Office Apprenticeships Will Save Mid-Market Manufacturing Operating Visibility Expanding Reach with Additive Manufacturing NDMACDIG.COM IIndustrial MachineryDigest.com
MONTH YEAR 2018 FEBRUARY
3 Game-Changers in the Automotive Industry in 2018
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TABLE OF CONTENTS
COLUMNS
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FEATURES 20
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WORKFORCE DEVELOPMENT Office Apprenticeships Will Save Mid-Market Manufacturing By: Andrea Olson, MSC and CEO of Prag'madik
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BUSINESS 4.0 Solar Solutions: Why Every Manufacturer Should Go Solar In 2018
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TALKING SHOP WITH: DAREX
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SAFETY & MAINTENANCE Plan of Action: Establishing your Machine Tool and Spindle Service Program
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24
NEW TECH Operating Visibility
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PROCESS Expanding Reach with Additive Manufacturing
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INDUSTRY INSIGHTS 3 Game-Changers in the Automotive Industry in 2018. By: Andrea Olson, MSC and CEO of Prag'madik
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DEPARTMENTS 6 EDITORS LETTER 8 FROM INDUSTRIALMACHINERYDIGEST.COM 40 ON EXHIBIT 46 PRODUCT SHOWCASE 56 SURPLUS BUYING AND SELLING 61 CLASSIFIED 62 ADVERTISER INDEX ON THE COVER
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“With Siemens, I control my future.“ As a machine shop owner, I want to be smarter and more flexible in my manufacturing; I want to be more competitive. So when I invested in my CNC machine, I insisted on the control system that delivers the greatest returns. By choosing SINUMERIK CNC, I now have a greater return on my machines, my operations and my people.
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EDITOR’S LETTER As our industry changes, Industrial Machinery Digest has you covered in the latest developments of advanced technology. This February, we examine exciting applications of additive manufacturing, solar technology, and the game changers facing the automotive manufacturing and OEM suppliers in 2018. Our On Exhibit coverage focuses on the leading product and service providers for the aerospace and defense manufacturers at this year’s AeroDef Manufacturing show. Applying solar technology continues to make strides as the reliable form of alternative, renewable energy source for businesses. Even as the political climate changes, and monetary incentives from the government are reduced by the current administration, the overall benefits of solar technology remain clear. SunPeak, a commercial solar PV developer headquartered in Madison, Wisconsin, details why every manufacturer should consider going solar in 2018. Maintenance strategies allow those on the floor to diminish the threat of downtime to critical parts. From simple “first in, first out” programs, to panic level emergency programs, asset availability, production, and quality level remain top factors for maintenance procedures. Gilman Precision details how certain programs can establish a solid plan of action. Mid-market manufacturing continues to suffer from lost knowledge. Entry-level positions are often mistakenly thought as internships. Such programs offer a near no-cost alternative, to training and introduction of a career. Andrea Olson, MSC and CEO of Pragmadik details how apprenticeships combat the factors of lost knowledge and benefits recruiting talented future employees. Knowing the status of key machines has become critical. Ecoclean provides industrial robotic washers for surface processing. Encountering sporadic problems heating their washers, Ecoclean turned to Siemens for a solution to improve their operational visibility by equipping their robotic washers with Siemens SIRIUS 3RR Monitoring Relays. Roush, a full-service product development supplier headquartered in Livonia, Michigan, and subsidiary of Roush Enterprises, parent company of Roush Performance, has recently acquired the largest powderbed additive system. Over the last 15 years, Roush has continued to invest in the benefits of 3D printing for automotive, aerospace, defense, and consumer products. The industry is changing. This is not limited to just the application of 3D printed parts or tooling. As consumer demands for reliable EV (electric vehicle) transportation continue to rise, manufacturers and OEM suppliers will face many game-changers over the next few years. Stefan Issing, Global Industry Director for Automotive at IFS, details three that we will face in 2018.
Editor, Industrial Machinery Digest
LOOKING AHEAD Next month, IMD focuses on material handling. New automation solutions, advanced vision systems, and safer lifting options will be leading topics. Also learn how manufacturers can maximize their product stream with ERP systems. Our On Exhibit coverage will focus on MODEX, held this April in Atlanta.
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Editor, Nick Boliek nick@indmacdig.com 800-366-0676 ext. 104 | Cell: 205-381-1400 Fax: 866-826-5918 Creative Director, Clint Cabiness clint@dialedinmediagroup.com Cell: 205-613-5910 Ad Materials to: creative@indmacdig.com SALES Sr. Account Executive, Lisa Hanschu lisa@indmacdig.com 785-965-9159 | Fax: 785-965-7199 Strategic Account Executive, Warren Pinheiro warren@indmacdig.com 800-366-0676 ext. 200 | Cell: 205-567-2002 Fax: 866-826-5918 Account Executive, Michelle Casey michelle@indmacdig.com 239-898-5346 Fax: 866-826-5918 Media Adviser, Adrienne Gallender agallender@indmacdig.com 888-407-7737 Accounting, Susan S. Strickland susan@indmacdig.com 205-542-1098 Fax: 866-826-5918 Interactive Specialist, Sarah Mayo sarah.mayo@indmacdig.com 800-366-0676 Fax: 866-826-5918 Circulation & Subscriptions IMD, 3590-B Hwy 31 South, Suite 233 Pelham, AL 35124 Fax: 866-826-5918 • circulation@indmacdig.com Reprints To purchase article reprints please call 800-366-0676 ext. 103 or email wstrickland@indmacdig.com
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FROM Industrial Machinery Digest.com Toyota-Mazda Auto Plant to Bring 4,000 New Jobs to Alabama The new plant will have the capacity to build 300,000 vehicles annually, with production split evenly between two lines for each company to produce a new Mazda crossover model that will be introduced to North American markets and the Toyota Corolla. The joint venture represents a $1.6 billion investment that Mazda and Toyota plan to make with equal funding contributions. The site for the new plant in Huntsville sits just 14 miles from Toyota Motor Manufacturing of Alabama, which produces four-cylinder, V-6 and V-8 engines for several Toyota models.
Senator Gillibrand Visits Gear Motions to Discuss ESOP U.S. Senator Kirsten Gillibrand paid a visit to Gear Motions’ Niagara Gear facility in Buffalo, NY. After touring the plant, the Senator held a round-table discussion with Gear Motions’ employees to hear about their experiences working at a company with an Employee Stock Ownership Plan (ESOP). According to the National Center on Employee Ownership, workers in ESOPs have higher wages and benefits, are four times less likely to be laid off, and have 2.5 times more in retirement savings than workers not in an ESOP.
RÖHM Service Center Provides Cost-Saving Chuck Repairs and Rebuilds To better serve its customers, RÖHM Products of America has made significant investments in its ability to offer truly comprehensive chuck repair and rebuild services. In doing so, the company creates a one-stop shop for all chuck service needs. The RÖHM Service Center provides rebuild quotes and services that extend the life of valuable products. Most parts needed for these rebuild processes are in stock at the company’s Georgia facility, though large, complex or custom fixtures may require parts from the company’s German factory.
Wildeck Awarded Patent for Innovative EdgeAlert™ Wildeck, Inc., has been awarded U.S. Patent No. 9,834,975 for its innovative “Hazard Alert Device for Elevated Barrier,” know commercially as Wildeck’s EdgeAlert™ Open Gate Alarm System. The EdgeAlert™ alarm is easy to operate and can be installed on new or existing swing gates, slide gates, tilt gates and scissor gates. For maximum visibility at elevated and ground levels, ambercolored LED lights are located on the front and back of the alarm enclosure. .
The Biggest Manufacturing and Supply Chain Expo of 2018 is Coming to Atlanta MODEX 2018 opens on April 9 and will include over 850 exhibits from leading solution providers and a comprehensive Educational Conference of over 100 sessions focusing on best-in-class
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solutions for manufacturing and supply chain operations. Exhibits will represent all segments of the material handling, logistics and transportation industry, from traditional, manual equipment to computerized, automated systems and smart, connected supply chain technologies. The MODEX Conference will include four keynotes and new theaters on smart city logistics and connected supply chain solutions and transportation and logistics solutions.
Wildeck Receives MVS Award Material handling equipment and safety products manufacturer, Wildeck, Inc., has earned the prestigious MVS (Most Valuable Supplier) Award for 2018. The MVS Award is granted by the industry’s trade association, MHEDA (Material Handling Equipment Distributors Association). According to MHEDA, this prestigious award recognizes companies who have demonstrated an exemplary commitment to safety for their dealer network, their employees and their community.
Michael Bebout Appointed Tebis Account Manager for U.S. West Region Tebis America has announced the appointment of Michael Bebout as Account Manager for the company’s West Region. Bebout, who brings a strong background in software sales and marketing management, will handle the West Region U.S. for Tebis and be based in Southern California. He was most recently with Vero Software in a senior sales position as Direct Account Manager. Prior to that, he was a Territory Sales Manager for Ketiv, an Autodesk reseller.
New Building for transfluid Makes Space for Further Progress Advanced ideas require development space in order to optimize tube machining processes through the introduction of perfectly suited solutions. This already applies to prototyping, and of course to fully automated complex production systems. This is why the solution finders from transfluid have now further extended their production area by an additional 1000 square meters, to a new total floor area of 7000 square meters. The additional space and latitude afforded by this new-build also stands to benefit the in-hour Prototyping department at transfluid.
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BUSINESS 4.0
S
OLAR OLUTIONS
E
very manufacturer should go solar in 2018. That may sound like a bold, overly broad statement to the average manufacturing business owner, and it’s understandable why. For decades solar power expansion has suffered from barriers like upfront expense, technological insufficiencies, and the consumer belief - however misguided - that solar power isn’t viable in parts of the world that seemingly don’t get much sun. However, after a decade of favorable market shifts, government incentives, and data collection on the efficacy of solar around the world, each of those barriers is crumbling, making cheap, sustainable energy realistically accessible to businesses nationwide. Going solar in today’s market isn’t simply a good idea, it’s become an imperative.
THE FINANCIAL INCENTIVES MAY NEVER AGAIN BE THIS GOOD The solar power industry is currently benefiting from market factors that make going solar an effective cost-savings strategy for manufacturing businesses with notoriously sizeable utility bills. For one, since 2010 energy produced via solar systems has been getting steadily cheaper than traditional energy sources offered through local utilities. Secondly, the depreciating cost of lean, grid-connected solar systems also allow businesses to spend less upfront and start producing a return on their investment sooner.
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Why Every Manufacturer Should Go Solar In 2018
BUSINESS 4.0
As a matter of fact, the average operation installing a turnkey photovoltaic (PV) system, like the ones offered by Midwest-based solar system provider SunPeak, can expect to produce carbon neutral energy at about half the cost of utility produced energy. As the cost of traditionally produced energy from oil, gas, and coal continues to rise, this gap between sustainably derived energy and traditional sources will only widen. Though we can count on traditional energy sources to rise in price as nonrenewable resources inevitably do, we cannot count on tax breaks and subsidies for the solar industry to always stick around. The federal government currently offers a 30% tax credit to help cover the cost of solar system installation through 2022, while some states like Illinois go even further. In the most recent legislative session, the Illinois legislature created a cash payment system that covers another 25% of the cost of solar installation through the Illinois Power Authority (IPA). In some states with additional solar subsidies and tax breaks, businesses can have their installation costs reduced by as much as 75 percent. For those daunted by the prospect of navigating a potentially complicated system of financial incentives and cost-benefit analyses, the aforementioned SunPeak also provides free financial feasibility studies, which include an analysis of any public benefits and solar tax breaks available in your region. Solar providers like SunPeak don’t expect their customers to go solar based on blind faith, and instead work as hard as possible to make the process transparent and stress-free. Continued technological progress will likely make solar systems more and more affordable in the long run, however, these massive public financial incentives will probably disappear at some point in the next five years as solar power becomes more popular. For US manufacturers working hard to stay competitive, going solar could
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be one of the biggest game changers, and now is the time to take advantage of these temporarily favorable market conditions, as well as any free feasibility studies offered by individual solar providers.
SOLAR POWER WORKS EVERYWHERE FOR EVERYONE Atmospheric scientists and solar engineers measure the rate of sunlight hitting the earth, known as solar insolation, in kWh/per area/per year, which allows us to predict how much solar power can be generated in a given region. Germany, the world’s leading producer of solar energy, actually experiences a lower rate of solar insolation than any other state in the United States, except Alaska. Despite these lower levels of sunlight in places like Germany and Spain, solar technology has advanced to the point that it’s still highly effective at offsetting traditional energy consumption. This data proves that even the Northernmost states of Wisconsin, Minnesota, and Maine can consider solar as a real alternative to nonrenewable energy sources. Another common misconception is that even if solar power is viable in the summer months in Northern parts of the US, it will be virtually useless in the winter. However, US rates of solar insolation during the wintertime still allow for solar power to be cost-effectively generated in cold-weather states. Winter is also a time when energy costs and energy usage typically goes up, making solar power an ideal solution for offsetting those increases. One of the benefits of grid-connected solar systems is that they produce renewable energy for the entire community, not just the operations that utilize those systems. When enough homes and businesses in a given area go solar, energy costs for the community as a whole go down, allowing families running on tight budgets to have an easier winter. Overall, the impressive levels of solar energy produced on an annual basis far outweighs the reduced production rates in cold weather months, and combined with the monetary incentives available to
businesses, manufacturers budgeting for high utility costs could realistically save hundreds of thousands of dollars just from offsetting a portion of their total energy expenditure with solar. Another perceived structural barrier that impacts manufacturers specifically when it comes to installing solar panels is the incompatibility most solar systems have with flat rooftops common on warehouses and plants. However, SunPeak’s globally experienced solar power engineers utilize an exclusive East-West mounting system designed to accommodate flat roofs, while still looking aesthetically pleasing from the ground. These low lying panels are placed in compact formations that result in higher energy production per square foot, thus making the most of the surface area SunPeak’s customers have to work with. Unlike the more commonly used South-facing solar systems, this unique East-West solar panel formation is lighter and lower maintenance, with a more consistent power output that mitigates the typical noon production spike while lengthening power duration in the morning and evening hours. SunPeak’s design also helps Northern states with shorter daylight hours during winter months make the most of the sunlight available to them. With an operation headquartered in notoriously frosty Madison, Wisconsin, this company knows what they’re doing when engineering winter-friendly solar systems around the world. These technological advances offered by exceptionally innovative companies like SunPeak combined with positive market forces have made renewable energy systems an economic imperative that businesses of all sizes now need to consider, which is why 2018 should be the year American Manufacturing goes solar. Other nations around the world competing in the global manufacturing market are noticing the viability of solar, and US companies have a limited window to upgrade their energy production and consumption in order to keep America making things.
About SunPeak SunPeak is a commercial solar PV developer headquartered in Madison, Wisconsin. We have the capability to professionally assess feasibility, design & engineer, install, commission, and maintain solar systems that provide decades of emission free electricity from the sun throughout the United States (focusing on Wisconsin, Iowa, Illinois, Minnesota and Michigan.) The SunPeak team is responsible for successfully installing over 450 MW of renewable energy globally, including solar reference projects as distant as Germany, Japan and Canada. This international experience in the solar market allowed us to foster extensive relationships with the world’s best-in-class solar racking, panel, and inverter suppliers, ensuring an optimal blend between cost effectiveness and performance. SunPeak only works with leading solar component manufacturers, who offer proven technology and solid warranties we know we can stand by. For more information, visit www.sunpeakpower.com
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TALKING SHOP
TALKING SHOP WITH
Q: How would you describe your company’s primary business? A: Darex is a 4th-generation family owned company in Ashland, Oregon. For over 40 years we have been creating industry-leading sharpening tools here in the USA.
transforming as well as how people work and live is fascinating. It is an interesting time to be part of and we plan to keep our focus on what our customers’ needs and wants are while empowering our coworkers to continue to innovate.
Q: What difficulties have you faced in the American market this Q: In brief, what is the history of your company. A: Darex began in 1973 in Beecher, Illinois. The D, A and R of DAREX past year? are the initials of three generations of the Bernard family; David, A: This past year the American market has been good. The economy Arthur and Richard Bernard. David and his father Richard founded Darex. Grandfather Arthur Bernard, who earlier founded the Bernard Welding Company, contributed his energy and guidance to Darex. In 1978, Darex relocated to Ashland, Oregon where we are located today. In 2012, Matthew Bernard became the fourth-generation family owner of the company. . Q: How has Darex changed through the years? A: Innovation. We have gone from all manual machines that required tooling to now having a fully automated 4 axis CNC Drill Sharpener.
seems to be up and our industry seems to be spending money again. It has been a lot of fun to see excitement and urgency in manufacturing again.
Q: What successes has your company had since last year? A: We are on pace to grow this year compared to last year. Anytime we can grow in a non-IMTS year we are doing something right..
Q: What do you want to see in the future for the industry? A: Steady growth and Innovation. A focus on technology as well as superior products and customer focus.
Q: What are your thoughts on Industry 4.0, or the fourth Industrial Revolution? A: The combination of technologies and velocity at which they are 14
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For more information, visit www.darex.com
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AMERICAN MANUFACTURER
SAFETY & MAINTENANCE
PLAN OF
ACTION
Establishing your Machine Tool and Spindle Service Program
I
f a spindle breaks down, what is your company’s plan of action? Is it the most practical and efficient way to deal with a down spindle? Spindles need maintenance at varying intervals, based on the length and design of their operation. Normal use of any machine will cause wear and tear, the spindle being the component that receives the majority of the wear. It is necessary for them to run at the right speeds and feeds to keep the wear minimal. Because of this, a good spindle program should take into consideration the specific operational information of each, individual spindle. Companies need to have a well-planned maintenance strategy in order to be successful compared to their competition. A faster and
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newer machine does not automatically mean that your company will keep the competitive edge. When a spindle breaks down, the company that manages their machine proactively will reduce downtime and expenses resulting in an increase of productivity. This will significantly boost your company ahead of your competitors. The process of managing your machine includes developing a machine tool and spindle service program. It is important to establish an effective machine tool and spindle service program to achieve a high level of overall equipment performance. Overall equipment performance is a measurement of performance comprised of three factors: asset availability, production, and quality level. The following
SAFETY & MAINTENANCE
four programs display the different types of procedures used when a spindle goes down. These range from the most basic plan of action to a highly advanced plan.
can take weeks or months before it is back up and running. This can put production behind, which can set your company back from your competitors.
The Emergency Program
The Scheduled Program
You can compare the emergency program to hitting the panic button. If an important spindle breaks down, the company will do whatever it takes to get that spindle repaired as soon as possible. No matter the expense, the company will have it shipped and serviced with the highest-priority. Repairing the spindle immediately reduces downtime, but the costs add up because of the urgency, making it less practical than other programs. Gilman Precision accommodates to this type of program by offering the option of a rush order service.
Routine maintenance checkups are performed when using the scheduled program. The checkups are scheduled based off the previous maintenance records. This program provides the spindle with enough attention to keep the spindle running in good operating condition. However, it does not take into consideration fluctuating hours of operation, environmental considerations, or whether or not it even needs to be serviced. The problem is the spindle could be running fine, but time and money may be lost because of unnecessary services.
The “First In, First Out” Program
The Spindle “Hotel” Program
The “first in, first out” program works as if there is no program at all. There are no precautions taken, such as scheduling routine maintenance checkups. Similar to the emergency program, if a spindle breaks down, it is simply taken in to be serviced. The difference is there is no urgency to fix it. This program may be impractical, especially if the spindle that is down is important. There is no priority put on it when being serviced which means it
The spindle “hotel” program takes preventative measures by possessing more than one spindle that is exactly alike. The spare spindle acts as a replacement in case the main spindle breaks down. The spare is kept either on site or at a designated repair facility. The positive to this is that downtime remains low. If the spindle breaks down the spare replaces it and the production does not have to stop to wait for it to be fixed.
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program is the best fit for your company should not only align with the goals of the company, but should be individualized to all your spindles. Monitoring your spindles can save it from unpredictable damage and allow it to maximize its production. Reducing unnecessary downtime and costs can help push you ahead of the competition. If you are questioning what you are going to do when a spindle breaks down, it is time to implement a strategy that will optimize your overall equipment performance..
About Gilman Precision Since 1952, Gilman Precision has been dedicated to the advancement of high precision linear & rotary motion solutions that improve efficiency and achieve longevity. Gilman develops customized slides and spindles for value-minded engineers with exacting needs and standards, and provides expert service for virtually any manufacturer’s equipment. Serving
The downside to this program is that the amount of capital sitting in the “hotel” could outweigh the convenience of the program. If this is the type of program your company follows, Gilman Precision provides a Spindle R&R service that allows any spindle to be housed for up to 12 months after being repaired. The most important consideration to factor in when deciding on a program is the goals of the plant. The program followed needs to align with the company’s objectives. Deciding what spindle service
a variety of industries and applications, these engineered solutions are advanced by a highly skilled, knowledgeable and experienced team that delivers on-time and within budget. Only the highest level of quality can be expected when you put Gilman Precision experience and expertise to work for you. For more information, visit www.gilmanprecision.com
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WORKFORCE DEVELOPMENT
Office Apprenticeships Will Save
BY: Andrea Olson
Mid-Market Manufacturing W
e talk a lot about apprenticeships within manufacturing, and
Internships vs. Apprenticeships
MSC and CEO of Prag’madik
many skilled positions require an apprenticeship prior to full
Apprenticeships are used across all roles and industries in Europe.
time employment. Yet with many mid-market manufacturers strug-
Just search for ‘office apprenticeships in the UK’ and you’ll find open,
gling with a wave of Baby Boomer retirees and business owners
paid positions ranging from Business Administration to Product
making challenging decisions on who will take up the mantle when
Management.
they step away from the organization, apprenticeships are more important than ever.
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Here in the US, we look at these entry-level roles in the “front of the house” operations as internships. Internships and apprenticeships
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both give you hands on training, but that’s where the similarities end. Internships in the US are readily available for most college students through their school or university and are often generalized rather than specified for a particular trade or industry. When it comes to an internship, most people either do it for a semester or summer and then move on to the next one or get hired full-time. With an apprenticeship, it can take years to complete and requires a full-time commitment. An intern gets work experience, but an apprentice gets more than that - it typically has classroom instruction attached to it. As we look to replace the “brain drain” that is occurring within manufacturing, the industry needs to start examining how to capture this knowledge and transfer it to the next generation through apprenticeships.
Transferring Tribal Knowledge Consider a Baby Boomer who has worked in a specific manufacturing industry for 30+ years. They have worked in
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WORKFORCE DEVELOPMENT
product development, and understand the historical changes in the
marketing campaign or developing a new service protocol. Often intern-
product designs, how they function in the field, and how customers
ships give people college credits, a small stipend or something to add to
can effectively maintain and service them. They have learned the
their resume, but doesn’t add value to the employer. The difference with
nuances. They know what the competitors have developed and
an apprenticeship versus other types of training is that it can be directly
where they are going next.
tied to addressing knowledge transfer instead of simply teaching tactical
Enter the young, recent engineering graduate with no background in the industry. How can this ‘tribal knowledge’ be effectively trans-
skillsets of low value. This is most critical to those industries where hands-on experience is key.
ferred? Is a traditional internship sufficient, where they typically work
Think about those ‘softer’ areas in your organization where you have
on small, insignificant projects and only learn the basic processes and
core team members that know your customers and industry inside and
operations of the company? Or is a full-fledged, paid apprenticeship,
out - sales, marketing, customer service, product development, tech
where the new hire is required to capture in-depth knowledge of the
support and human resources. The difference in these individuals is
industry and product history more valuable?
their experience, not solely technical training. Leveraging the concept of
Anyone who has completed an internship knows you aren’t going to have too much responsibility. Yes, you’ll get to see how the marketing department works or how customer service operates, but chances are you won’t be creating a
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office apprenticeships will enable manufacturers to bring in more young talent to the industry, retain organizational knowledge and set the stage for long term growth in the future. Dump the internships and trade up for apprenticeships.
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NEW TECH
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leaning and surface processing are important production stages in many manufacturing industries, especially automotive. For example, machined parts and sub-assemblies must be thoroughly clean before they move into subsequent stages of assembly or coating. Metal burrs, filings and dust from machining, plus oils and other surface contaminants caused by previous production steps must be removed. And surface processing is a critical adherence requirement for any component that will have a specialized coating or paint applied or be subject to some sort of surface conditioning. Ecoclean is a global leader in providing the kind of industrial robotic washers these industries need. Its automotive customers include car and truck manufacturers as well as engine makers for those vehicles. In particular, they use the company’s EcoCFlex and EcoCAgile systems to clean powertrain, engine and transmission parts with heated, water-based soap solutions, including cycles with pressures of up to 10,000 psi before they move to assembly lines for installation. Downtime for this equipment can disrupt those assembly lines, costing hundreds of thousands, if not millions, of dollars in lost production.
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with Siemens SIRIUS 3RR Monitoring Relays.
Monitoring Health Unfortunately, early versions of the EcoCFlex Classic robotic washers were having sporadic problems heating water. That’s the job of up to two large immersion heaters located in the bottom of a tank holding as much as 1,000 gallons of water. Ecoclean uses various size heaters in its washers, from 8kW to 90kW, drawing three-phase 480 VAC. Each heater comprises several heating elements connected with a fuse and a simple on-and-off contactor to energize them. The washer tank water can take from 1.5 to 2 hours to heat, depending on the washer model’s tank size. The main symptom of a heating problem was excessive heating times. Due to the heaters consisting of several heating elements, the issue might have been a blown fuse or an open element
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NEW TECH
pulling less current than it should. But operators were finding it hard to identify the offending element, forcing a technician to go inside the tank, draining all the water, forcing a refill, and do the needed troubleshooting and repair. The task could take the better part of an entire work shift, slowing down production, if not stopping it altogether. According to Les Brumar, Ecoclean’s manager of Controls Engineering, the heater failures were occurring often due to damage from the coarse debris that would accumulate at the bottom of the tanks on top of the water heaters. “Our customers typically put two washers on a line,” he explains. “The first is a primary wash, which cleans a lot of large refuse, such as aluminum or cast-iron shavings, from rough broaching and drilling operations. The second provides more thorough cleaning at the end of the line, but also accumulates debris.” While the Ecoclean washers have a pump and filter to remove suspended particle matter, heavier debris from objects like 500-pound engine blocks and cylinder heads fall through a grate to the bottom of
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the tank. The heavy debris is then cleared every few months as part of the washer’s maintenance schedule. “One or two workers enter an empty tank, remove the grate and shovel out the debris,” Brumar says. “But in doing that, they can inadvertently damage the heaters. Even a small pin-hole in their housings can cause trouble, so we installed shields. But, sometimes, too, a combination of soaps and oils or coolants from prior operations would create a tar-like sludge on top of the heater elements, causing excessive heat at the elements and damaging them. Clearly, Ecoclean needed a better indication of heater performance in their industrial washers. “Because the elements heat such a large tank of water, we initially just monitored the water temperature and when it reached the desired set point, the heaters automatically turned off,” Brumar says. “Since we expect it would take a pre-determined amount of time to heat a given volume of water, timers were the only way back then that we had to know the heaters were working properly,” he adds. “But we realized we had to figure out how to alert operators to an impending
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heater failure, so they can manage the heating process with the other heaters inside a tank. That way, they could schedule preventive maintenance and repairs before an under-temperature situation slows down or shuts down an assembly line.”
Improving Operating Visibility Seeking a solution, Brumar first contacted Ecoclean’s heater supplier. They suggested that the thermocouple in each heating unit be connected to a temperature controller for monitoring. An alarm contact on the controller could then alert an EcoCFlex operator as to whether a heater was working or not. Brumar and his team tried this approach but found it didn’t work. “The problem was that the thermocouple device was mounted to only one of many elements inside each heater,” Brumar recalls. “So, while one element might be fine, others might not be, resulting in the heaters pulling less current and causing long heat-up times again. This delay would then create a bottleneck on the production line, causing customers to lose throughput.” After finding the thermocouple solution insufficient, Brumar shared his vexing issue with his local Siemens representative, who suggested trying a Siemens SIRIUS 3RR Current Monitoring Relay to monitor the power drawn by each heater. “It worked,” he says. “After all we had gone through to fix this issue we were elated to find a reliable way for our customers to tell if the heaters in our washers were working properly.” Ecoclean’s industrial washers are now using a three-phase standard version of the SIRIUS 3RR current monitoring relay. In addition to motor loads this relay can monitor multi-element heater loads and detect single element failures and alert maintenance prior to subsequent failures which lead to extensive downtime and repair. It provides a visual display for operating and diagnostic messages. The relays are directly mounted to a Siemens 3RT contactor and can also be mounted on DIN rail when using third-party contactors. In turn,
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they can communicate with the washer’s third-party PLCs. If analog current monitoring is desired the 3RR Current Monitor Relay with IO Link can be used. “We chose the size of the SIRIUS 3RR relay that’s appropriate for a washer heater’s current range, then set the minimum amps, and if a heating element falls under that, we alert the operator to a problem,” Brumar says. “Take, for example, our 45kW heater. It should pull 52 to 54 amps, so we set the monitored limit at between 48 and 50 amps and if while operating the heater current falls below 50, we alert the operator.”
Preventing Production Bottlenecks Today, Ecoclean uses the Siemens SIRIUS 3RR Current Monitoring Relays as standard components in all its robotic washers to keep operators informed of their unit’s water heating performance. But the big benefit of the Siemens SIRIUS 3RR relays goes to Ecoclean’s customers. “Now, if the Siemens 3RR relays show diminished or no amps being drawn, a plant electrician can check for blown fuses or open elements that are operating at reduced power and therefore causing long heat-up times,” Brumar says. By adding this capability, Ecoclean’s washers can help a factory support condition-based and predictive maintenance models. That’s because each washer can have up to two large immersion heaters and heat-up times are proportional to how many heating elements are working at any given time. “If a tank heater loses a few elements, it might extend heat-up times by several minutes or even hours,” Brumar says. “But at least the operators are aware that those heaters will need repair soon or that sludge might be building up. They can then schedule interim maintenance inside of our washers’ required maintenance windows.” Brumar points out the value that the added visibility provides: “By knowing some heaters have failed or are failing because their drawn
Siemens Industry, Inc.
amps are dropping, operators can then choose to nurse it along until a time when production is slack and doing maintenance and repair won’t impact the production line. That can save the plant a small fortune in lost output.”
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PROCESS
Expanding Reach with
Additive Manufacturing
PRODUCT DEVELOPMENT SUPPLIER BUYS WORLD’S LARGEST POWDERBED ADDITIVE SYSTEM TO EXPAND REACH IN MULTIPLE INDUSTRIES
Today Roush is the first service supplier in North America with
The company has expanded its additive manufacturing capabilities
the largest metal additive manufacturing system of its kind. Additive
with equipment to benefit multiple industries, including aerospace,
manufacturing is a process that creates a physical object from a
automotive, defense, energy, entertainment, medical and consumer
digital design.
products.
Roush has purchased the Xline 2000R, the largest powderbed
“During the past year, Roush has invested millions of dollars in
metal additive system in the world. Acquired by GE Additive in 2016,
new additive manufacturing equipment to expand our reach into
the Xline 2000R from Concept Laser has a build envelope of 800 x
more industries,” said Dean Massab, executive vice president of
400 x 500 mm for large-scale production, such as engine blocks. The
business development for Roush Enterprises. “Investing in the latest
machine includes a rotating platform that allows two build modules
additive manufacturing technology continues our commitment to
to be used reciprocally.
innovative, high-performance solutions — from concept maturation
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SAFE AND EASY
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HOIST RINGS ARE: Roush Performance and optimization, all the way through to hardware integration and development.” Roush has been providing additive manufacturing and rapid prototyping services, commonly known as 3D printing, for more modeling with large-frame machines from Stratasys; direct metal
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additive and topology optimization to its existing stereolithography, selective laser sintering and rapid prototyping services. The company’s services that support additive manufacturing
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capabilities include 3D scanning; metallurgical testing and inspection; machining, fabrication and assembly; and full-spectrum design engineering. Increasing these additive manufacturing capabilities and topology optimization technologies complement other Roush
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offerings, such as performance testing, product design and advanced engineering. “Roush is a single-source product development supplier for customers,” said Brandy Badami, business development manager, additive manufacturing for Roush. “Our unique advantage in the additive manufacturing industry allows Roush to provide seamlessly integrated services like no one else can.” Roush’s new 3D printing capabilities also include working with advanced materials, such as production-grade thermoplastics and carbon fiber-filled nylon material. Aerospace industry customers will benefit from Ultem materials (used in production aircraft components) with their high heat and chemical resistance, and certifications
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| FEBRUARY 2018 | IMD |
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PROCESS of the carbon-fiber-filled nylon material for
composite parts to have exotic geometries
of Defense Trade Controls (DDTC) regis-
high performance components.
that cannot be manufactured by traditional
tered for tanks and military vehicles, aircraft
means.
and associated equipment, military training
Also with these advanced materials, Roush can 3D print sacrificial tooling for composite
Roush is International Traffic in Arms
components and parts. This allows for
Regulations (ITAR) compliant and Directorate
equipment, spacecraft
auxiliary systems
military and
equipment, associated
equipment. “Our
clients
are
achieving
market
dominance faster and with better performance with these expanded opportunities in additive manufacturing combined with Roush’s leading expertise in innovative design, engineering and development services,” said Badami.
About Roush Roush, a full-service product development supplier headquartered in Livonia, Michigan, has over 4,000 employees in facilities located throughout North America, Europe and Asia. Widely recognized for providing engineering, testing, prototype and manufacturing services to the mobility industry, Roush also provides significant support to the aerospace, defense and theme park industries. Roush is a subsidiary of Roush Enterprises, Inc., which is also the parent company of Roush Fenway Racing; Roush Performance, developer and manufacturer of performance vehicles and products for the automotive aftermarket; and Roush CleanTech, developer and manufacturer of alternative fuel systems for the fleet vehicle market. For more information, please visit www.roush.com.
About Concept Laser Concept Laser GmbH, which was founded in 2000 by Frank Herzog, is one of the world’s leading providers of machine and plant technology for 3D printing of metal parts. Since December 2016, Concept Laser has been part of GE Additive, a division of the world's leading digital industrial enterprise General Electric (GE). GE Additive was founded in 2016 and acquired 75% of the company shares of Concept Laser, among others.
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Roush Performance The technology driver is the patented LaserCUSING® technology from Concept Laser. The powder-bed-based laser melting of metals opens up new freedoms when it comes to configuring parts and also permits the tool-free, economic fabrication of highly complex components in fairly small batch sizes. The company’s customers come from many different sectors of industry, for example medical and dental technology, the aerospace industry, toolmaking and mold construction, the automotive industry and the watch and jewelry industry. Among other materials, Concept Laser’s 3D metal printers process powder materials of stainless steel and hot-work
steels, aluminum and titanium alloys and – for jewelry making – precious metals. In addition to first-class additive production machines, also from Concept Laser, GE Additive offers materials and extensive development consulting for various industries. GE Additive is dedicated to the further development and transformation of the industrial sector with software-defined plants as well as networked, adaptable and forward-looking solutions. For more information, visit www.concept-laser.de
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INDUSTRY INSIGHTS
3
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3
GameChangers
in the Automotive Industry in 2018
By: Stefan Issing
Global Industry Director for Automotive at IFS
N
ew data-driven services, strong light-weight materials and a rapidly built out infrastructure for EVs (Electric Vehicles) are trends impacting the automotive industry the coming year.
1) Service revenue in Automotive will increase by 30% during 2018 When German car manufacturers Opel first launched in 1863 they made sewing machines, switching to cars in 1899. Peugeot milled corn and then steel for eighty years before turning their hand to cars in 1891. So, although it’s sometimes seen as conservative, the auto industry has change woven deep into its DNA. Today’s automotive leaders need to show the same resilience, agility and adaptability so as not to fall behind when their competitors invest in new digitally-driven services. Take the Schaeffler Group, one of the world’s largest suppliers of bearings, clutches, torque converters and transmission systems to the automotive industry. In 2016 it sold automotive parts worth US $10.88 billion and announced a new digital strategy for its automotive operations. In October 2017 Schaeffler acquired autinity systems GmbH, a German IT company specializing in digital condition monitoring and machine data recording. Schaeffler CEO Klaus Rosenfeld said to US trade weekly Automotive News, “The scenario we prepare for assumes that in 2030, globally, 30% of the 120 million vehicles produced in the world could be purely battery-driven. Change is nothing new to us. We have great experience with changing our product portfolio with new technology.” And Schaeffler is not alone. One IFS client, a major automotive supplier, recently finalized an important new contract in which it not
only produces and supplies parts for the OEM, but collects data from the parts too, using it to carry out aftermarket services for dealers. This includes providing data for spare parts that may be needed for recalls and completing the spare parts documents directly at the dealers. If it sounds futuristic, think again. The supplier starts implementing the contract in one month’s time. But it is a radically new scenario. Going from just producing components to producing customer schedules, and handling and managing spare parts throughout for the OEM, including warehouse management, requires connected business systems and thinking. But as Klaus Rosenfeld points out, the clock is ticking.
Start today. Tomorrow will be too late Today’s gasoline cars typically require around 30,000 parts. EV cars require around 10-12,000. Britain and France will both begin phasing out gasoline cars by 2040, Paris has said it will ban gasoline cars in 2030, India wants all EVs by 2030. For manufacturers of components like exhausts (that don’t even exist in EVs), servitization is a lifeline. But they need to start counting backwards from 2020, 2030 and 2040 today—and get ready. It takes time to integrate the kind of enterprise software that will ensure the agility and capacity for this change. Waiting is no longer an option.
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| FEBRUARY 2018 | IMD |
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INDUSTRY INSIGHTS
2) New lighter, stronger materials like CFRP will be the new silver bullet What’s it going to be—lightness or safety? And why can’t we have both? Well, we can. But for many years automotive manufacturers have faced a dilemma, as they’ve tried to satisfy conflicting demands: One for lighter vehicles, that produce less CO2 emissions, and another for safer vehicles, that, paradoxically, require heavier components. In 2018, we will see an accelerating uptake of a new generation of materials that are lighter and safer—meeting tougher regulatory demands for safer vehicles that simultaneously emit less CO2. Materials like aluminum and high-tensile steel will become standard. And the exceptionally strong, safe engineered plastic CFRP (carbon fiber reinforced plastic), currently used mainly in sports cars, will start to be used more in other vehicles. Also called carbon-fiber laminate, CFRP is made of woven layers of tough, almost pure carbon fibers, bonded by a hardened plastic adhesive like epoxy resin.
Increased R&D in CFRP will bring down costs The new materials are expensive. A new study from Goldman Sachs, Cars 2025, shows CFRP is currently 40 times more expensive per kilo
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than normal steel. Plus it takes more specialist skills and equipment to produce. But developers are collaborating with universities across Europe on research in new plastic and carbon laminate materials. As uptake in regular vehicles accelerates, costs for high-tensile steels and aluminum could well fall, and ultimately the cost of CFRP too will come down as new production methods emerge. What will not change are regulatory demands on emissions and safety—and these materials are the solution to that.
3) 1 in 4 new cars will be an EV by 2022, and complete electrification could occur by 2027 Recent fluctuations in the fortunes of EVs are important, with 7.7% fewer EVs being sold in 2017 than in 2016 (when, famously, sales passed 2 million worldwide). The overall trend toward wider EV uptake is solid. But even in in China, where a strong, central government has legislated clearly for EVs, two major roadblocks remain: a lack of standardized charging stations, and battery capabilities. China leads in the number of charging stations it has, with approx. 150,000 public charging points, and plans to install enough to support 5 million EVs by 2020. But lack of standardization on the ground presents a big problem for customers. A September 2017
INDUSTRY INSIGHTS
Citylab article dives deep into how China handed out subsidies to a wide range of private companies to build charging stations. The result being that almost every station uses different payment models and takes anywhere from one to eight hours to recharge a vehicle, depending on its operator and which of the dozens of EV manufacturers it serves. One Chinese hybrid consumer said, “I’ve tried charging my car away from home, but couldn’t, either because the charger head would not fit, or I had to buy a pre-charged card.” It’s a clear warning to regulators, government and manufacturers that even in countries where EVs are actively being promoted, without standardized charging, EVs could take longer than previously predicted to reach their market potential. Batteries too remain an issue. Accelerating research into hydrogen fuel cells and recent Japanese government targets to significantly bring down the cost of fuel cells by 2025 are all encouraging. And the business potential for battery development too, estimated currently at US $240 billion, remains huge, and hard fought for. But right now there are no clear winners. Manufacturers and OEMs need to keep their eyes on the big picture. A McKinsey July 2017 report on the car industry in China found sales of locally produced EVs would grow.
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“The domestic industry’s growing production share of EVs rose from 18 percent in 2016 to 23 percent in 2017, providing proof that Chinese brands may increase their presence in the EV segment as more car buyers recognize that Chinese carmakers produce acceptable EVs.” And McKinsey continues to keep China at the top of its Electric Vehicle Index. So the time has come for EVs. But batteries and standardized charging remain serious bumps in the road, holding up the speed of development the industry had previously aimed for.
About IFS IFS develops and delivers enterprise software for customers around the world who manufacture and distribute goods, maintain assets, and manage service-focused operations. The industry expertise of their people and solutions, together with commitment to their customers, has made IFS a recognized leader and the most recommended supplier in our sector. Their team of 3,500 employees supports more than one million users worldwide from a network of local offices and through their growing ecosystem of partners. For more information, visit www.ifsworld.com
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AeroDef
Dates: March 26-29 | Exhibits: March 27-28 Long Beach (CA) Convention Center For the future of the aerospace industry, look no further than this year’s AeroDef Manufacturing show produced by SME. Featuring not only the top suppliers and manufacturers in the aerospace and defense manufacturing industry, AeroDef will also host panel discussions, technical sessions, and workshops. For more information on AeroDef, visit www.aerodefevent.com
EXHIBITOR HIGHLIGHTS AERODEF | BOOTH: 963 BLM GROUP USA New LT8.10 Fiber Laser With its 3 kW fiber laser, the LT8.10 provides excellent flexibility for precise laser cutting on a variety of materials for tube diameters up to 9.5 in. (241 mm). The system is ideal for cutting highly reflective materials such as brass, copper and aluminum and can process round, square, rectangle, special shaped tube or bar and open profiles with ease. The standard cutting head configuration of the LT8.10 has a tilting axis (± 45°) which makes it possible to do chamfers and other non-orthogonal cuts. For more information, visit www.blmgroup.com
AERODEF | BOOTH: 930
Optical CMM 3D Scanner: Metrascan 3D Unexpected costs, production and part approval delays from non-conformities are no longer an issue when using Creaform’s portable optical CMM 3D scanner, the MetraSCAN 3D. Help operators better manage processes and respond faster to the industry’s increasing quality control (QC) requirements—all without compromising the manufacturing throughput. Optical metrology provides measurement accuracy that is insensitive to the instabilities of the environment, making the MetraSCAN 3D optical CMM the prime choice for shop-floor quality control metrology. For more information, visit www.creaform3d.com AERODEF | BOOTH: 1146
IG 280 SD Rotary Surface Grinder The IG280SD is designed with glass, ceramic, carbide and crystal fabrication in mind. It can be used in any low, mid or high-volume applications. The programmable control saves grind parameters by part number for repeatable process automation. The servo driven Z-axis delivers true feed rates and repeatable positioning. An electromagnetic rotary chuck with electronic sensed demag is standard while optional configurations may include mechanical, vacuum, pneumatic or hydraulic work-piece fixturing. For more information, visit www.dcm-tech.com
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AmCon Design & Contract Manufacturing Expos See Manufacturing’s latest cutting-edge technologies at any of our upcoming shows
Spring 2018 Schedule Seattle (Bellevue), WA February 19-20 Kansas City, KS April 3-4 Denver, CO April 24-25 Louisville, KY May 15-16 Orlando, FL May 22-23 FREE ADMISSION • FREE ATTENDEE PARKING • FREE SEMINARS • 3D Printing • Design • Engineering • Prototyping • Machining • Cutting • Grinding • Forming • Fabricating • Rubber • Plastics • Components • Castings • Molds • Tools • Dies • Patterns • Finishing • Assembly • Fixtures • Electronics...and much much more. Register Today at www.amconshows.com, or just call 800-829-7467
ON EXHIBIT
EXHIBITOR HIGHLIGHTS
AERODEF | BOOTH: 530
The VM 9 CNC Turning Center Machines Large Chucked Components The VM 9 Vertical Turning Center is made of a MINERALIT® polymer concrete column. The particularly good damping properties of Mineralit®, combined with the compound slide with the X- and Z-axes ensure excellent machining quality, high speed processes and short idle times. The main spindle provides the necessary power with a 83 kW rating and a torque of 990 Nm. Depending on the desired interface (BMT or VDI), the tool turret features eight or twelve tool positions, which can also be equipped with driven tools to carry out drilling operations. The integrated probe ensures process reliability and guarantees consistently high workpiece quality. For more information, visit www.emag.com AERODEF | BOOTH: 944
EOS M 290 – A Benchmark for Industrial 3D Printed Metal parts With a building volume of 250 x 250 x 325 mm, the EOS M 290 allows a fast, flexible and cost-effective production of metal parts directly from CAD data. An intuitive user interface, the intelligent software concept with a combination of open and standardized parameter sets and the improved filter system are specially designed for the industrial production. The exceptional high beam quality of the laser spot and its excellent detail resolution is ideal for manufacturing highly complex DMLS components ensuring homogeneous part properties from part-to-part, job-to-job and machine-to-machine. For more information, visit www.eos.info AERODEF | BOOTH: 1049
FANUC Machining Simulator FANUC America has developed a new machining simulator that from part design and engineering to CNC programming to virtual production simulation. The new FANUC Machining Simulator encompasses the complete manufacturing process with Autodesk Fusion 360 CAD/CAM/CAE software, a FANUC CNC Simulator (based on the FANUC 0i-F) and a custom machining simulation program. The FANUC Machining Simulator comes with Fusion 360, a cloud-based 3D CAD, CAM and CAE software platform that helps bridge the gap between design and machining and works on both Mac and PC. Students can perform CAD/CAM work and the included post processors will convert the designs into G-code suitable for the included CNC. For more information, visit www.fanucamerica.com AERODEF | BOOTH: 654
Manufacturing Management Software (MMS) version 6 Fastems’ Manufacturing Management Software (MMS) is one of the most progressive solutions for automatic production processing, complete with planning, controlling, visualization and monitoring capabilities. Based on a manufacturer’s current order and all required or available resources, the software plans the production straight from an ERP system. Not only does MMS administrate all NC programs needed for the production processes, but also all the tool data. It also monitors tool life and prompts the operator for new tooling if required. For more information, visit www.fastems.com
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AERODEF | BOOTH: 864
Two Machines – One Bed from Gosiger The market’s first “two in one” machine for heavy machining in titanium. For the first time ever it is possible to operate one machine for optimal roughing and optimal finishing. RigiMill – two different machines on one bed, configured with the customized gantries you require for milling aluminum or titanium. Our footprint occupies one-third less space than other gantries. Cycle time is reduced 30-50%. Optimized for productivity and to reduce tooling costs, the per minute chip removal rates up to 55 cubic inches in titanium and 970 cubic inches in aluminum. For more information, visit www.gosiger.com
AERODEF | BOOTH: 633
Super Duty Air Reciprocating Saw from Ingersoll Rand Super Duty Air Reciprocating Saw With increased comfort, performance, and durability, the 4429 is a premium tool designed for all types of cutting tasks. It offers a wealth of features for body, exhaust, and muffler work. The Composite grip area allows for increased comfort and control, while the piped-away exhaust benefits a cleaner work area. For smooth operation and protection against accidental starts, the 4429 features a tease trigger with lock-off and adjustable guard. For more information, visit www.ingersollrandproducts.com
WORK IN CLEAN AIR THE WAY MOTHER NATURE INTENDED
Removes:
Coolant Mist Welding/Diesel Smoke Grinding Dust Paint Overspray Woodworking Dust
2500 M-25
CF M
Destroys:
Heavy Odors Toxic Gases Chemical Fumes VOC’s Carcinogens Mold, Viruses, Bacteria
M-35P 1050 CFM
- Up to 5-stage filtration available - AIR-VAC’s on sale now starting at $1649
00 UV 3 M-30
0 CF M
VMC 2000 CFM
- Helps maintain OSHA compliance 1-800-234-2473 | Air-VacSystems.com
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ON EXHIBIT
EXHIBITOR HIGHLIGHTS
AERODEF | BOOTH: 649
Compact Waterjet for Prototyping from OMAX The new ProtoMAX abrasive waterjet is a compact, self-installed cutting system ideally suited for prototyping and relatively low volume cutting of almost any material around 1� thick. The system brings all the versatility benefits of large abrasive waterjet cutters in a sleek and economic package that is perfect for small job shops, engineering classrooms, makerspaces and personal use. It is also a handy addition for large shops and fabricators that need occasional waterjet capabilities to complement their other cutting systems. For more information, visit www.omax.com and www.protomax.com
AERODEF | BOOTH: 756
ROTA NCR Power Chuck from SCHUNK 6-jaw power chuck with oscillation mechanism for low-deformation clamping of thin-walled components. Also available with additional centrifugal force compensation system. This precision angle lever power chuck is for top quality demands and allows for excellent machining processes. The high efficiency of the angle lever system lends itself to process-reliable clamping due to high clamping forces. Features include optimum jaw support for O.D. and I.D. clamping due to a very long base jaw guidance. The ROTA NCR allows high clamping forces at a long service life with an optimized lubrication system. For more information, visit www.schunk.com AERODEF | BOOTH: 849
G120C Extends Siemens Offering Into More Markets With the Sinamics G120C, Siemens Drive Technologies expands its product portfolio of inverters. It is suitable for use with pumps, compressors and fans, as well as mixers, extruders, conveyor belts and materials handling machines. The target groups for this new line are production machine builders (OEMs) and distributors seeking to buy readyto-install inverter units. The G120C offers one of the highest power densities in its class and can be mounted directly as a machine module, without sacrificing power. Compared to conventional systems on the market, the G120C requires up to 30 percent less space, with up to 40 percent higher power density. For more information, visit www.industry.usa.siemens.com
AERODEF | BOOTH: 444
Strong Hand Tools Magnetic Grasshopper Clamp The New Magnetic Grasshopper Clamp locates and holds steel stock, and small or odd shaped parts in the vertical, horizontal, or inverted position for tack welding. The springloaded Grasshopper clamp arm delivers positive, self-adjusting holding pressure and is an ideal solution for tight-space and repetitious workholding. Locate and hold workpieces vertically with minimal obstruction for tack welding. The adjustable, magnetic v-pad base securely holds onto round, square, flat or angled surfaces at any point. For more information, visit www.stronghandtools.com
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AERODEF | BOOTH: 1033
Industry 4.0 Capable ROBOTsander from SUHNER Suhner has released its new ROBOTsander, a highly capable and adaptive surface treatment solution used in the automotive, aerospace, appliance, off-highway and outdoor power equipment market. Operations that benefit from the ROBOTsander are material protection, surface brightening, paint preparations and CFRP activation. Applications include grinding, brightening, polishing, deburring and sanding. The ROBOTsander can safely be used on metal and composite materials alike, using Suhner application-specific abrasives. Its design significantly reduces cycle time and use of abrasive materials. For more information, visit aerospace.suhner.com
AERODEF | BOOTH: 1052
Tebis Accelerates Processes Tebis has especially optimized the performance of its software with the current Version 4.0, Release 5. This helps users significantly accelerate their processes without functional restrictions. Examples include machine simulation, working with tool sets, searching for tools in feature machining or exchanging tools in the Job Manager. For this complex part, Tebis Version 4.0 Release 5 automatically selects the total of 705 tools for collision-free machining of the 270 features in just two minutes, a time savings of 80% in comparison with the previous version. For more information, visit www.tebis.com
It can easily be used in most Drill Presses, Milling Machines and CNC systems. Ideal for Automated Production Lines.
N
INS
Process works in steel, stainless steel, copper and aluminum up to ½” thicknesses. Standard UNC, UNF, NPT and Metric sizes are available up to 1.5” in diameter.
OW
RM
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Formdrills form sturdy bushings that can be threaded to produce your own inserts. These built-in inserts are as strong or stronger as the same-diameter welded nuts.
UR
FO
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S
COSTS ABOUT 1 CENT PER HOLE
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Formdrill USA 773-290-1040 info@formdrill-usa.com www.formdrill-usa.com
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PRODUCT SHOWCASE
Foot Load Cells Eliminate Bulky Weigh Modules
Precise Weld Force for Miniature Parts Welding
A new line of foot load cells that can add accurate weighing capability to bins, conveyors, hoppers, tanks, and virtually any other platform has been introduced by Alliance Scale, Inc. Alliance Anyload® FatFoot Load Cells are compact machine feet that can be attached to virtually any platform to add weighing capability without the need for bulky weigh modules. Featuring a transducer which has a natural perfect linearity and a swivel foot with thread-in installation, they come in various capacities and have rubber boots that enclose the bearing area.
AMADA MIYACHI AMERICA, Inc. announced that its state-of-the-art Series 300 electronic weld head offers the precisely controlled weld force profile ideal for miniature parts welding. Originally released more than twenty years ago, there are more than 1000 Series 300 electronic weld heads in use all over the world, with more than half going into operation in the last decade. The Series 300 enables up to 3 welds per second, with programmable force and weld positions, excellent force and position repeatability, and displacement monitoring.
For more information, visit www.alliancescale.com
For more information, visit www.amadamiyachi.com
ATI Develops Universal Compliance Compensator ATI Industrial Automation’s new U1-050 Universal Compliance Compensator combines a variety of features to achieve the highest level of adaptability in tasks such as automated assembly, bin picking, loading and unloading machines, robotic finishing, and more. The U1-050 UCC complies in many directions to overcome misalignment between the tool and the workpiece. The patented mechanism is ideal for demanding high-endurance applications and offers simultaneous X-Y lateral compliance, X-Y-Z axis rotation, and Z compression. The stiffness can be tuned for specific payloads by varying the pneumatic pressure. For more information, visit www.ati-ia.com
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Rover Plast J CNC Router/Cutter from Biesse The Rover Plast J CNC router/cutter guarantees maximum quality and reliability with its heavy duty steel frame and gantry. The high speed electrospindle ensures a fast feed rate and finishing quality for processing plastics, nonferrous metals, composites and wood. The high speed tangential knife systems provide accurate cutting capabilities for a wide variety of foam materials and various film applications. Affordable, flexible and user friendly, the Rover J combines strength and quality at a great price. Rover J Plast is part of Biesse’s Advanced Materials Range with all the experience and DNA of Biesse. For more information, visit www.biesseamerica.com
FUTUREPROOF
YOUR SUPPLY CHAIN AT MODEX 2018
Whatever manufacturing and supply chain solutions or insights you need to FUTUREPROOF your business, you’ll find them at MODEX 2018. With over 850 of the industry’s solution providers on site and more than 100 hands-on education sessions, MODEX 2018 allows you to make new contacts, discover cutting-edge solutions and learn the latest trends that are sure to give you a leg up on the competition.
MODEX Keynotes:
Georgia World Congress Center Atlanta, Georgia April 9-12, 2018
THE GREATEST SUPPLY CHAIN SHOW ON EARTH.®
Monday, April 9 8:45 AM – 9:30 AM
Tuesday, April 10 8:45 AM – 9:45 AM
Wednesday, April 11 8:45 AM – 9:45 AM
Wednesday, April 11 1:00 PM – 2:00 PM
Anticipating Tomorrow’s Supply Chain Challenges – Today
Harnessing Our Digital Future How the Digital Revolution is Accelerating Innovation, Driving Productivity and Irreversibly Transforming Employment and the Economy
2018 MHI Annual Industry Report Keynote Panel
Why Dirty Jobs Matter
JUAN PEREZ Chief Information and Engineering Officer, UPS
Monday, April 9 9:30 AM – 10:00 AM Welcome to MODEX 2018 GOVERNOR NATHAN DEAL Governor of Georgia
GEORGE W. PREST CEO, MHI SCOTT SOPHER Principal, Deloitte Consulting LLP
ANDREW MCAFEE Co-Founder & Co-Director, Initiative on the Digital Economy
MODEX is FREE to attend.
LEARN MORE AND REGISTER AT MODEXSHOW.COM.
MIKE ROWE Founder, mikeroweWORKS Foundation
PRODUCT SHOWCASE
BIG KAISER’s Optimal Tool Holder for Problematic Clearance Applications
Cortec® Counters Costs and Hassle of Metal Corrosion with CorShield® 352
BIG KAISER announced its HDC Straight Shank holder to the market, used for increased versatility. The extremely slim design provides superior balance, concentricity and is ideal for reaching into confined areas. HDC Straight Shank super slim holders can be clamped into other base holders to extend overall reach of the tool assembly and avoid the need for special tools. The slim nose design provides the necessary clearance for use with deep workpiece access, making them an ideal solution for 5-axis tool holding requirements.
Manufacturers often protect metal parts from corrosion by using rust preventatives or coatings. These protective layers, applied directly to the metal part, create a barrier between the metal surface and surrounding oxygen, moisture, or other corrosive elements. Cortec’s technology tackles corrosion from a new perspective. Instead, Vapor phase Corrosion Inhibitor Technology turns basic packaging materials like paper, cardboard boxes, and plastic bags into corrosion inhibiting tools that protect by vapor phase action without the direct application of a rust preventative or coating to the metal.
For more information, visit www.us.bigkaiser.com
For more information, visit www.cortecpackaging.com
Samag Machining Centers and Deep Drilling Machines Now Available in US New Anti-Static Super Air Knife EXAIRs new Gen4 Super Ion Air Knife eliminates static electricity 34 percent better at low inlet pressures which saves compressed air and money. Production speeds, product quality and surface cleanliness can improve dramatically. It eliminates static on plastics, webs, sheet stock and other product surfaces where tearing, jamming or hazardous shocks are a problem. New design features include a metal armored high voltage cable to protect against abrasion and cuts, integrated ground connection and electromagnetic shielding.
Now available from German Machine Tools of America (GMTA), a full line of Samag multi spindle machining centers is offered for the North American market. With “FIT 2 PART,” the modular construction kit of the multi-spindle horizontal machining center has been developed consistently from the point of view of the workpiece. Attention was focused on flexibility, among others, the X Y Z axes of the 2-spindle machine can be corrected independently of one another . Four sizes and two types of drive offer options for high-speed machining and heavy-duty cutting.
For more information, visit www.exair.com
For more information, visit www.gmtamerica.com
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>> CONFERENCE: MARCH 26–29, 2018 EXHIBITS: MARCH 27–28, 2018 LONG BEACH [CA] CONVENTION CENTER
FLY HIGH THE PREMIER CONFERENCE AND EXPOSITION FOR AEROSPACE AND DEFENSE MANUFACTURERS. Developed in conjunction with executives from leading OEMs, AeroDef provides you with the tools and connections you need to improve revenue generation, drive efficiency and improve supply chain performance. AeroDef immerses you in the most intelligent manufacturing that the aerospace and defense sector has to offer and provides educational sessions on: n Additive n Integrated Manufacturing/ Assembly 3D Printing n Precision Machining n Automation & n Finishing & Robotics Coatings n Composites & n Quality, Advanced Materials Measurement & n Cybersecurity Inspection n Digital Technologies n Smart Manufacturing n Industrial Internet of Things (IIoT)
Join the industry experts and your colleagues at the can’t-miss aerospace and defense event of the year!
>> REGISTER NOW AT AERODEFEVENT.COM
produced by
PRODUCT SHOWCASE
1000°F Top Loading Oven From Grieve No. 895 is a 1000°F (538°C), top loading oven from Grieve, currently used for curing composite materials in large molds at the customer’s facility. Workspace dimensions of this oven measure 168” W x 48” D x 48” H. 120 KW are installed in lncoloy sheathed tubular heating elements, while a 12,500 CFM, 10-HP recirculating blower provides horizontal airflow. This Grieve top-loading oven features 8” thick insulated walls comprising 2” of 1900°F block and 6” of 10 lb./cf density rockwool. Other features include aluminized steel exterior, Type 304, 2B finish stainless steel interior, reinforced ¼” steel plate top.
Heavy-Duty Benchtop Mill/Drill with Variable-Speed Head!
For more information, visit www.grievecorp.com
For more information, visit www.grizzly.com
The G0795Z comes with a dovetail column, a variable-speed, 1 HP, 220V motor, an R-8 spindle, and a large 7-1/2” x 27-1/2” work table. The mill/drill base is made from heavy cast iron to ensure cuts are smooth and vibration free. This is an excellent value and great for seasoned machinists or those just starting out. This G0795Z is the same as our G0795, but features a 2HP BLDC Variable Speed Motor for even more power.
LazerArc Division Custom Engineered Robot Transfer Units
HEMCO Clean Rooms are built to your exact size and design requirements. From ISO 6 to ISO 8, clean rooms can feature a single pass or re-circulating airflow system. Clean Rooms feature a modular design that allows the room to be easily installed, disassembled, moved and reassembled. A wide selection of options such as airlocks, temperature controls, doors, windows, electrical and furniture are available.
LazerArc was established by Motion Index Drives in 2017 to separate the custom engineered solutions from standard product offerings for those customers looking for a wider selection of machinery to suit today’s manufacturing automation needs, including robot transfer units. In order to address the needs of robot integrators, LazerArc has begun manufacturing the 7th Axis Slide, or Robot Transfer Unit customized to fit your application.Due to the low cost and high flexibility of Robotic Arms, they continue to be a popular choice in manufacturing.
For more information, visit www.HEMCOcorp.com
For more information, visit www.lazerarc.com
Modular Clean Rooms
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STRUCTURAL STEEL CO., INC. STRUCTURAL STRUCTURAL STEEL STEEL CO., CO., INC. INC.
Essex Provides: Essex Essex Provides: Provides:
New Liftomatic Line of Portable Drum Handlers Liftomatic Material Handling, Inc., an industry leading material handling equipment manufacturer, recently introduced the Ergo-Matic® line of portable drum handling equipment. The Ergo line comprises a range of models and features for repetitive applications. The product family is fully modular and designed for efficient manual handling of a single drum. The Ergo-Matic® line features high-lift capability up to 36” to double-stack drums, spark-resistant components for flammable areas, double “Parrot-Beak®” clamps for fiber and plastic drums plus special wheels and coatings for FDA Approved applications. For more information, visit www.liftomatic.com
• Pre-Engineered Buildings Built To Withstand The • Pre-Engineered Buildings Built • Rugged Pre-Engineered Buildings Built To To Withstand Withstand The The Northeast Winters. Rugged Rugged Northeast Northeast Winters. Winters. • Commercial, Industrial & Agricultural Buildings Built • Industrial & Agricultural • Commercial, Commercial, Industrial &Needs. Agricultural Buildings Buildings Built Built To Satisfy Your Building To Satisfy Your Building Needs. To Satisfy Your Building Needs. • • Steel Steel Structure Structure Sub-Structure, Sub-Structure, & & Sheeting Sheeting • Steel Structure Sub-Structure, & Sheeting
Call For A Quote On Your Next Project Call Call For For A A Quote Quote On On Your Your Next Next Project Project
STRUCTURAL STEEL CO., STRUCTURAL STEEL CO., INC. INC. STRUCTURAL STEEL 607 Route 13, Cortland, NY 13045CO., INC. 607 Route 13, Cortland, NY 13045 607 Route 800-323-7739 13, Cortland, NY 13045 National: National: 800-323-7739 National: 800-323-7739 607-753-9384 • FAX: 607-753-6272 607-753-9384 • FAX: 607-753-6272 607-753-9384 •• FAX: www.essexstructuralsteel.com 607-753-9384 FAX: 607-753-6272 607-753-6272 www.essexstructuralsteel.com www.essexstructuralsteel.com 607 Route 13, Cortland, NY 13045
KCD-MN1
Heavy Duty Quick-Release Grease Coupler Lumax’s exclusive patented design heavy duty quick release coupler has an innovative design that enables it to firmly latch onto the grease fitting, enabling hands free greasing. The heavy duty quick re- lease grease coupler locks-on and creates a leak-proof seal. The LX-1403 has a working pressure of 15,000 PSI and burst pressure of 22,000 PSI. The LX-1403 has the highest pressure rating in the world. It has hard- ened 4-jaws to withstand high pressures without deformation. No spurts or splashes when disconnecting. A clean work environment at all times. For more information, visit www.lumax.com
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PRODUCT SHOWCASE
Compact Simultaneous 5-axis Machine Features Auto Work Changer
NETZSCH adds sizes to full service-in-place version of NEMO®
Mazak’s versatile VARIAXIS i-300 simultaneous 5-axis vertical machining center is now even more flexible and efficient with the addition of a high-capacity Auto Work Changer (AWC). Designed for automated small- to medium-size part-processing operations, the new VARIAXIS i-300 AWC excels in machining aluminum and other nonferrous metals for a wide variety of industries, including aerospace, medical and automotive. The machine comes standard with a multiple drum tool storage system that holds up to 145 tools, while the AWC with 32 positions accommodates workpieces up to 13.779” in diameter, 12.401” high and weighing up to 135 lbs.
NETZSCH Pumps North America, LLC, has added to its line of FSIP (full service-in-place) industry-leading NEMO® progressive cavity pumps. Ideal for wear-intensive applications, the maintenance-friendly FSIP™ design has been re-engineered to provide full access to all the pumps’ rotating parts. Users can conveniently open the in-service pump housing, dismantle all rotating parts, and simply install them again without having to remove the pump from the pipe assembly or having to disconnect wiring. The NEMO’s rotor-stator unit can be lifted out after opening the newly designed inspection cover on the pump housing.
For more information, visit www.mazakusa.com
For more information, visit pumps.netzsch.com
SG-PLUS WHISPER grinding wheel from PFERD An Economical Bench Surface GrinderOption For Small Shops A perfect choice for small shops, Palmgren’s 6 x 12 Bench Surface Grinder is an economical option because it has many of the same features found on larger units. The grinder’s Meehanite cast iron construction reduces vibrations while maintaining rigidity and accuracy. Its precision steel balls produce an extremely smooth table operation along the ways. It features a swarf guard, easy-to-read dials and an optional heavy-duty steel floor stand. Palmgren is a C.H. Hanson brand.
The SG-PLUS WHISPER grinding wheel from PFERD delivers a patented design that creates significantly less vibration and noise than conventional grinding wheels while increasing service life and stock removal rates. Its ergonomic design cuts noise by up to 12 dBA, a reduction of more than 90%. In addition, the wheel structure permits soft and comfortable grinding with an excellent surface finish. The PFERD WHISPER depressed center grinding wheel has a unique, layered construction, employs aluminum oxide abrasive and is ideal for weld grinding, surface grinding, and fillet weld grinding on steel and stainless steel (INOX).
For more information, visit www.palmgren.com
For more information, visit www.pferdusa.com
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k
2 1 ST A N N U A L
PEARL CONFERENCE & EXHIBITION
k
REGIS T E R NOW! April 13–15, 2018 Hyatt Regency Greenville Greenville, SC 877.287.3275 www.pearl1.org
WHAT TO EXPECT IN 2018 • Keynote session given by Dr. Nabil Nasr, Associate Provost and Director of the Golisano Institute for Sustainability • Two tracks offered with presentations and topics geared for management and technicians • A new Exhibitor Product Forum and enhanced exhibit hall • Networking and social opportunities to facilitate exchanges of ideas and business opportunities • And so much more!
PRODUCT SHOWCASE
Machine Tool Probe Technology at Your Fingertips The Raymond Corporation has launched a Virtual Reality (VR) Simulator to serve as a supplemental tool to assist in the development of new and existing forklift operators. The Raymond Virtual Reality Simulator allows the user to enter a simulated warehousing environment utilizing an existing Raymond® forklift truck by plugging into the company’s patent-pending sPort, or Simulation Port. After the vehicle is no longer needed for instruction, the sPort can be disconnected and the forklift can be placed back into operation in the warehouse.
Recognizing how smartphones and tables can also assist in a multitude of working environments, Renishaw, a world-leading engineering technologies company, has developed a range of smartphone apps for users of their machine tool probing hardware. Together with associated training materials and user reference tools, the GoProbe technology is designed to make Renishaw machine tool probes and tool setters easy to use. Key to the simplicity of GoProbe is its programming format, which consists solely of a single-line command. This eliminates the need for extensive knowledge of machine codes and programming techniques.
For more information, visit www.raymondcorp.com
For more information, visit www.renishaw.com
Raymond Virtual Reality Simulator Launches
Latest Invomilling™ CAD/CAM Software Changes Gear Cutting
Seco Double-sided Round Inserts Give Cutters Added Value and Performance
Sandvik Coromant has extended the functionality of its InvoMilling™ software. The latest version of this user-friendly CAD/CAM solution for fast and simple NC programming offers even more possibilities when manufacturing gears on universal five-axis machining centers. As of late 2017, the software will also enable customers to produce straight bevel gears and herringbone gears. InvoMilling™ exploits machine tool kinetics for the effective and flexible manufacturing of high-quality gears and splines in quality level 6 or better (according to DIN 3962).
Seco Tools has introduced its R217/220.28 cutters with completely new body designs that incorporate double-sided round inserts to deliver cost-effective performance as well as boost productivity. Double-negative-positioning pocket seats of the R217/R220.28 cutters deliver enhanced cutting capability and significant gains in productivity. These pocket seats also enable safe and user-friendly indexing to save time and provide trouble-free operation. The R217/ R220.28 performs face milling, slotting and contouring in ISO M and ISO S materials, as well as some difficult-to-machine ISO P materials, such as martensitic stainless steel.
For more information, visit www.sandvik.coromant.com
For more information, visit www.secotools.com
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New TDM Shopfloor Manager in TDM 2017 Delivers maximum flexibility. TDM Systems, a subsidiary of Sandvik Machining Solutions has announced the introduction of TDM Shopfloor Manager in TDM 2017 Global Line. The Shopfloor Manager software module records the entirety of a tool’s circulation, from planning for tool assembly, presetting and tool use at the machine, to disassembling. In addition, the modular design of the software allows it to be easily configurable for an individual user needs. In addition, the TDM Shopfloor Manager is fully integrated into the inventory management system of the TDM Tool Crib Module Global Line. For more information, visit www.tdmsystems.com.
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New TC120, TC121 and TC122 Supreme Taps from Walter
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Walter has introduced the TC120, TC121 and TC122 Supreme, three new blind hole taps. These new entries in the Walter Supreme line have been specially developed for machining steel. The taps cover all tensile strengths from 43-200 kpsi. The TC120 Supreme with a 45° helix angle makes it possible to reliably produce threads up to 3 × DN in soft and medium-strength steels (ISO P, N). It stands out due to its partial TiN coating in the chamfer section which increases wear resistance and tool life.
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ADVERTISER INDEX & Web Site Links Accudyne Products...............................................29.
ENM Co........................................................................ 61.
Radwell International, Inc................................. BC.
www.ezpullerusa.com
www.enmco.com
www.Radwell.com
Actek Manufacturing & Engineering..............31.
Essex Structural Steel Co., Inc.......................... 51.
RAS Machine Tool Technology In.................. 19.
www.actekmfg.com
www.essexstructuralsteel.com
www.rasmachinetool.com
Action Machinery Co., Inc.................................. 57.
Formdrill USA Inc....................................................45.
Salinger Electric Co., Inc.....................................59.
www.actionmachinery.com
www.formdrill-usa.com
www.salingerelectric.com
Air-Vac Systems....................................................... 43.
H&K Equipment, Inc..............................................58.
Scotchman Industries........................................... 15.
www.air-vacsystems.com
www.hkequipment.com
www.scotchman.com
Alloys & Components........................................... 61.
HMI div of Betenbender Manufacturing..... 33.
Select Equipment Company.............................60.
www.alloysandcomponents.com
www.betenbender.com
www.selectequipment.net
AmCon Shows.......................................................... 41.
IMDauctions.com............................................ 55, 58.
Siemens Industry, Inc............................................. 5.
www.amconshows.com
www.IMDauctions.com
www.usa.siemens.com/cnc
IMTS 2018................................................................... 37.
Jergens, Inc..................................................................7.
AeroDef........................................................................49.
www.imts.com
www.jergensinc.com
www.aerodefevent.com
Betenbender Mfg. Inc........................................... 27.
Kanetec USA Corporation................................... 51.
South Bend Lathe Co...............................................9.
www.betenbender.com
www.kanetec.com
www.southbendlathe.com
Carell Corporation.....................................................3.
L & L Special Furnace Co., Inc..........................59.
Stor-Loc Division of
www.carellcorp.com
www.llfurnace.com
Ryan Metal Products...........................................IBC.
Coxreels....................................................................... 33.
Lenzkes Tools Inc................................................. IFC.
www.coxreels.com
www.lenzkesusa.com
www.storloc.com Syclone ATTCO Service....................................... 39. www.skyhookmfr.com Darex............................................................................. 32.
MacMillin Hydraulic Engineering
www.darex.com
Corporation...............................................................29.
The Electric Barn....................................................59.
www.macmhydraulic.com
www.electricbarn.com
Denver Breaker & Supply....................................56. www.denverbreaker.com
Marvel Manufacturing Company.....................17.
Tormach...................................................................... 21.
www.marvelsaws.com
www.tormach.com
Material Handling Industry of America....... 47.
Trim-Lok Inc...................................................... 23, 25.
www.mhia.org
www.trimlok.com
Design 2 Part............................................................. 61. www.d2p.com Dynabrade, Inc.........................................................FC. www.dynabrade.com Eagle Bending Machines........................................3.
PEARL - Professional Electrical Apparatus
US Shop Tools............................................................11.
Recyclers League.................................................... 53.
www.usshoptools.com
www.pearl1.org
www.eaglebendingmachines.com Racing Equipment News....................................55. Eastern Electrical Liquidators...........................58.
www.racingequipmentnews.com
www.eastelec.com
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