the gripper and a controller. In fact, our controller system is central to the gripper’s ability to automatically adjust to different types of parts without halting production, and with no additional reprogramming required. This

is also ideal for operations that produce small lots since the gripper automatically adjusts to part changes without the need for sensors or an expensive vision system. This allows our grippers to reconfigure to pick up anything from a loaf of bread to large, heavy parts and materials. We even have a demonstration for our cobot controllers, where someone puts their hand in the gripper and actually feels how it regulates its grip pressure according to what it’s holding, providing a delicate but secure grip.

This technology seems ideal for cobots working in proximity to human operators.

Absolutely, which is completely intentional. As cobot technology evolves, our grippers enable adoption throughout any manufacturing or packaging process. There are the ergonomic benefits I’ve mentioned, along with meeting safety concerns involving human/cobot interaction. Our soft fingers eliminate pinch points, providing what we feel is the safest gripper available for collaborative robots, where safety is of paramount importance.

Tell us about the services you offer to your customers.

We have a dedicated sales team, knowledgeable application engineers, and every type of engineer you can imagine, We’re prepared for whatever challenge an end-user might encounter.

Besides service and maintenance assistance, these professionals also provide consultation to customers as they choose the ideal type of gripper system for their particular application. So our

relationship with our customers is in-depth and ongoing. And we’re really proud of the fact that our technology helps keep the supply chain functioning smoothly, especially during times such as these when we’re dealing with issues like coronavirus exposure in the workplace. We are constantly adapting to the evolving nature of robot/cobot developments.

For more information go to www.softroboticsinc.com.

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Safety & Maintenance

Protective Systems for Press Brake Applications Fiessler AKAS 3-P Safety System from Press Brake Safety Has New Features to Ensure Employee Safety and Maintain Production

P

ress Brake Safety originally operating under the name of Advanced Manufacturing Solutions, LLC. The company was founded in 2001 by Douglas Boyer, Jr. who had over 25 years of experience working at Hurco Companies, a major US machine tool builder. In the years thereafter, Doug continued to sell industrial metal working equipment while struggling through a nationwide major downturn in manufacturing after the 9-11 attack. During this time, Doug met Gotz Fiessler and started developing contacts and techniques to promote the Fiessler European line of industrial safety devices in North America. Their retrofittable AKAS line of press brake safety lasers became quite popular. Soon customers were ordering the retrofits avoiding OSHA fines without having to replace costly machines to keep operators safe.

This business has continued to grow so much that a service company started in 2014 now provides the customer base with

North America repair support, staffed with factory certified technicians. The Service group is headed up by Bruce Meyer, an industry seasoned professional and newcomer Andrew Litton, an excellent technician.

The sales company’s name was changed to Press Brake Safety, more adequately defining their relationship with their major product line of safety equipment for press brakes. Joining the family business in 2013 and taking on the leadership role, Jason Boyer came on board, and as President of the company, now oversees the sales and marketing. Another addition to the team was Kimberly GregonisBoyer who is the Chief Financial Officer of Press Brake Safety. Since day one, their mission was to be a full-service safety product provider, offering solutions to the industrial sector throughout North America.

First Co-Moving Press Brake Safety System Modern press brakes are characterized by high productivity and precision. Due to the higher stroke rate during work speed, considerably more workpieces can be manufactured in the same period. New press brakes have to be equipped by a safety system that provides the operators with a reliable protection from squeezing, crushing or shearing of fingers, hands and arms.

Protective systems for the press brakes should be designed in a way that, on the one hand, the operator who is working within the bending area of the press is protected in all situations, and on the other hand, the productivity of the staff and the machine is not restricted. One needs to consider the primary goal is the protection of personal health and life and is a priority over profit.

The Fiessler AKAS 3-P is the first co-moving press brake safety system worldwide that provides high-speed operation up to the clamp point. The new AKAS 3-P, designed for the OEM manufacturers, features top-level productivity while providing

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IMD – The Industry’s Most Extensive Industrial Publication

maximum safety at the same time. When using this press brake safety system, there is no loss in productivity. On modern press brakes, the closing movement, which is in high speed until the clamp point during regular bending, is provided by this safety system. During the entire closing movement, the operator’s hand or fingers are protected from being squeezed between two opposed moving machine parts by the presence of the three-dimensional safety laser beam grid that is located beneath the ram. The system provides full safety during regular bending and box-bending modes.

In order to provide the required adjustment after a tool change using upper tools with different tool sizes without any loss of time, the AKAS 3-P transmitters and receivers come with fully-automatically moving supports. The adjusting procedure is done by a simple push of the adjustment start button. The time that is otherwise required to adjust the unit is saved and can be used for other procedures such as material handling or programming the machine parameters.

The AKAS 3-P is TUV CE type approved/ cUL listed and complies with the standards of the B11.3, EN12622, Z142 and NR12.

ABOUT PRESS BRAKE SAFETY Press Brake Safety, headquartered in Zionsville, Indiana has supplied metalworking machinery throughout the U.S. and Canada for 19 years and is a leading industry advocate for press brake operator safety. PBS is the exclusive North American installer of Germany-based Fiessler AKAS® laser safety systems, the most sophisticated press brake safety systems in the world, and provides complete maintenance, service and training to users. As the industry tries to balance profitability, operator safety and regulators’ capabilities to effectively audit operators’ practices, Press Brake Safety can help you protect your workers and your bottom line.

PRESS BRAKE SAFETY www.pressbrakesafety.com 800-901-1193 Fiessler AKAS-3P video

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IMD 17

Manufacturing Showcase

SUHNER

By Russ Willcutt

E

stablished in Brugg, Switzerland, in 1914 by Otto Suhner, the company initially focused on producing flexible wiring for electrical transmission. This eventually led to the development of flexible shaft cables to transfer torque in powering rotary tools.

Since that time Suhner has grown into a global entity comprised of four main divisions: Abrasive, Machining, Transmission, and Stamping.

Each division has strengths in different geographic markets, but the company as a whole is represented in more than 64 countries, with seven manufacturing facilities located around the world.

Continuing its tradition of Suhner leadership – after Otto, then Willi, Otto H., and now Jürg – the company’s U.S. operations are based in Rome, Georgia. While active in other countries, Abrasive, Machining, and Transmission are the focus for the U.S. and Canada (or North America), with Stamping serving the European market alone. A huge boost was provided by U.S. automakers in the 1980s, when Ford, GM, and Chrysler incorporated Suhner’s flexible rotary cables into its automobiles to improve the accuracy of their speedometers. Today the cables are also used to operate the controls of adjustable seating, with an average of two cables being required inside each seat.

According to Lee Coleman, local manager of the Machining division, the company’s most

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significant growth occurred under the leadership of Otto H. Suhner, current chairman of the board, who was responsible for bringing it to the U.S. in 1976 after having spent a few years in the States studying market potential. This convinced him of the value of the U.S. market, and from there he established many of Suhner’s global locations in countries such as Mexico, India, and China, among many others.

“He was really the driving force behind our global expansion as well as establishing a U.S. service group offering training, engineering consulting, and technical assistance,” Coleman says. “He also helped us move toward a model of seeking big multi-year contracts and building relationships with OEMs who would install our live tooling on machines imported into the U.S. from their manufacturing facilities overseas.”

With primary markets including industrial, automotive, and medical devices, Suhner also provides flexible torque transfer cables to the home & garden manufacturing sector.

Each one of its four divisions has tailored their approach according to the markets they serve. With Abrasive, for instance, customers are concerned with speedy delivery, while Machining acts in a sales and service capacity, providing live CNC tooling, drilling and tapping units, and accessories for robotic applications; a growing market with a great deal of potential.

IMD – The Industry’s Most Extensive Industrial Publication

When it comes to product development, Coleman says that Suhner's approach is centered around its relationships with OEMs rather than R&D driven by market research. “We go directly to them and ask what they need, and then we develop it with their input,” he says. “That way we already know we’ll have a customer from the beginning of the design process.”

Such was the case in the development of the Suhner Turbo Trim meat processing knife, available through the Abrasive division – led by David Guilford – which is its only “protein processing device,” as Coleman describes it. “It’s a niche market, but it’s been a very successful addition to the company’s product lineup,” he says.

Supplemented by a carefully chosen network of sales representatives and distributors, Suhner is primarily known for its direct sales professionals; highly specialized individuals who are invaluable resources to the company’s customers throughout the relationship. Innovative service approaches for end-users are also paramount, including calculators built into the company’s website to help them determine their needs based on data such as the application itself, the materials involved, and even the feed rates determined in the bid preparations.

“By making these tools available to our customers so they can conduct research on their own, they are more comfortable and well-informed once our experts step in to help guide the process,” Coleman says. “One thing we’ve emphasized from the beginning is being responsive to the market at large, while at the same time focusing on each customer’s specific needs.”

To learn more visit www.suhner.com.

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IMD 19

Workforce Development

Technical Skill Assessments: A Tool for Managers, Machinists, and More By: Tony Glockler, CEO and Cofounder of SolidProfessor

T

he industrial manufacturing sphere is facing many exciting opportunities for innovation and digital transformation thanks to Industry 4.0. Many sectors — from heavy equipment and machinery to mold, tool, and die — will be growing significantly over the next decade. The industry is slated to create several million jobs, encompassing skilled production roles such as CNC machinists and programmers as well as engineers, scientists, and researchers.

However, all of this growth and opportunity comes with some major hurdles, one of which is the significant shortage of skilled workers. This skilled labor gap has the potential to leave millions of new jobs unfilled and is already causing hiring delays in the industry.

One way that organizations are tackling this challenge is by hiring outside of their typical job requirements. This often means focusing less on technical skills and instead hiring for skills such as logic troubleshooting, spatial visualization, critical thinking, and most importantly, a willingness to learn.

Organizations must then take a more active role in providing training resources and opportunities to help workers get their technical and software skills up to par. Employers are offering more apprenticeships, coordinating on-the-job training, and providing access to tools like online learning platforms.

With the need to upskill employees quickly, tools like skill assessments are incredibly helpful for both employers and potential candidates. Skill assessments for technical skills like CAD and CAM software can be used in a number of different ways to aid in the hiring process and build an effective training program for manufacturing workers.

What Are Skill Assessments and How Do They Work?

Skill assessments test an individual’s proficiency in specific competencies. Unlike resumes and in-person interviews, skill assessments offer an objective and standardized method for measuring skills. The assessments provide clear scores, ratings, and analyses that highlight strengths and weaknesses.

Technical skill assessment scores are one of the most important inputs when conducting a skills gap analysis. In a skills gap analysis, you can compare these scores to help determine where gaps exist between existing and required skill levels, and even between different employees on a team.

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Many online learning platforms offer skill assessments for technical skills including CAD and CAM software. Some platforms will even aggregate team results and/or break down the assessment scores by separate skill sets. For example, an online SOLIDWORKS skill assessment might give you scores in Drawing, Assemblies, and more in addition to an overall score so you can get a clearer understanding of individual competencies as well as overall results.

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The Manufacturing Sector’s Skills and Labor Shortage

THE SHORTAGE OF MANUFACTURING LABOR IS DIRECTLY TIED TO A SHORTAGE OF SKILLS.

The U.S. manufacturing industry needs to fill more than 4 million jobs over the next decade, but 2.4 million of these jobs could go unfilled.

84%

49% of respondents say their 49%

their manufacturing employees’

agree there is a shortage of skilled

current skills against skills they

workers in their industry.

will require in the future

Manufacturers’ top challenges are: Finding skilled new hires (99%)

2.4 million unfilled positions

Upskilling the incoming workforce (92%)

54%

over the next decade IN-DEMAND SKILLED ROLES: The National Association of Manufacturers estimates that this labor shortage could result in a loss of $2.4 trillion in GDP.

54% don’t currently budget for employee development

88% say their company is below

CNC machinists

Mechanical engineers

CNC programmers

Quality engineers

outside resources to upgrade the

Manufacturing engineers

Design engineers

skill sets of employees

88%

average when it comes to offering

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and engineering teams need to close the skills gap and change up their hiring process.

company has not begun assessing

84% of manufacturing executives

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Sources: Reliable Plant. U.S. Manufacturing Faces a 2-million Worker Shortage. | PBS. Manufacturers say their worker shortage is getting worse. Here’s why. November 2018. | Tooling U-SME. 2018 Manufacturing Workforce Report. 2018.

Deloitte. 2018 Deloitte and The Manufacturing Institute skills gap and future of work study. 2018.

How Should Managers Use Technical Skill Assessments?

Technical skill assessments are highly useful for machine shop managers and engineering managers for a number of different applications. They can play a critical role in the hiring process.

Managers might require job candidates to complete a CAD or CAM skill assessment to see if their skills match up with the organization’s needs. Or, if managers are trying alternative hiring approaches in order to expand their pool of applicants, skill assessments can be taken after candidates are hired in order to establish a baseline for key skills and then determine the best strategy for on-the-job training.

Uses for skill assessments don’t stop there. Skill assessments are valuable for all employees regardless of experience level or job title.

Technical skill gaps are common on engineering design and skilled production teams and can slow down workflows without teams even realizing they exist.

In these instances, managers can use skill assessments to get a quantified view of their team’s proficiency. This makes it much simpler to identify inefficiencies, pitfalls, and hidden skill gaps. This then enables managers to implement training programs to address those skill gaps, saving time and boosting productivity.

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Plus, skill assessments can be repeated— managers that have their teams take the same skill assessments annually or even quarterly will have the best insight into their employees’ skill improvement and the effectiveness of their training program.

How Should Machinists, Drafters, and Designers Use Technical Skill Assessments?

Technical skill assessments are a powerful management tool, but they can be just as useful for professional machinists, drafters, and designers that are looking to prove their software skills or qualify for a new position.

Taking a skill assessment as an individual is a great way to gain an understanding of your technical strengths and weaknesses.

For example, if you’re training for an industry-recognized credential or software certification, try a related skill assessment as a form of pre-test. If you’re applying for a new role, especially if you’re an entry-level employee or switching industries, take a skill assessment and see how your skills stack up against the job requirements. When using an online testing tool, your results should make it very clear which areas you need to improve in order to achieve the position you want.

Take the skill assessment again and see how you perform once

you feel confident in your abilities. A high test score on a skill assessment is a great metric to add to your resume. For example, sharing that you received 90 percent on a SOLIDWORKS Advanced assessment is an impressive way to communicate to potential employers that you know how to work efficiently in the software.

The same advantages apply for experienced workers—even if you’re not on the job hunt.

Taking a technical skill An example of group skill assessment results via SolidProfessor Skills Analyzer assessment can give you a confidence boost by proving what you really know. Your results will also help you pinpoint To learn more Information: areas where you might be struggling. That way, you can save time by training only on what you really need to learn. And while high scores Take SolidProfessor’s free SOLIDWORKS skill assessment and get are great for resumes, they can also be valuable proof points if you’re customized training recommendations by visiting www.solidprofessor. trying to cinch that next raise or promotion! com/skills-analyzer.

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IMD 23

5:36 INDUSTRIAL MACHINERY DIGEST.COM 3/22/20

PM

New Technology

Why Use a CT Scanner for an Industrial Job? By: Dean Solberg, Co-Founder, Exact Metrology

T

he ability to “see through” a solid object was once thought to be a tool of the future, or a power belonging to Superman– but the technology is here today, and more widespread and accessible than you may have thought.

Until recently, the technology of CT imaging was only available for use in medical settings. Over the last several years, it has found a new home in the world of manufacturing, and is opening up myriad opportunities never before available.

CT, or Computed Tomography, is now commonly used in various industrial metrology settings, both in the lab and online or inline for product evaluation and packaging integrity assessment. The main advantage is that it allows the inspection of a part’s interior structure or a package’s closure functionality without causing any harm or destruction to the objects themselves.

Industrial CT scanners utilize the same type of technology as CT scanners in hospitals and doctors’ offices--taking multiple readings from various angles and converting the CT grey scale images into voxel-based 3-dimensional point clouds. Once the

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24 IMD APRIL 2020

CT scanner generates the point cloud, a specialist can generate a CAD-to-part comparison map, construct a 3D model of the part, or reverse engineer the part to suit their needs. In the packaging world, especially where pharmaceutical or personal products are concerned, this ability is paramount. High-speed scanning inline, for example, can examine the seals on pill bottles for airtight quality assurance, while online or lab scanning can instantly compare a manufactured product to the CAD program in various ways.

Industrial scanners offer a multitude of advantages, such as: obtaining internal structure of an object nondestructively, validating extremely accurate internal dimensions, allowing comparison to reference models, no shaded zones, compatibility with all shapes and sizes, no post-processing work and extremely high-resolution imaging.

Some of the most common uses of 3D and now CT scanning in industrial metrology applications include: » Reverse engineering – the process of taking measurements of an existing part or object, then creating an exact CAD replica.

IMD – The Industry’s Most Extensive Industrial Publication

This technology is extremely useful, when you have a manufactured part or object, but not the original prints or design data. » Non-contact measurement – the process of capturing the geometry of existing objects through the use of laser emitting camera-like 3D scanners. » Contact measurement – a method of collecting single points relative to each other. There is a wide range of solutions for contact measurement and generally two types of systems solutions are used with portable CMMs: 1) For capturing localized or small volume information, digitizing or articulating arms are used, 2) For larger volumetric projects, optical solutions including laser trackers and photogrammetry units.

» Long range scanning – for a detailed 360° 3D snapshot of a structure, bridge, plot of land, plant or process operation with millimeter accuracy.

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IMD 25

» Art forgeries – a bit unusual for what is thought to be an industrial product, but hundreds of art museums, dealers and auction houses use scanning each year to validate works of art, as well as the structural integrity of sculpture, for example. » Model to manufacture processing – here again, artists will often have their models, whether fashioned or human, scanned for dimension prior to casting a statue in bronze or producing a high-fashion line of clothing.

These 3D imaging devices and long-range scanners serve a wide range of industries, and help assure that they are performing the highest level of testing and accuracy possible. A few of the diverse industries currently using this technology and the goals sought are: » Manufacturing – for internal inspection of components and to ensure that a part meets specifications; this includes injection molded, cast, forged or fabricated parts made from metal, plastic, polymers, composites and even 3D printed products » Power generation/nuclear – can scan the complex, hard to reach and hazardous areas of a nuclear power plant or conventional power generation facility for pipe alignment, boiler integrity, containment building stability and more » Medical – devices & equipment, implants, orthotics & prosthetics; a one-off knee joint, for example, can be accurately

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compared to the original CAD program as well as the doctor’s MRI for accuracy » Automotive & aerospace – allows engineers to do virtual testing of machinery, helps understand failures, works as a research & development tool to analyze structure, simulate reactions » Arts – in the detection of forgeries and sculpture integrity » Metal castings – to check for air bubbles and overall porosity » Foods – to examine contents & packaging integrity » Plastics industry – to inspect quality, wall-thickness and porosity analysis » Moldmaking - provides a powerful inspection and measurement tool to validate precise injection molds and check structural integrity of a part There is a wide range of industrial scanning equipment styles and sizes available to suit different types of applications. Micro units in table top styles for lab use up to full industrial grade floor models for in-plant or in-process use, to portable measuring arms that can be used on the shop floor or out in the field are all available today, usually from a manufacturer or a service organization, for one-time contract use, with rent or lease-to-buy arrangements optional. Many of our customers, having used our services, subsequently purchase the equipment and training to

add this high-end metrology to augment their inside CMM or test lab, for example. In the case of larger production facilities, we often see metrology today being integrated into the line for instant analysis of parts, whether molded, stamped, welded or otherwise fabricated, as well as packaged goods.

Typical CT scanners offer a wide range of measurement capabilities and features. Sizes start with small desktop models which meet the most stringent demands and measure the smallest 3D detail from 0.25µm. They can be equipped with different X-ray powers, from 160kV for nanometer resolution through 225 kV, 320 Watts to the highest power of 300 kV, 320 Watts. (Shari: I think this is just the range of the ProCon scanners our client bought.

Reference the range of the entire ProCon line of portables.)

Larger scanners are available for extremely fast CT data acquisition on workpieces up to 500 mm diameter and 600 mm in height, weighing up to 50 kg (110 lbs.). Typical functions performed on this type of system might include 3D analysis of a scanned turbine blade, automatic pour porosity volume analysis on an aluminum casting and 3D measurements with nominal-actual CAD comparisons on a machined aluminum cylinder head.

The future of industrial scanning holds unlimited possibilities, especially when combined with 3D printing or other additive manufacturing methods. As improvements are made in technology and performance and costs continue to decrease, the industrial scanning industry is preparing for explosive growth in the next 5-10 years.

ABOUT EXACT METROLOGY, INC. Exact Metrology, with facilities in Cincinnati and Milwaukee and affiliated offices throughout the Midwest, is a comprehensive metrology services provider, offering customers 3D scanning, reverse engineering, quality inspection, product development and 2D drawings. The company also provides turnkey metrology solutions, including equipment sales and lease/rental arrangements.

Exact Metrology is an ISO 9001:2008 and AS9100 Certified Company.

For more information on CT scanners and scanning services, or to arrange a demonstration, please contact:

EXACT METROLOGY, INC. 20515 Industry Avenue Brookfield WI, 53045 Telephone: 262.533.0800 www.exactmetrology.com deans@exactmetrology.com Dean Solberg, President

INDUSTRIAL MACHINERY DIGEST.COM

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IMD 27

Process

Demand Outpacing Production

True Precision Machining implements OB7 on wire EDM machine, doubling machine output and meeting deadlines early for their high-technology customers in the medical, aerospace and communications industries.

A

s a full-service machine shop, True Precision Machining promises quality control, quick turnaround time and innovative solutions to meet their customers’ challenges and requirements. However, even with their highly trained and skilled team, it was challenging to meet certain deadlines. Producing parts fast enough on their wire EDM machine is just one example of this challenge.

“We typically run two shifts per day for five days, totaling 80 production hours per week,” explained Marvin Rodriguez, vice president of True Precision Machining. “A 500-part job would take at least a week to finish working at that pace—and that’s not accounting for downtime or breaks. To stay competitive and meet our customers’ high demands, we need to be faster than that.”

Rodriguez recognized that the existing production schedule took advantage of only 80 of the 168 hours in a week. What if True Precision could operate at a higher capacity, taking advantage of all available hours, unhindered by machine downtime?

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Discovering OB7 During their extensive research of collaborative robotics, True Precision discovered Productive Robotics’ OB7 at a tradeshow and taught it a task on the spot.

“We were impressed by the no-programming user interface and how simple it was to teach the cobot tasks. This would be a solution that we could develop on our own without hiring outside integration,” stated Rodriguez.

True Precision was also drawn to OB7’s seven axes, which provide greater flexibility and the ability to work in confined spaces.

“We saw how well OB7’s 7th axis worked during the CNC demo, and we wanted that in our shop,” emphasized Rodriguez.

The 7th axis is an especially desirable feature for machine shops because it allows operators to place OB7 to the side of a machine door, rather than directly in front of it. The OB7 can reach around into the machine, freeing up space for machine operators to work.

It was clear that OB7 is an easily teachable robot and one with

IMD – The Industry’s Most Extensive Industrial Publication

“

People think that robots take away jobs, but they actually helped grow our business, become more competitive and better utilize the talents of our team.

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IMD 29 8/13/19 11:31 PM

the flexibility to fit the physical needs of True Precision’s shop— and what’s more, it would allow them to expand their hours of production through working “lights out” or around-the-clock even when employees are not at the facility.

Ready, Set, Assemble!​ Now on the road to faster production, it was time to install the OB7 Alpha Wire EDM 5 axis machine. With their skilled staff, True Precision set up the automation work cell entirely on their own. “We did not have any prior experience with cobots, but we were able to create the necessary tooling and configure our environment to work with OB7,” stated Todd Ackert, President of True Machining. After the few days spent planning the work cell, the team turned to assembling the OB7 and had it up and running in a matter of hours.

“OB7’s intuitive user interface made the process simple. We physically moved the robot control handle to introduce a task and customized our waypoints on the tablet interface for more precision,” stated Rodriguez.

The simple teaching platform is a key benefit to working with OB7 for many teams—it enables fast job teaching and requires absolutely no programming. The 500-part job on the wire EDM machine was soon working 200% faster and could continue to operate round-the-clock.

“We finished a job in 3.5 days that would have taken a week to complete” said Rodriguez. “Working ‘lights out’ with OB7 allows us to go home and return the next morning with a job completed, ready to start the next. OB7 has saved us significant time and money, while increasing quality and precision.”

True Precision also recognized the valuable and reassuring role of Productive Robotics’ dedicated support team.

“If we had a question, we called Productive Robotics’ support team. They would help us over the phone or come out to our facility,” added Ackert.

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30 IMD APRIL 2020

Introducing OB Vision

Making Robot Vision A Simple Reality OB Vision is Productive Robotics' commonsense and automatic approach to robot vision. Building on our "No Programming" approach to robot training, Productive Robotics' OB Vision brings "No Programming" to robot vision.

OB Vision is fast, simple and completely automatic in most common robot vision applications. Just show OB7 what you want to pick up, push one button, and OB Vision learns to recognize the object, and to pick it up in a one fully automatic step. We say: You push the button and OB does the rest.

OB Vision: No vision programming. No worries.

OB Vision is completely integrated into the OB7 learning system and is available for all OB7, and OB7 Max robots.

OB Vision Specifications: Working Area: 12” to 18” (300mm to 450mm) Largest Object: 8” (200mm) Lighting required: None. All necessary lighting integrated.

Expanding Implementation of OB7 to Grow Business True Precision attributes its success over the years to effectively introducing modern machinery and state-of-the-art equipment to deliver quality results. Implementing OB7 is a prime example.

“People think that robots take away jobs, but they actually helped grow our business, become more competitive and better utilize the talents of our team,” stated Ackert.

OB7 allowed True Precision to bring in more work, meet deadlines faster, and simultaneously allow their workers to focus on other highly valuable tasks. The success of OB7 was so immediate, simple, and effective, that looking forward, True Precision plans to implement OB7 on multiple other machines in their facility.

“Working with OB7 has been a highly rewarding experience,” emphasized Ackert. “And in the process, we learned to strategize more efficient, creative, and innovative methods for automating future jobs with collaborative robots.”

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IMD 31

Industry Insight

Over the past couple of years, EMAG has enjoyed growing success with turnkey manufacturing solutions.

The New EMAG Systems: EMAG provides complete turnkey solutions from a single source

T

he production of comprehensive manufacturing solutions from a single source is the main requirement for many mechanical engineering production planners. Typically, a general contractor would be responsible for the development of a complex line of interlinked machines with a variety of technologies.

This provides the manufacturing company with two major benefits: the overall planning is easier (of the new factory) and a production partner that guarantees a perfectly designed, flexible, manufacturing solution, even for the most complex production situation.

For years, the EMAG Group has been this partner, as it is one of the few machine builders that covers the entire process chain from soft to hard machining. Now, the experts are taking the next step with the creation of EMAG Systems and combining their project engineering expertise. The new company is the perfect partner for creating turnkey solutions and is responsible for the overall project – combining the experience and knowledge of the various EMAG branches when necessary.

For example, e-mobility: Here, the requirement for increased quantities is currently shifting the focus to the establishment of comprehensive production systems. Ultimately, this is the only way to be able to produce complex components such as rotor shafts or differentials in a process-consistent and cost-efficient manner.

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Bernhard Böttigheimer, Managing Director of the new EMAG Systems: "The demand for complete turnkey production systems is growing. We provide extensive expertise for this task."

In the interlinked systems, for example, soft machining, hardening and hard machining take place in direct succession and numerous technologies from turning, drilling and milling to induction hardening and grinding are used.

With increasing demands for product quantities, the focus is shifting to the establishment of comprehensive production systems.

"When designing a complex system like this, there are naturally many questions during the planning phase ", explains Bernhard Böttigheimer, Managing Director of the new EMAG Systems. ”For example, users must understand the precise benefits and performance limits of the various tool processes, opportunities for the component assessed and a reliable process developed on this basis. To compile all of this information, the user must have access to a large amount of internal technological expertise. At EMAG, we have been working toward this for years – we have a variety of core processes within the Group, and are also developing in-house automation technology.”

Combined System Expertise With all of these tools at their disposal, EMAG has been enjoying growing success in the production of turnkey manufacturing solutions in recent years. The mechanical engineering company even underwent an audit by a major OEM, in which all processes and structures relating to the development of large production systems were successfully examined. The specialists regularly provide proof of their system expertise outside the automotive industry, as demonstrated by various solutions for oil production technology manufacturers.

In the past, experts within the individual EMAG

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34 IMD APRIL 2020

The EMAG Group controls the entire process chain from soft to hard machining and therefore repeatedly acts as a general contractor.

companies performed the corresponding project management. Why is EMAG Systems now taking on this task globally?

"We are convinced that this business area is becoming increasingly important. The demand for complete production systems is growing because the range of products and parts is also increasing at many supplier companies and OEMs. This is putting more demand on production systems to be more flexible, and project engineering needs are being outsourced by many companies”, says Bernhard Böttigheimer.

And for these customers, EMAG Systems provides a central point of contact with experience in comprehensive turnkey production.

These specialists, based in Salach, Germany, will examine each inquiry in detail, and then determine which technologies are needed for the project. With this information they will form a project team, consisting of engineers from different EMAG companies – this team will work together to form a completely customized solution for the project.

Although EMAG Systems may be new, our team is not! We have a variety of experts from within the company, who have been responsible for similar projects for EMAG in the past. With this team, customers will benefit from the experience and in-depth knowledge of all of the Group’s technologies. Within this new organization, the expertise of the employees will be combined, and the internal processes will be simplified. This allows those at EMAG Systems to focus on providing customers with a comprehensive process, while the individual EMAG companies focus on their specific technologies.

Initial Success Confirming the Path Overall, the EMAG Systems experts see their market opportunities as very positive. After all, in the automotive industry, for example, many supplier companies must position themselves much more broadly and establish independent production solutions for a larger number of different drive technologies - from the classic combustion engine and hybrid solutions to completely electric.

"In this industry, the demand for our resource planning expertise is growing quickly” explains Bernhard Böttigheimer.

A second factor in the success of EMAG Systems is Industry 4.0. After all, Smart Factories that increase the productivity of a location, or improve process reliability are impossible without comprehensive, linked systems. This is where EMAG Systems and its project engineers play a critical role. A variety of current projects shows that this full scope approach is working in the market, especially in e-mobility. For example, EMAG is currently developing two production systems for machining a rotor shaft for European customers.

"We are clearly on the right track", sums up Bernhard Böttigheimer.

"With EMAG Systems, we intend to bring our long-standing project engineering expertise to the market in a selective manner, while continuing to grow over the next few years and at the same time pressing ahead with the technological development of production systems. We are in an ideal position for this."

For more information, visit www.emag.com INDUSTRIAL MACHINERY DIGEST.COM

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Advanced Manufacturing Solutions

Advanced Manufacturing Solutions Additive Manufacturing, Metrology, & Digital Solutions 3D printing, or additive manufacturing, continues to provide manufacturers with new ways to design parts that are more efficient, and cheaper to produce. From small desktop to large-scale industrial printers, there are options to work additive manufacturing into your current production line.

With the latest metrology and IIoT solutions available, manufacturing and fabricating professionals can gain valuable insight not only about the parts produced, but on the status of your equipment as well. » For more advanced manufacturing solutions, visit www.IndustrialMachineryDigest.com

BOOTH: 1507

CGTech and Thermwood to Demonstrate Simulation of Large Scale Additive Manufacturing Machines LSAM is a new technology for large scale 3-D printing of thermoplastic polymers. Thermwood’s LSAM machines utilize unique patented technology to produce the highest quality thermoplastic polymer printed structures available. The machines feature both additive and subtractive heads to accommodate printing and trimming of large scale “near net shape” parts on the same machine.

VERICUT CNC machine simulation, verification and optimization software simulates all types of CNC machining, additive, and hybrid manufacturing processes to verify that the finished part matches the intended engineered design. » For more information, visit www.cgtech and www.thermwood.com BOOTH: 826

Cincinnati Incorporated’s SAAM and SAAM HT The SAAM machines were originally designed as a complement to CI’s larger BAAM and MAAM industrial sized additive manufacturing machines. They allow for prototypes to be created before entering full-scale production on the larger machines. Both the SAAM and SAAM-HT are ideal for creating functional parts as well. The machines are small enough to fit on desktops and similar surfaces, making them the ideal solution for additive manufacturing capabilities when space is limited. Both machines utilize CI’s patented Automated Ejection System to provide the capability for continuous, unattended 3D printing. They are the only 3D printing machines that offer this function. » For more information, visit www.e-ci.com BOOTH: 3025

LASERTEC 12 SLM High Precision Building of 3D Parts Being a complete supplier in additive manufacturing of metal parts DMG MORI offers the LASERTEC 3D hybrid and LASERTEC 3D series for laser deposition welding and LASERTEC SLM series in the field of powder bed machines. Designed for applications in selective laser melting, DMG MORI offers the new OPTOMET software. It has self-adjusting and learning algorithms that calculate the required parameters of the SLM process in advance within minutes. OPTOMET reduces material development efforts by 70 % using its material database that allows users to use material from all manufacturers without having to test them in advance. » For more information, visit us.dmgmori.com

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36 IMD APRIL 2020

IMD – The Industry’s Most Extensive Industrial Publication

BOOTH: 1213

FANUC’s Industrial IoT Solution Zero Down Time ZDT’s predictive analytics have already saved millions of dollars by preventing unexpected down time in the automotive industry.

Now, small to medium-sized manufacturers are realizing there is even more to ZDT than down time avoidance. In addition to reducing unexpected down time, ZDT allows users to maximize production throughput, optimize maintenance costs, increase the life of their robots, and access data from anywhere via the ZDT web portal. Since its introduction in 2015, ZDT analytics have successfully identified potential equipment issues, and notified customers to take corrective actions and avoid unexpected down time in over 600 cases, saving companies more than $75 Million.

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Formlabs Digital Fabrication with the Launch of Form 3 and Form 3L, Formlabs provides two advanced professional Low Force Stereolithography (LFS) 3D printers in its hardware lineup: Form 3 and Form 3L. LFS 3D printing is an advanced form of stereolithography (SLA) that delivers consistently flawless parts. The LFS process uses a flexible tank to drastically reduce the forces of the peel process, providing incredible surface finish and detail, and linear illumination to deliver accurate, repeatable parts. The powerful LFS print process behind the Form 3 is built to scale: Form 3L simultaneously uses two Light Processing Units (LPUs) to bring large format 3D printing in-house. » For more information, visit www.formlabs.com

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IMD 37

BOOTH: 800

GE Additive’s Arcam EBM Spectra L The latest addition to the Arcam EBM Spectra family will be manufactured at the GE Additive Arcam EBM facility in Gothenburg, Sweden and is available for order now, with delivery expected at the end of Q1 2020. Spectra L supports grade 5 Ti6Al4V, grade 23 Ti6Al4V and is well-suited for large titanium The Spectra L features 4.5 kW beam power which increases build speed by 20%, compared to the Arcam EBM Q20plus. And with system improvements to powder layering and heat model control improvements, the Spectra L completes a full height build 4.5 hours faster than the Arcam EBM Q20plus. » For more information, visit www.ge.com BOOTH: 806

Hexagon releases PC-DMIS 2020 R1 PC-DMIS 2020 R1 brings new features, capabilities and an enhanced user experience to portable measuring arm operators and those who scan and create point cloud data. The new feature ‘Guided Portable Execution’ streamlines the creation and execution of contact Auto Features. This takes the guesswork out of measurement manual measurement paths by guiding the user through the measurements, showing where measurement points need to be taken in red and points already captured in green, whilst automatically scaling and rotating to the active Auto Feature. » For more information, visit www.hexagonmi.com

BOOTH: 1231

Fastest, Most Accurate Bar Puller On The Market Watch the video now at: ezpullerusa.com • NO MECHANICAL ADJUSTMENT NECESSARY (X axis end point gets changed in the program when changing bar diameters) • ONE TIME SETUP • NEVER NEEDS ADJUSTMENT •CHANGE BAR SIZE IN SECONDS (BY CHANGING “X” VALUE IN PROGRAM) • EXTREME REPEATABILITY RESULTS IN LESS MATERIAL WASTED PER PART • NO GRIPPING FINGERS TO ADJUST, LOSE OR BREAK

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38 IMD APRIL 2020

The Matsuura LUMEX Avance-25 relies on one-machine, one-process manufacturing of complex molds and parts by fusing metal laser sintering technology with high speed milling technology. The Hybrid technology creates a “finished” part with machined surface finish and accuracy, without inducing the additional variation caused by multiple machine set-ups and part handling. The Avance-25 achieves this high accuracy in part fabrication since metal powders are melted and sintered via laser, while surfaces are precisely milled at high speeds. 3D cooling channels can be incorporated into molds in the single setup. » For more information, visit www.matssurausa.com

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SLM Solutions focuses solely on metal additive manufacturing technology and pioneered multi-laser machines. This years-long experience mastering multi-laser optics, together with their patented bi-directional recoating mechanism makes selective laser melting systems the most productive on the market. With four lasers enabling build rates up to 171 cm3, the SLM®500 serves as the flagship metal 3D printer for high volume processes while offering automated, closed-loop material supply, recovery and sieving to minimize operator handling of metal powder.

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TruPrint 5000 achieves outstanding 3D printing times with unique multi-laser principle TruPrint 5000 works according to the multi-laser principle and is equipped with not just one, but three scanner-guided, 500-watt TRUMPF fiber lasers. The three lasers are fitted with optics specially designed by TRUMPF enabling them to operate simultaneously at any point in the system's construction chamber. As a result, they can generate components much faster and more efficiently, irrespective of the number and geometry of the components. Based on Laser Metal Fusion (LMF) manufacturing technology, the system uses laser power to generate complex metallic components layer by layer in the powder bed. » For more information, visit www.trumpf.com

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IMD 39

Product Showcase

PRODUCTSHOWCASE WANT TO BE FEATURED? Send your latest product information to editorial@indmacdig.com

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

Patented No Drip Air Atomizing Nozzles Conserve Precious Liquids EXAIR’s new 1/8 NPT No Drip Internal Mix Air Atomizing Spray Nozzles mix liquid and air inside the nozzle and produce the finest atomization of liquids. The new, patented No Drip Internal Mix Atomizing Spray Nozzles work in the same way our standard atomizing nozzles do, but have the added benefit of positively stopping liquid flow when compressed air is shut off. When spraying any type of liquid, post-spray liquid flow can cause big problems.

Drips occurring after spraying waste precious resources such as expensive coatings, chemicals or water, and are now eliminated with EXAIR’s patented design. Unwanted drips can ruin product function on sealing or mating surfaces and can ruin the appearance of painted or coated finishes. EXAIR’s No Drip Air Atomizing Nozzles are ideal where no post-spray drip is permissible. When the compressed air supply is shut off, the no drip nozzle positively seals off the flow of liquid eliminating the possibility of drips. » For more information, visit www.exair.com

ABB and Covariant Partner to Deploy Integrated AI Robotic Solutions

ATI Industrial Automation has introduced the AOV-10 Axially-Compliant Orbital Sander

ABB, the world-leading supplier of industrial robots, and Silicon Valley AI start-up, Covariant, today announced a partnership to bring AI-enabled robotics solutions to market, starting with a fully autonomous warehouse order fulfilment solution. The partnership brings together the two companies with a shared vision for robotics enabled by AI, where intelligent robots work alongside humans in dynamic environments, collectively learning and improving with every task completed.

Given the accelerated global growth experienced in the e-commerce sector, ABB identified a significant opportunity for AI-enabled robotics solutions across a broad range of applications including logistics, warehousing, and parcels and mail sorting.

ATI Industrial Automation has introduced the AOV-10 Axially-Compliant Orbital Sander, specifically designed for robotic surface preparation and finishing. With built-in compliance, the AOV-10 is well-suited for many different robotic applications—even those that require a light touch. A pneumaticallyactuated compliance mechanism allows for dynamic control of contact forces and ensures an ideal result every time. The compliance force is adjustable to accommodate a wide variety of applications. Double-acting motion offsets the weight of the tool to produce the desired finish no matter how it is oriented. Users can mount the AOV-10 directly to their robot or to a fixture, in any orientation, including upside-down.

» For more information, visit www.abb.com or www.covariant.ai

» For more information, visit www.at-ia.com

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40 IMD APRIL 2020

IMD – The Industry’s Most Extensive Industrial Publication

Dillon Hard Jaws Feature Diamond-Shaped Serrations for Increased Pull-Down Effect Hard Jaws from Dillon Manufacturing, Inc., feature diamond shaped serrations for increased pull down effect which reduces part slippage and push back from using a bar feeder. The aggressive serrations on the gripping surfaces are also ideal for cast parts, scaly parts or parts with imperfections. The hard jaws are available in one-step or two-step sets and are reversible for OD or ID chucking. Only one set is necessary to cover a wide clamping range. Dillon hard jaws are available in standard sizes from stock and in different mounting configurations including serrated, T&G, Acme, and square serrated key types to fit all brands of chucks.

BIG KAISER Adds New Inserts BIG KAISER Precision Tooling is adding more than 30 pressedgeometry carbide inserts for its tools. The new insert design is the result of extensive research and testing. The new grades and geometries offer improved chip control due to optimized chip breakers, even when boring gummy materials like low-carbon or stainless steel and Improved coatings for increased speed and better wear resistance. More positive cutting geometries reduce cutting forces, chatter and vibration when used in deep-hole boring operations and provide longer tool life. The new inserts off up to 20 percent savings when compared to current grades

» For more information, visit www.dillonmfg.com

» For more information, visit www.bigkaiser.com

High-Throughput DMP Flex 350 Metal 3D Printer from GF Machining Solutions The robust, flexible DMP Flex 350 enables efficient 24/7 production of very dense, pure metal parts from 11 ready-to-run challenging alloys, including thoroughly qualified Inconel, titanium, cobalt chrome, aluminum and steel. Improved gas flow technology produces more-uniform part quality throughout the build area. The DMP Flex 350 guarantees excellent microstructure density, stable mechanical properties and consistent powder quality for high-quality parts. Total cost of ownership remains low thanks to high powder recyclability, low consumables usage and a long-lasting process filter. For the ultimate in flexibility, the DMP Flex 350 upgrades to the DMP Factory 350, with integrated powder management system, high-performance sieving and automated powder conveyance. » For more information, visit www.gfms.com

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IMD 41

Power Skiving with Integrated Cutter Resharpening Delivers High Quality, Reduced cost A fully integrated on-board cutter resharpening unit is now available for Gleason vertical Power Skiving machines, allowing for the completely automated resharpening of cutters used in the production of both soft and hardened gears up to 600 mm in workpiece diameter. By automating cutter resharpening operations, Gleason Power Skiving machines require minimum operator involvement, greatly reducing the time typically required for frequent tool changes and subsequent first-part inspection cycles.

Additionally, the usual cost for external tool refurbishment can be avoided. . The integrated cutter resharpening unit then executes the necessary grinding strokes while the cutter performs the infeed and the indexing from tooth to tooth.

2200F° Inert Atmosphere Pit Furnace from Grieve No. 1040 is a 2200°F inert atmosphere pit furnace from Grieve, currently used for heat treating automotive parts in baskets at the customer’s facility. Workspace dimensions of this furnace measure 36” wide x 36” deep x 48” high. 78 KW are installed in heavy gauge, high temperature Kanthal AF alloy wire heating elements of rod overbend design and powered through a low voltage transformer to heat the workload. Inert atmosphere construction includes continuously welded outer shell, high temperature door gasket, sealed heater terminal boxes, inert atmosphere inlet, outlet, flow meter and manual gas valve.

» For more information, visit www.gleason.com

» For more information, visit www.grievecorp.com

C-FRAME PRESSES

GROB Systems to Highlight Machining Centers • 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.

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GROB’s G-Series, which includes the G350, G550 and G750 5-axis universal machining centers offers limitless possibilities for milling parts made of the most diverse materials. They are ideal for the aerospace industry, where complex components with high cutting volumes need to be achieved. Each machining center features a compact design, maximum milling performance, high visibility and optimized work area access. The Access-Series, featuring basic models G350a and G550a, include more features than ever before, which are backed by GROB’s more than 90 years of experience with machine tools. These 5-axis universal machining centers have short payback time, yet still deliver the best machining quality for production facility.

www.betenbender.com » For more information, visit www.grobgroup.com/en/

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42 IMD APRIL 2020

The Multigrind® CB XL 5-axis CNC grinding center machines

New Norton Disc Grinding Wheels Offer Over 30% Longer Wheel Life

The development of the Multigrind® CB XL model was a challenge for the engineers from Haas Schleifmaschinen because of significantly larger part dimensions and weights. The design task included maintaining “small part” microns accuracy even on larger parts. No small task. The solution was based on the award-winning, flagship Multigrind® CB, a model designed from the beginning to be adapted and deployed for future demanding grinding tasks. This new CB XL grinding center has much of the same structural design as the CB, but with a “stretched” X-axis and machine table. Due to its symmetric design, the Haas Multigrind® CB XL maintains stability and rigidity, regardless of part length.

Saint-Gobain Abrasives announced the introduction of its new Norton Stellar inserted-nut grinding wheels for double and single disc grinding that offer improved wheel life, increased parts per wheel and lower cost per part. The new grinding wheels are ideal for a wide range of industries including automotive, bearing, tool manufacturing, compressors, knife blades and job shop/ general machining. Norton Stellar grinding wheels have an over 30 percent longer wheel life than existing disc grinding products and require less dressing and parameter changes for increased productivity. The new wheels also have an improved material removal rate of more than 15 percent.

» For more information, visit www.multigrind.com

» For more information, visit www.nortonabrasives.com

OnRobot Launches New 3-Finger Electric Gripper Ideal for CNC machine tending The 3FG15 three-finger gripper’s design, specifically developed for machine-tending tasks, automatically centers workpieces, resulting in a strong, stable grip and precise placement in machine chucks.

With a gripping force from 10 N to 240 N, the 3FG15 competes with much less flexible finger grippers. The gripper is also ideal for packaging and palletizing applications, and is seamlessly compatible with any major collaborative or light industrial robot arm through OnRobot’s new award-winning One System Solution, the platform that provides a unified mechanical and electrical interface between the robot arms and any OnRobot EoAT. » For more information, visit www.onrobot.com

char-lynn hydraulic products low speed high-torque motors… The Char-Lynn

motor range consists of three major types based on the valving used to distribute fluid through the Orbit gear set (geroler or gerotor), Spool Valve, Disc Valve and VIS (Valve-in-Star). A variety of displacement sizes are available in each of the three motor types to provide a wide range of speeds and torques.

steering control units… offer these advantages: • Minimal steering linkage reduces cost, provides design flexibility.

• Complete isolation of load forces from the control station.

• Continuous, unlimited control action with low output torque.

• Wide selection of control circuits and meter sizes.

• Works with many kinds of power steering pumps or fluid supply. gear pumps… Eaton Series 26 gear pumps with 13-tooth gears minimizes flow ripple to reduce noise and vibration.

Bearing lubrication system uses inlet oil rather than high pressure oil, improving volumetric efficiency and power output. The 13 available displacements and many mounting configurations provide for an easy retrofit. Other series available.

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IMD 43

Seco QC Modular Toolholder Simplifies Swiss-style Machining For ease of use, the Seco QC Modular Toolholder allows users to remove both cutting heads and inserts as a single assembly, quickly index them and reinstall. Manufacturers may also use this system to exchange cutting heads and inserts with a second set for even greater efficiency. The QC cutting head also features double carbide pins for accurate, consistent and secure insert mounting and indexing. Seco Jetstream Tooling® technology precisely directs high-pressure coolant through the QC Toolholder to the cutting zone. Seco Jetstream Tooling® Duo, available on a selection of cutting heads, adds a second coolant channel to the underside of the holder. The second coolant channel can be switched off if needed for even more versatile machining.

High-Precision Scotchman Accu-Table The Scotchman Industry Accu-Table helps simplify critical control measurements. The high-precision caliper table measures material up to 16 feett. long to an accuracy of +/-0.004 inches. Its Windows® Tablet PC reads and stores measurements and can be accessed wirelessly over a network. The machine is available in 8-, 10-, 12-, 14-, and 16-feett. lengths. It offers repeatability of ±0.0015 inch.

Readings are displayed in inch or metric conversions. Accu-Table has capabilities for creating custom measuring solutions including calculating Statistical Process Control (SPC) data, creating graphs, charts and important production information. Made in USA.

» For more information, visit www.secotools.com

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SPRINTER MACHINES… • Provide reliable, low cost, ink code marking.

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44 IMD APRIL 2020

Clamp Virtually Any Workpiece Geometry with the Centco4 SMW Autoblok introduces the versatile four-in-one Centco4 2+2 self-centering and compensating chuck. The Centco4’s superb engineering and flexibility enables it to securely and efficiently clamp virtually any type or shape of geometric part including round, cubic, angular and irregular. The Centco4 is available in both power and manual models and is ideal for deformation-sensitive workpieces.

The 4-jaw Centco4 provides four times less deformation as compared with three-jaw clamping and can be used on all industryspecific machine tools. The ability to handle virtually any part shape means fewer chuck change-outs and vastly reduced downtime.

Diverse manual and hydraulic applications include turning, milling, inspection and finishing operations. » For more information, visit www.smwautoblock.com

Suhner Offers EconoMaster® Drilling Units for ValuePriced Production Use Suhner introduces the EconoMaster® line of drilling units, affordably priced at under $3000 for the basic unit, in stock for immediate delivery or customizable to suit the particular operation. This economical solution is ideal for multiple materials such as light metal, wood, composite, plastic and foam. Because these units are entirely produced at the Suhner factory in Rome, Georgia, response times for delivery and customized construction are fast. The EconoMaster® drilling unit features low power and air consumption, adjustable motor housing, adjustable total stroke up to 4”, hydraulic feed control cylinder, J33 taper spindle end, 0-1/2” drill chuck. » For more information, visit www.suhner.com/en

Universal Robots and RightHand Robotics Cobot-Powered Fulfillment Solutions With e-commerce generating the greatest year-over-year growth of all U.S. retail industries, there is now more warehousing space being built in the U.S. than projected warehousing jobs required to fill that space. When thousands of supply chain professionals were asked in a recent Materials Handling Institute survey what technologies would yield the greatest boost to productivity, ‘Robotics and Automation’ was their answer. RightHand Robotics’ RightPick platform has successfully completed many millions of picks autonomously across numerous industries, including e-commerce, retail, pharmaceuticals, grocery, and more » For more information, visit www.universal-robots.com

New MU5 double-sided indexable insert boosts reliability in steel and stainless turning With forged parts, particularly in automotive production, Walter’s MU5 geometry minimizes crater wear and enables reliable and fully automated production. For users with changing material demands and smaller batch sizes, the MU5 is appealing due to its universal use in steel and stainless materials. These characteristics of the MU5 insert are due to its positive macro- geometry, while maintaining a negative clearance. Other features include an open chip breaker groove for long tool life and soft cutting features, a V-shaped chip breaker for improved chip breakage, and a curved cutting edge yielding high surface finish quality. » For more information, visit www.walter-tools.com INDUSTRIAL MACHINERY DIGEST.COM

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IMD 45

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IMD 47

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ATTCO, Inc. DBA Syclone ATTCO Service — www.skyhookmfr.com ......................................... 13 Betenbender Manufacturing, Inc — www.betenbender.com ......................................................... 7

YEARS

Carell Corporation — www.carellcorp.com .......................................................................................17 COLE-TUVE Inc. — www.coletuve.com ............................................................................................49 Denver Breaker & Supply — www.denverbreaker.com .................................................................. 47 Design-2-Part Shows — www.d2p.com ............................................................................................48 DHM Associates, Inc. — www.dhmassociates.com ........................................................................49 Dynabrade, Inc. — www.dynabrade.com ............................................................................................ 5 Eagle Bending Machines — www.eaglebendingmachines.com ....................................................17 Essex Structural Steel Co. — www.essexstructuralsteel.com ........................................................ 41 Formdrill USA Inc. — www.formdrill-usa.com ................................................................................. 25 H&K Equipment, Inc. — www.hkequipment.com ............................................................................ 47 HMI div of Betenbender Manufacturing — www.betenbender.com ...........................................42 HYDMECH — www.hydmech.com ........................................................................................................1 IMTS | International Manufacturing Technology Show — www.imts.com ................................. 33 Kanetec USA Corp — www.kanetec.com ..........................................................................................45 KHK Gears — www.khkgears.us ........................................................................................................... 27 Lenzkes Clamping Tools, Inc. — www.lenzkesusa.com ................................................................... 3 L&L Special Furnace Co., Inc. — www.llfurnace.com .....................................................................49

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MacMillin Hydraulic Engineering Corporation — www.macmhydraulic.com ...........................43 Morgan Manufacturing, Inc. — www.morganmfg.com ..................................................................49 Pro-Line — www.1proline.com ............................................................................................................49 Radwell International, Inc. — www.Radwell.com .............................................................................. 2 RAS Machine Tool Technologies Inc. — www.rasmachinetool.com ........................................... 23 Royal Products — www.mistcollectors.com .....................................................................................49 Scotchman Industries, Inc. — www.scotchman.com ..................................................................... 15 Select Equipment Company — www.selectequipment.net ..........................................................46 Sprinter Marking, Inc. — www.sprintermarking.com ......................................................................44 Standard Direct.com — www.Standard-Direct.com ....................................................................... 47 Stor-Loc — www.storloc.com ............................................................................................................. 21 Stor-Loc — www.storloc.com ............................................................................................................. 52 The Grieve Corporation — www.grievecorp.com ............................................................................. 9 Tormach — www.tormach.com .......................................................................................................... 19 Trim-Lok — www.trimlok.com ............................................................................................................. 37 US Shop Tools — www.usshoptools.com ..........................................................................................11

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SERVING AMERICAN MANUFACTURERS FOR OVER

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