Search - December 2010
‘SEARCH’, India’s leading B2B magazine on general engineering and manufacturing, is aimed to equip its readers with latest business trends, news, views and insights. A ready-reckoner for all techno-commercial information, it is a sumptuous source of business trends and growth opportunities. Encompassing all the segments of manufacturing along with sourcing solutions, this monthly presentation is a unique platform for SMEs as well. With multitude of dedicated readers patronising this flagship magazine, launched in 1998, SEARCH has retained the leadership position in its domain.
Check out the views of the strait from the 48th floor! Best place to park in New York is on the roof. Road sign to airport hidden. If you miss it, hang the second left and then the third right. Turn off the radio. Bossa nova playing in the street. Watch your step � the receptionist teaches tango! NO ONE KNOWS THE AMERICAS LIKE WE DO When it comes to delivering on time every time, local knowledge is everything. As the pioneer of international express shipping, our local expertise, customs clearance experience and international express network are unparalleled. That's why we can offer faster, more reliable deliveries than ever across the Americas. And all at competitive rates. Something we thought you should know. Sign up for a DHL Account and get a chance to win an iPod �.*+ For more details, log on to www.simplydhl.com/india. Offer closes on 31st December so hurry up! *Terms and conditions apply + iPod is a trademark of Apple Inc., registered in the U.S. and other countries. ** 30 300 345 from private landline & mobile phones & 1800 111 345 MTNL/BSNL networks EDITORIAL Infomedia 18 Limited, Special Interest Publications Division, `A' Wing, Ruby House, J. K. Sawant Marg, Dadar (W), Mumbai - 400 028, India Tel: +91-22-30245000, Fax: +91-22-30034499 firstname.lastname@example.org EDITORIAL Executive Editor Archana Tiwari-Nayudu Features Editor Prerna Sharma Senior Features Writer Sumedha Mahorey Senior Correspondent Shivani Mody (Bengaluru) Features Writer Sandeep Pai, Sudhir Muddana, Purna Parmar, KTP Radhika Jinoy & Anwesh Koley (Delhi) Correspondent Geetha Jayaraman (Delhi) Copy Desk Marcilin Madathil, Kimberley D'Mello Products Desk Michael Anthony INDIA UPBEAT & HOW! DESIGN & PRODUCTION Assistant Art Director Varuna Naik Design Team Sanjay Dalvi, Uttam Rane Production Desk Dnyaneshwar Goythale, Lovey Fernandes, Pukha Dhawan, Varsha Nawathe, Akshata Rane, Ravikumar Potdar, Sanjay Shelar, Abhay Borkar Our growing global clout can be assessed by the fact that the very first country Obama visited during his Asia visit was none other than India. But India's potential was never an issue among Indians at least. It was the trust and the perception of the world that was limiting. Thankfully, it is drastically changing now with the US president endorsing India's bid for a permanent UN Security Council seat. So it is established that India is upbeat with potential that is unparallel... and you will hear and read that there are telltale signs and bold indicators to confirm the same. There will also be talks of spotting the trends and making most of this opportunity. Now here is a dilemma... a dilemma, which topples every company, every manufacturer, every businessperson, every entrepreneur and anybody & everybody who wants to ride this India growth wave. How do they spot a trend, how do they turn a brilliant idea into a prosperous business entity, which way should they turn for progress? Confused? Help is at hand! As our informed and involved reader, you must have marked that the last issue, that is the November issue of SEARCH carried an `India Upbeat Series' tag on the cover page which was also on ManuFuture, or simply the Future of Manufacturing. Accordingly, this December issue -- a Robotics & Sensors Special -- is also about the Future Factories, and is the second in the India Upbeat series. This will culminate into our MEGA Anniversary Issue in January! As we enter into our teens, this being our 13th Anniversary issue, we are eager to show you the vision and the view. This four volume Special Edition is not just for a techie, but a leader, a competent designer and manager of complex systems, who can adapt to rapid societal and technological change. It is all set to provide Manufacturing Solutions for the 21st Century. All growth-oriented questions and business enabling information are packed in this one issue, be it the defining characteristics of super shop floors, or ways to stay globally competitive. Technology window will enable you to marvel at all the technological developments and not to forget there will be success stories and ways to turn success stories into profitable prospects. If you think it is packing too much into one issue, well there is more! The Innovations edition, which is all about Product Design, Shop Floor Innovations and New Engineering Materials, is shaping up to be a trendsetter! With this promise, we leave you with the Robotics & Sensors Special December issue, only to return with a much-awaited annual issue. Archana Tiwari-Nayudu email@example.com I t was a murmur, then a debate, and finally, a lot of noise, which was mistaken as being just an echo of handful of people. The India growth story has come of age and how! From being part of the BRIC euphoria, which was questioned right from the point of its emergence, to the First Man of the world himself saying those golden words: `India is not simply emerging; India has already emerged'. 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Rd., Taichung, Taiwan Tel: +886-4 2329 � 7318 Ext. 16, Fax: +886-4 2310 � 7167 email@example.com � Monthly Issue Price: Rs 100 � Annual Subscription: Rs 799 Printed by Mohan Gajria and published & edited by Lakshmi Narasimhan on behalf of Infomedia 18 Limited and printed at Infomedia 18 Ltd, Plot no.3, Sector 7, off Sion-Panvel Road, Nerul, Navi Mumbai 400 706, and published at Infomedia 18 Ltd, `A' Wing, Ruby House, J. K. Sawant Marg, Dadar (W), Mumbai - 400 028. SEARCH - The Industrial Sourcebook is registered with the Registrar of Newspapers of India under No. 67827/98. Views and opinions expressed in this publication are not necessarily those of Infomedia 18 Limited. Infomedia 18 Limited reserves the right to use the information published herein in any manner whatsoever. While every effort has been made to ensure accuracy of the information published in this edition, neither Infomedia 18 Ltd nor any of its employees accept any responsibility for any errors or omission. Further, Infomedia 18 Ltd does not take any responsibility for loss or damage incurred or suffered by any subscriber of this magazine as a result of his/her accepting any invitation/offer published in this edition. No part of this publication may be reproduced in any form without the written permission of the publisher. All rights reserved. D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 27 CONTENTS EXTREME ENGINEERING SOLAR IMPULSE | Pg 100 The Meridian Hour In Aviation Daring a technological challenge to create something that has never been thought about by anyone is an extreme case. Creating history, a team of pioneers in the field of aviation has come up with the aspiration of encircling the world in a solar-fuelled plane with a wingspan as big as an airbus but having just the weight of a car. Guiding a spurt in innovations and weaving the future around the theme of renewable energy is the project ` Solar Impulse'. 27 EDITORIAL India Upbeat & How! SMART STRATEGIES 136 Design And Manufacturing Integration Annihilating Production Scrap 40 NATIONAL NEWS Latest In The Indian Manufacturing SME ADVANTAGE 143 48 WORLD NEWS Snapshot Of Latest Global Happenings In Manufacturing Domain 3D CAD Accelerating Innovation Interview Karnataka Government's Policy Framework Is A Boon For Industrial Development SS BIRADAR, President, Karnataka Small Scale Industries Association (KASSIA) 148 MANUFACTURING ZONE 108 Manufacturing Execution System Drawing The Line Of Excellence VIEW FROM THE TOP TECHNOLOGY TRENDS 112 116 Technology Update Cutting Edge Solutions Manufacturing Enterprise Landscape Transformation `Melting' Barriers, Harmonising Business Processes Pg 53 APPLICATION ZONE 122 Electric Rod-style Actuators Actuating Optimal Performance EQUIPMENT BUYING GUIDE 126 Automation Equipment Keeping Mistakes At Bay DESIGN INNOVATION 130 Design & Business Tough Love `Automation Has Changed The Way Manufacturing Functions' FAROOK MERCHANT, Chairman & MD, Messung Group of Companies 28 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 CONTENTS SPECIALS IN THIS ISSUE INDUSTRY UPDATE Robotics & Sensors INSIGHTS & OUTLOOK Welding 62 66 71 Flexible Manufacturing Think `Flexible' Think `Robots' Low-cost Robotics Equipping SMEs with Affordable Solutions Optimal Temperature Sensor Selection Achieving Accurate Temperature Measurement 76 84 Sensors Preventing Product Defects Through Errorproofing Tips & Tricks: Sensors Taking `Stock' Of Inventory New-age Welding Technologies Imparting Coalescence For Optimal Performance Robotics In Welding Extending A `Tech' Arm For Efficient Functioning Sensors For Welding Withstanding Temperature Extremities 90 94 80 CURTAIN RAISER 150 154 156 161 162 Engineering Expo Ahmedabad 2010 Setting Inspirational Benchmarks IPVS 2010 All Set To Pump Up Prospects Hannover Milano Fairs India 2010 Staging The Best-in-class Industrial Innovations EA Water Expo 2011 Showcasing Water Management Techniques Engineering Expo Indore 2011 Unveiling Promising Opportunities REGION PROFILE West Bengal 169 174 179 182 West Bengal Industrial Development Snipping Off The Shackles Opportunities Unlimited 10 Reasons To Invest In West Bengal West Bengal Investment Portfolio Fortifying Development Through Planned Initiatives INTERVIEW `The Government & Administrative Machinery Need To Have A Shared Vision To Facilitate Growth' RAJESH NATH, MD, German Engineering Federation (VDMA) REPORT 166 India Energy 2010 Energising India's Economic Growth 256 264 271 278 International Products Showcasing Product In A Global Arena PRODUCT UPDATE 184 188 198 202 206 249 Region Profile West Bengal Robotics & Sensors Latest Products In Robotics & Sensors Welding Latest Products In Welding New Launches Latest Products In The Offing General Products Rolling Out The Best-in-class PRODUCT INDEX Alphabetical Listing Of Products Presented In The Issue ADVERTISEMENT INQUIRY FORM Get In Touch With Supplier Of Products You Wish To Buy ADVERTISERS' LIST Advertisers' List In Chronological Order 82 PREVIEW HiTech Material Handling Show Inspiring Innovations PRODUCT INQUIRY FORM For Product Inquiries Showcased In This Issue, Fill In The Form And Send It Back To Us Details on pg. 213-216, 275 PRODUCT UPDATE 30 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 NATIONAL NEWS $55 bn to flow into renewable energy in 5 yrs ndia, one of the leading producers of wind power, is encouraging investment in renewable energy to curb emissions and reduce dependency on oil as the country imports nearly three quarters of the oil it consumes. At present, renewable sources account for about 6,000 MW out of India's capacity of about 80,000 MW, but the government believes that the country can raise output of renewable energy to 85,000 I FDI Equity Inflows (Month-wise) During The Financial Year 2010-11: Financial Year 2010-11 (April-March ) Amount of FDI inflows* (In Rs. Cr.) April 2010 May 2010 June 2010 July 2010 August 2010 2010-11 (up to Aug. 2010)# 2009-10 (up to Aug. 09) % age growth over last year 9,697 10,135 6,429 8,359 6,196 40,816 66,857 (-) 39% (In US$ mn) 2,179 2,213 1,380 1,785 1,330 8,887 13,760 (-) 35% MW in a little over a decade. According to a top official source, India expects investments of up to $55 billion in the next five years in the renewable energy sector that would generate 35,000 MW of power. Speaking on the sidelines of DIREC 2010, a three-day International Renewable Energy Conference held in the last week of October, Debashish Majumdar, chairman and MD, Indian Renewable Energy Development Agency (IREDA), said, "There would be investments to the tune of $55 billion by 2015 in the renewable energy sector which is expected to produce 35 GW of power." Apart from this, the government is also targeting electrification of 10,000 remote villages across the country by March 2012. New and Renewable Energy Minister Farooq Abdullah said, "We will provide electricity to 10,000 villages at the cost of `500 crore by the end of current plan period." Ashok Leyland plans global acquisitions shok Leyland, a Hinduja Group company, has said that it was scouting for acquisition opportunities, in the bus segment. Dheeraj G Hinduja, Chairman, Ashok Leyland, says, "The company should be among the global top 10 in commercial vehicles and top five in buses, within a time span of five years." Currently, Ashok Leyland is globally at the 16th position in CVs and ranks 6th in the bus segment. In terms of volumes, # Figures are provisional, subject to reconciliation with RBI, Mumbai. Sectors Attracting Highest FDI Equity Inflows: (Financial Year-wise): Amount Rupees in crores (US$ in million) Sector Services Sector Computer Software & Hardware Telecommunications Housing & Real Estate Construction Activities Power Automobile Industry * Metallurgical Industries Petroleum & Natural Gas Chemicals 2010-11 % age to total (April -Aug. Inflows 2010) (In terms of US$) 5,793 21 % 2,090 9% 4,789 2,492 1,352 3,121 519 2,807 987 675 8% 7% 7% 4% 4% 3% 2% 2% A Note: Cumulative Sector- wise FDI equity inflows (from April 2000 to August 2010) - Annex-`B'. * Earlier data has been revised, due to some figures interchange with the respective sectors. it will be 150,000 units of CVs and 40,000 buses, within five years. "We are always open for new acquisitions, which would give access to technology, new markets and customers," says R Seshasayee, MD, Ashok Leyland. "We have a strong hold in SAARC countries and West Asia and now we want to focus on North Africa, South East Asia and Latin America," said Hinduja. Seshasayee added that the company would also look at opportunities in the engineering & design, and foundries. "We will also look at the possibilities of brownfield expansion," he added. In July, Leyland entered into an agreement with UKbased bus manufacturer Optare to acquire 26 per cent stake, for $7.5 million (`33 crore). The company has said this acquisition will give access to technology, including a modern range of mid-sized and full-sized city buses which can appeal to both domestic and global markets. Share Of Top Investing Countries FDI Equity Inflows: (Financial Year-wise): Amount Rupees in crores (US$ in million) Country Mauritius Singapore U.S.A. U.K. Netherlands Japan Cyprus Germany France U.A.E. Total FDI Inflows * 2010-11 % age to total (AprilInflows August 10) (in terms of US $) 13,461 42% 4,934 9% 2,944 7% 1,263 5% 2,213 4% 2,330 4% 1,437 4% 315 2% 1,178 2% 1,042 1% 40,816 - India to supply GM `4,500-cr parts by 2012 eneral Motors is planning to double the level of sourcing of automotive components from India to $1 billion (`4,500 crore) annually in the next two years. For the year 2010, the company has placed $550 million worth of orders to its Indian vendors. GM sources components such as castings, forgings and metal parts from India for its various facilities around the world, a G company official said. "We have a vendor base of 250 in India who are presently supplying to Note: (i) *Includes inflows under NRI Schemes of RBI, stock swapped and advances pending for issue of shares. (ii) Cumulative country-wise FDI equity inflows (from April 2000 to August 2010) � Annex-`A'. (iii) %age worked out in US$ terms & FDI inflows received through FIPB/SIA+ RBI's Automatic Route+ acquisition of existing shares only. Source: Department of Industrial Policy & Promotion, Ministry of Commerce and Industry, Govt. of India Seventy two vendors will supply components to our global operations. We are looking at doubling our sourcing from India by 2012. KARL SLYM, President & MD, GM India our facilities. Of this, 72 vendors will also supply components to our global operations. We are looking at doubling our sourcing from India by 2012," said Karl Slym, President and MD, GM India. On the sidelines of the annual manufacturing conference of Confederation of Indian Industry (CII), he said that in addition to sourcing of components for global operations, GM had placed orders worth $356 million (`1,580 crore) for its Indian operations as well. 40 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 NATIONAL NEWS EVENTS In India Siemens targets revenues of over 40 billion by 2014 n fiscal 2014, Siemens wants to exceed the 40 billion revenue mark with green technologies with various products and solutions. Currently, in fiscal 2010, Siemens generated revenue of around 28 billion with products and solutions from its environmental portfolio, compared to slightly less than 27 billion in fiscal 2009. The original target of generating revenue of at least 25 billion in 2011 was thus, reached AHMEDABAD Gujarat December 10-13, 2010 Gujarat University Exhibition Hall I INDORE Madhya Pradesh January 7-10, 2011 Maharaja Shivajirao School Grd, Chimanbaug CHENNAI Tamil Nadu March 11-13, 2011 Chennai Trade Centre significantly earlier than planned. Energy and healthcare industry are tremendously contributing to the company's green portfolio, company officials said. In 2010, the largest individual reductions in CO2 emissions were achieved by highly efficient combined-cycle power plants, wind farms, the retrofitting of existing power plants, energy-efficient lighting systems and eco-friendly trains. "Green innovations are our lifeblood. We're the largest supplier of environmental technologies in the world. We want to increase our advantage over our most important competitors," said Barbara Kux, Member, Siemens' Managing Board who is responsible for sustainability and the further development of the Environmental Portfolio. Other future growth drivers include, smart grids and their key components. This is an area in which the company anticipates total orders of around 6 billion by the end of 2014. India's premier industrial trade fair on products and technologies from machine tools, hydraulics & pneumatics, process machinery & eqpt, automation instrumentation, packaging & auxiliaries, IT products, electrical & electronics, material handling, safety eqpt. For further details contact: Tel: 022 3003 4649/4651 Fax: 022 30034499 Email: firstname.lastname@example.org Web: www.engg-expo.com Harley Davidson to set up assembly unit at Haryana wing to enormous response to its s u p e r- m a c h i n e s and the constantly growing auto industry in the country, American superbike maker Harley Davidson is setting up an assembly unit at Bawal, Haryana. This unit is likely to come up in the first six months of 2011 and will be the company's second plant outside the US. This move will help Harley substantially cut the price of its bikes in India. It will pay only 10 per cent import duty on completely knocked-down units, instead of the steep 60 O F&S MANUFACTURING IT Focus: Manufacturing IT When: November 25, 2010 Where: Hyatt Regency, Mumbai Ashwin Haleyur: Tel: (+91) 08041783543, Cell: (+91) 8095887607 Email: email@example.com Log on: http://www.frost.com/ manufacturing-IT Summit F&S MANUFACTURING SUMMIT Focus: Identified Best Practices relevant to the Manufacturing Fraternity When: December 2-3, 2010 Where: The Orchid, Mumbai Caroline Lewis P: +91.98217 37935 F: +91.22.2832 4713 E: firstname.lastname@example.org per cent on completely-built units. The domestic price of Harleys ranges from `6.95 lakh to `34.95 lakh. This is significant, considering the fact that the superbike market in India is no more than 1,000 units annually. Anoop Prakash, MD, Harley Davidson India, said, "We are evaluating tariff structures. Our new pricing will be announced in January. The company will take into consideration investments being made in our assembly and subsidiary operations, conversion costs, transportation, marketing and other such factors, including the need to grow our business." He adds that "While our clients come from across age groups ranging from 25-60 years, most of them are 35-40 years,". According to Sanjay Tripathi, Director � Marketing, Harley Davidson India said, "Our customers do belong to a higher income group. However, demand comes from across sectors." This expansion in India will lead to a healthy competition with other superbike makers such as Honda, Suzuki, Yamaha, Ducati, and BMW which will also start their operations in December. Tata to make Hyderabad its aerospace hub n a recent decision announced by Ratan Tata, Group Chairman, Tata Group, the company plans to centralise its aerospace and defence business in Hyderabad. Unveiling the first Sikrosky S-92 helicopter cabin made in India, in a facility set up jointly by Tata Advance Systems and Sikorsky Aircraft Corp, the US, Tata said, "For Tata Group, aerospace and defence are larger and I It reflects the determination, project execution and precision-manufacturing expertise that India as a nation possesses. RATAN TATA, Chairman, Tata Group newer areas. Going ahead, we hope that our aerospace and defence investments are centered in AP particularly , around Hyderabad. The current tie-up with Sikrosky is the beginning. It is an important milestone for the company's plans in the aerospace industry and reflects the determination, project execution and precision-manufacturing expertise that India as a nation possesses." 42 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 NATIONAL NEWS EVENTS In India Suzlon Energy eyes Latin America, Africa market uzlon Energy, in a recent decision, has said it will enter new regions, mainly Latin America and African continent soon to explore local business opportunities. Speaking at a conference on renewable energy in New Delhi, Harish Mehta, Director, Suzlon Energy said, "Though our major focus is on India, we are planning to enter the markets of Latin America and African countries in the next few years." Adding further, Mehta said, "Suzlon plans to S focus more on technology improvement to make operations cost effective." Taking the decision forward, Suzlon appointed Silas Zimu as Concurrent Shows MUMBAI Maharashtra February 17-19, 2011 NSE Ground, Goregaon Suzlon plans to focus more on technology improvement in order to make operations cost effective. HARISH MEHTA, Director, Suzlon Energy One of the largest advanced design and manufacturing events in India featuring machine tools, hydraulics & pneumatics, process machinery & equipment, packaging & auxiliaries, it products, electrical & electronics with a special focus on automation & instrumentation, material handling For further details contact: Tel: 022 3003 4650 Fax: 022 30034499 Email: email@example.com CEO of its office at South Africa. Post appointment, Zimu said, "My vision is clear: I want to see this country embracing wind for all the right reasons -- closing the energy gap, offering green electricity, creating green jobs and enabling sustainability in the social, environmental and ecological spheres." Suzlon Energy founder, chairman and MD Tulsi Tanti hailed the appointment, saying that Zimu's experience was second to none, and that he also shared the company's vision for a "greener tomorrow". Waaree Group sells majority shares to Baumer Group W IPVS - INDUSTRIAL PUMPS VALVES AND SYSTEMS Focus: Industrial pumps, valves and systems When: December 9-11, 2010 Where: Chennai Trade Centre, Tamil Nadu Tele: 044 - 22316033, 044 22315551 Fax: 91 22 24102805 Email: firstname.lastname@example.org Ho.email@example.com F&S, ANNUAL ENVIRONMENT INDUSTRY AWARDS Focus: Water and Wastewater, Solid Waste Management, Air Pollution Control, and Point of Use (PoU) systems When: December 14, 2010 Where: Hyatt Regency, Mumbai Sasidhar Chidanamarri Tel: +91 9952965389 Fax: 02224081709 Mobile: +91 99309 35112 Email: firstname.lastname@example.org aaree Group, a leading player in process control equipments, industrial valves, solar energy, lubricants & petrol/fuel station equipments has sold majority shares in one of their businesses � Waaree Instruments to Swiss Baumer Group. However, the financials of the deal between the both has not been disclosed as yet. "This transaction will help the company to achieve a leading position in the Indian market," states Hitesh Doshi, Chairman, Waaree Group. According to Dr Oliver Vietze, Chairman & CEO, Baumer Group, "The acquisition will boost our activities on the Indian subcontinent. It complements the international expansion strategy of Baumer and is an excellent opportunity to strengthen our process instruments business." He added, "Waaree Instruments is an established player in India with a widespread Indian distribution network and stateof-the-art manufacturing facilities. This will improve our ability to meet local customer requirements, speed up our local delivery and to timely react to the dynamic and growing Indian market." CRI Pumps commits 36 per cent to energy savings RI Pumps, a multiw i n g e d organisation that produces different varieties of pumps and motors, has been awarded Bureau of Energy Efficiency's (BEE's) first pilot project `Agriculture Demand Side Management' (Ag DSM), at Mangalwedha, sub-division of Solapur circle, Maharashtra. In this pilot Ag DSM project, CRI pumps would undertake the responsibility of identifying and replacing 3,530 old agricultural pumps with energy efficient star rated pump sets, within a span of the next 6 months. C Under this project, farmers will be provided with Energy Efficient Pump Sets (EEPS) free of cost. Agriculture Implementing Agency (AgIA) shall be responsible for dismantling the existing pump sets, procurement of new EEPS, installation, maintenance and repair/replacement. The Repair & Maintenance for 60 months shall be provided at no cost to the farmers. Rajendran, MD, CRI Pumps, said, "Power crisis in India should be addressed aggressively in the present scenario. Agricultural sector uses over 120 lakh electric pumps, all primarily used for irrigation, consuming 6000 crore kWh of electricity which accounts for 40 per cent of the energy usage. If the 6 lakh pump sets used per annum are replaced with fully energy efficient pump sets, it will result in a savings of `2,500 crore." CRI Pumps has committed a cumulative energy saving of 36 per cent over the next 5 years. This would be monitored by a third party agency appointed by BEE with the approval of Maharashtra State Electricity Distribution Company. The total estimated cost of the project is `7 crore. 44 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 NATIONAL NEWS EVENTS In India HANNOVER MILANO FAIRS INDIA Focus: Concurrent trade shows on material handling & logistics; motion, drives & automation; building automation; energy & surface technology When: December 15-18, 2010 Where: Bombay Exhibition Centre, Mumbai Tel: +91 22 40050681/82 Fax: +91 22 40050683 Email: email@example.com EA WATER EXPO Focus: Water and Wastewater Management When: January 06-08, 2011 Where: Bombay Exhibition Centre (BEC), Mumbai Tel: +(91)-(11)-29531288 Fax: +(91)-(11)-29531291 SME INDIA OUTLOOK 2011 Focus: IT & Automation companies specifically for the SME When: February 10, 2011 Where: Novotel Mumbai Juhu Beach Mradul Verma Tel: +91 22 4208 1731 Fax: 02224081709 Mobile: +91 99309 35112 Email: firstname.lastname@example.org RENEWTECH INDIA 2011 Focus: Renewable energy and emerging technologies When: February 17-19 2011 Where: Bombay Exhibition Centre, Goregaon (E), Mumbai, India Tel: +91-22-2660 5550 Fax: +91-22-2660 3992 / 93 Email: sales@renewtechindiacom Web: www.renewtechindia.com BLECH INDIA 2011 Focus: Technology exhibition for sheet metal working When: April 14 - 17, 2011 Where: Inter Ads - Brooks Exhibitions (India), Haryana Tel: +91 (0) 124 452 4200 Fax: +91 (0) 124 452 4234 Ingersoll Rand to set up facility in Southern India ngersoll Rand, a world leader in creating and sustaining safe, comfortable and efficient environments, announced plans to establish a third manufacturing facility in India. The company presently has two local manufacturing operations in Naroda, Ahmedabad, and Sahibabad near Delhi. The new greenfield manufacturing plant will be located in Southern India. Earlier this year, the company I announced an investment of $100 million in India over the next three years. Local manufacturing, innovation and market-centric product development are the key focus areas for Ingersoll Rand in India. The new manufacturing facility is part of the company's overall growth strategy to drive innovation, technology and product development in areas such as food preservation, energy efficiency, climate control, and security technologies. Michael Lamach, Chairman, President and CEO, Ingersoll Rand, said, "India is a strategic market for Ingersoll Rand and is fast emerging as a hub for innovation and product localisation for emerging economies. With the new manufacturing facility, Ingersoll Rand India will be better positioned to achieve our growth goals for emerging markets and better able to serve our customers with localized products and services." F&S to host MindXchange on manufacturing IT rost & Sullivan's I n d u s t r i a l Automation & Process Control (IPC) Practice, in its endeavour to help the manufacturing companies understand the need for IT adoption, is organising an exclusive executive congress titled, `Manufacturing Excellence in a Flat World' on November, 25 2010, at Hyatt Regency, Mumbai. The summit will focus on understanding manufacturing F intelligence, Plant Information Management Systems (PIMS) and imperatives for next generation manufacturing. Besides this, it will also cover Manufacturing Execution Systems (MES), Product Lifecycle Management (PLM) and Digital Manufacturing, Plant Asset Management (PAM), integration of automation systems with enterprise applications, impact of SaaS and cloud computing on adoption of Manufacturing IT, virtualisation and its impact on automation and Manufacturing IT, energy management and optimisation for industries' energy consumption and visibility tools leveraging wireless for mobility in industrial asset management. The event will benefit the end users as it will be a platform which provides insights and tools for actionable strategies for adopting manufacturing IT. Representatives from both discrete and process industries are expected to attend this summit. Giving thrust to LabVIEW ecosystem W Email: email@example.com ith the focus on software tool's compiler speed, N a t i o n a l Instruments India, virtual instrumentation services provider had recently organised India LabVIEW Conference 2010 in Delhi. Built on the inherent parallel nature of graphical programming, LabVIEW 2010 delivered new features such as off-the-shelf compiler technologies that execute code at an average 20 per cent faster rate, a comprehensive marketplace for evaluating and purchasing add-on toolkit for integrating custom functionality into the platform, etc. Pradeep Nair, Strategic Business Development Manager, National Instruments India, said, "The India LabVIEW Conference facilitates exchange of information and ideas about innovative advances in technology and NI products." Almost 400 engineering colleges in India use LabVIEW as part of the educational curriculum. "Our strong presence in India has evolved the India LabVIEW sphere as a powerful India ready LabVIEW ecosystem, committed to serve the community of engineers and scientists in the country. NI India through the Planet NI Foundation is also committed to facilitate Indian entrepreneurs and students, with access to technology at affordable costs, to innovate and create real solutions that address the world's engineering challenges," Nair added. 46 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 WORLD NEWS EVENTS Abroad UK manufacturing output growth accelerates in October rowth of UK will provide reassurance that new export orders for 5 manufacturing manufacturing remained a months, with the export production driver of UK economic growth performance of intermediate accelerated for the at the start of the final quarter. and investment goods first time in seven months from Rates of expansion in output producers especially robust." 53.5 to 54.9 in October. Output and new orders strengthened Talking about sustainable rose in response to faster following the sharpest gain in recovery he said, "Looking inflows of new business ahead, business and increase in new export confidence, private orders. However, supplyinvestment spending and side constraints and exports will be important expected future input price to sustain the recovery as An improvement in the UK growth derived from the increases led to a marked Manufacturing PMI will provide public rise in purchasing and sector and survey record growth in reassurance that manufacturing consumers is hit by raw material stocks. remained a driver of UK economic austerity measures and Rob Dobson, Senior growth at the start of the final quarter. rising job insecurity. To Economist, Markit and this end, the October author of the UK rebound and a sharp Manufacturing PMI, said, increase in manufacturing ROB DOBSON, "An improvement in the job creation provide early Senior Economist, Markit UK Manufacturing PMI positive portents." Machine Tool Indonesia Focus: Tools & Tooling Equipment When: December 1-4, 2010 Where: Jakarta International Expo (JIExpo), Jakarta, Indonesia Tel: + (44)-(20)-78402100 Fax: + (44)-(20)-78402111 NRC Conference 2011 Focus: Rail Manufacturing When: January 5-8, 2011 Where: Marriott Harbor Beach Resort & Spa 3030 Holiday Drive Fort Lauderdale, FL 33316 US Tel: 202-715-2919 Fax: 202-318-0867 Medical Design & and Manufacturing (MD&M West) Focus: Materials, components, electronics, machinery, systems and services When: February 8 -10, 2011 Where: Anaheim Convention Center800 W. Katella Avenue Anaheim, CA 92802 US Tel: 310-445-4200 Fax: 310-996-9499 Tire Technology Expo 2011 Focus: Tire design and manufacturing When: February 15-17, 2011 Where: Cologne, Germany Tel: +44 (0) 1306 743744 Fax: +44 (0) 1306 742525 Lean Transformation Summit 2011 Focus: Lean Manufacturing When: March 9-10, 2011 Where: InterContinental Dallas 15201 Dallas Pkwy Addison, TX 75001 US Tel: 202-715-2919 Fax: 202-318-0867 G Global manufacturing shows signs of strength ccording to a data that suggests global economic recovery may be on firmer footing, manufacturing growth in India and China powered ahead last month with the US industry also picking up steam. USA In the US, where Federal Reserve is widely expected to announce that it will counter a sluggish economy by buying long-dated treasury debt, the manufacturing sector unexpectedly grew at its fastest A pace since May, according to the Institute for Supply Management. The Institute for Supply Management said its index of national factory activity rose to 56.9 in October from 54.4 in September. Zach Pandl, Economist, Nomura Securities International says, "It is clear that stronger growth overseas and the weakening of the US dollar has provided a significant boost to US manufacturers." Chinese & Indian economies China's PMI rose to a six- month high in October of 54.7 from 53.8 in September, easily beating market forecasts of 52.9. The strength of China's official PMI was especially striking because the index normally heads down in October, said Yu Song and Helen Qiao, Economists at Goldman Sachs. Manufacturing in India also put up a performance as strong as that of China's. The HSBC Markit PMI for India rose to 57.2 in October from 55.1 in September. Suntech opens new US manufacturing plant he Chinese solar PV manufacturer Suntech recently opened a new 30 MW capacity module production facility in Arizona. The 117,000 sqft facility will be used to produce Suntech's 280 Watt Vd-series module that are mostly used for commercial and utility-scale projects. T Suntech says it will expand the facility by 50 MW next year, growing the staff from 75 people to 150. The company plans to eventually grow the facility to 120 MW. Although a lot of solar manufacturers have moved over to China in recent years, this move shows that foreign companies see the value in setting up shop in the US. With some markets in Europe declining, the US is expected to make up for some of the slumping global demand. Many companies have also moved into the US so that they can produce modules compliant with Americanmade requirements under the American Recovery and Reinvestment Act. 48 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 WORLD NEWS EVENTS ProMat 2011 Abroad Crude steel production rises orld crude steel production for 66 countries reporting to the World Steel Association (worldsteel) was 112 million metric tonne (MMT) in September. This is 0.9 per cent higher than September 2009. China's crude steel production for September 2010 was 47.9 MMT, a decrease of 5.9 per cent compared to September 2009. Elsewhere in Asia, Japan produced 9.2 MMT of crude steel in September 2010, up 11.7 per cent as compared to the same month last year. South Korea's crude steel production for September 2010 was 4.7 MMT, 3.2 per cent up compared to the same month last year. Focus: Manufacturing, Engineering, Material Handling, Supply Chain, Logistics, Distribution When: March 21- 24, 2011 Where: McCormick Place South, Chicago, IL US Tel: 800-345-1815 Fax: 704-676-1190 Ifpe 2011 Focus: Fluid Power, Engineers, Manufacturing, Machinery, Motion Control, Machine Tools, Power Transmission When: March 22 - 26, 2011 Where: Las Vegas Convention Center Las Vegas, NV US Tel: 800-867-6060 Fax: 800-867-6060 Hannover Messe 2011 Focus: Industrial automation, Motion, drive & automation, energy, power plant technology, etc. When: April 4-8, 2011 Where: Hannover, Germany Tel: +49 511 89-31146 Fax: +49 511 89-31149 E-mail: firstname.lastname@example.org National Manufacturing Week (NMW) Focus: Mechanical or industrial engineering When: May 24-27, 2011 Where: Melbourne Convention & Exhibition Centre, 2 Clarendon Street, Melbourne, VIC 3006 AU Tel: 02 9422 8921 Fax: +61 (02) 9993 8342 W In the EU, Germany's crude steel production for September 2010 was 3.3 MMT, an increase of 4.1 per cent on September 2009. Italy produced 2.3 MMT, 19.8 per cent more than the same month in 2009. Spain produced 1.4 MMT, a 1.2 per cent decrease compared to September 2009. Turkey produced 2.5 MMT of crude steel in September 2010, 17.9 per cent higher than September 2009. The US produced 6.6 MMT of crude Country China Japan S. Korea Germany Italy Spain Turkey US Brazil Steel production change - 5.9 per cent +11.7 per cent +3.2 per cent +4.1 per cent +19.8 per cent - 1.2 per cent + 17.9 per cent +15.0 per cent -1.2 per cent steel in September 2010, an increase of 15.0 per cent compared to September 2009. Brazil produced 2.7 MMT of crude steel in September 2010, a 1.2 per cent decrease over the same month last year. World crude steel production in September 2010 is 3.5 per cent higher than September 2008 when the global economic crisis started showing the impact on the world crude steel production. The crude steel capacity utilisation ratio of the 66 countries in September 2010 rebounded slightly to 74.4 per cent compared to 73.3 per cent in August 2010. Compared to September 2009, the utilisation ratio in September 2010 decreased by 3.8 percentage points. China winning race for green jobs hina's green jobs report. Some 70 per cent of energy employers � up from from solar and the parts in renewable energy three in 2008 � according to other clean tech installations in the US are Clean Tech Job Trends 2009. industries are manufactured overseas. Part of But Brazil, South Korea, growing faster than the US and the reason is cheap labour cost Germany, Japan, the US are other countries, says an annual in Asia. Opining on this, experts still very much in the game, as report by cleantech research say that the lack of a strong and clean-energy manufacturing firm Clean Edge. robust federal renewable grows and becomes more According to the report, portfolio standard puts complex. Ron Pernick, MD, clean energy is spawning countries like the US at a Clean Edge, says "Clean-tech millions of high-paying green significant disadvantage. jobs are not amorphous as jobs worldwide, even as the Another policy absent in critics claim. These instead global economy continues to America is the national feed-inrepresent some of the most sputter. Total jobs surpassed tariff programme. The US also dynamic sectors in the three million in 2009, shows needs significant regulatory and technology landscape." In comparison, the US data from research group REN financial support, including Government devoted $50 21. China accounted for "billions in loan guarantees," billion of the $800 billion federal 7,00,000 of that amount, due the report advised. Around 30 stimulus package to develop in large part to measures that countries have such policies in cleantech factory jobs. "But promote solar heating. The place, including China, which results of this attempted Chinese Government spent has targeted 15 per cent of its manufacturing revival in the US $34.6 billion last year to propel energy from renewables by are decidedly mixed," says the its low-carbon economy, more 2020. While the survey comes than any other nation as a boon for China, it's and almost double of The Chinese Government spent $34.6 a wake up call for the what the US invested. billion last year to propel its low-carbon USA. "Time is running The country is now out for us to take a more headquarters for six of economy, more than any other nation and serious, approach," almost double what the US invested. Pernick added. the biggest renewable C 50 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 CHAIRMAN & MD, MESSUNG GROUP OF COMPANIES AUTOMATION has changed the way MANUFACTURING FUNCTIONS "Industrial automation has become synonymous with higher production rates, efficient use of materials, and better product quality. It has improved safety, shortened the workweeks for labour and has reduced factory lead times. Despite claims of high quality from good workmanship by humans, automated systems typically perform the manufacturing process with less variability resulting in greater control and consistency of product quality," avers Farook Merchant, Chairman & MD, Messung Group of Companies, as he shares his expertise on factory automation with Purna Parmar. Excerpts... D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 53 CHAIRMAN & MD, MESSUNG GROUP OF COMPANIES AUTOMATION REPLACING MANUAL PROCESSES Automation is a must when you need accuracy, high quality and mass production. For example, just a few years back the media industry used to have an extremely high human error rate, until it was automated and several safety equipment were introduced. Another example is the car assembling and painting industry. Today, automatic painting guns and robotic arms can paint and assemble cars as per consumers' requirements. This was considered unbelievable just a few years back. There is an increased use of error proofing methods on the shop floor, for example Poka-Yoke, Torque Wrenching, Traceability, etc. use of water despite facing challenges such as power cuts, vast land topography and water scarcity. If automation becomes a standardised norm in the Indian agricultural industry, it will grow by leaps and bounds. Look at Israel which revolutionised its agriculture sector by adopting automation years back. Another example is the food & beverages industry where maintaining hygiene is crucial. Here, automation has decreased the human-product contact thus bringing down contamination levels. etc. has become the need of the hour. It's no wonder then that the microprocessors, which control the CPUs, are getting faster, and so are their instruction and execution time. THE GROWING NEED FOR AUTOMATION Automation has changed the way the manufacturing functions. It has rapidly spread across all segments of manufacturing and has thereby drastically reduced human errors. As the need for speed is growing � so also is the demand for automation which delivers faster communication while maintaining higher reliability. Accessing data at a faster speed from devices such as the controllers, drives/ inverters, servo drives, motion controllers, As automation brings all the machines together, it helps to manage & control production activities to optimise quality, production volume, delivery & cost. Thus, the entire factory can be controlled and supervised by a single control system. There is also a good demand for automated products with safety features. Automation is increasingly being used for energy saving and power management. AUTOMATION AND ITS GROWTH PROSPECTS The prospects of automation, especially at the bottom of the pyramid, are growing day by day. We have received enquiries from farmers seeking to know how automation can help them make optimum ROLE OF DESIGN & INNOVATION Innovation plays a vital role in the automation industry. For example, Up, Close & Personal : The automation industry in India saw a revolution in the year 1981 when Merchant, a modest engineer from Pune, gave India its first indigenous PLC (Programme Logic Controller). Considered as the pioneer in PLC, Merchant realised his automation dream through his own venture Messung Systems. Merchant's persistence and hardwork finally bore fruits in 1984 when Messung embarked on another milestone as Relay Contractor Logic was replaced by Merchant's PLC called Meprolog-H. Merchant started in a garage and moved to a leased shed in Parvati Industrial area before finally shifting the company's base to Bhosari in 1988. Under his leadership, Messung has churned out world-class yet diverse products that are used in the automation industry today. An innovator and a trend setter, Merchant continued to successfully launch higher and more advanced customer centric and cost effective products. The XMP8 � a new range of products focussed at the small and medium sector from Messung's portfolio launched in 1992 were very well received by their customers nationally. It was Merchant's continued wisdom and support that helped Messung reach incredible heights in automation. In 1995, Messung introduced Messung Systems and became eminent Distributors for Mitsubishi Electric, Japan for Factory Automation (FA) products in India. 54 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 CHAIRMAN & MD, MESSUNG GROUP OF COMPANIES controllers when custom designed can help manufacturers enhance productivity at a lower cost. And so many of the important players are constantly improvising on their products to satisfy their customers' growing demands while working in tandem with them to provide optimum product mix. Design also plays an important role while customising a product. Automation is a must when you need accuracy, high quality and mass production. For example, today, automatic painting guns and robotic arms can paint and assemble cars as per consumers' requirements. higher failure rates and were expensive to maintain. (As there are a lot of moving elements and resultant wear & tear). These machines had a huge motor, huge shaft and a gear box. Changing the speed of the motor meant affecting the speed of the whole machine. Consequently, these machines required continuous maintenance for their smooth functioning. However, servo-based automation has eliminated these problems. We have removed the shaft and the gear box and fixed a motion controller and servo motors. All of which is connected to the master controller with an optical fibre cable. Now, one can change the speed of the motor and at the same time control the speed of the machine and its associated units. The capital investment involved here may be high, but the machine's lifespan has certainly increased. WHY SHOULD AUTOMATION BE ADOPTED? As automation brings all the machines together, it helps to manage & control production activities to optimise quality, production volume, delivery & cost. Thus, the entire factory can be controlled and supervised by a single control system. Automation ensures that world-class quality products are manufactured. It decreases the dependency on manual processes. Automated machines ensure easy maintenance and diagnostics. ROBOTICS AND SEMIAUTOMATED PROCESSES In India, it is expensive to manufacture robots and so, only big companies have ventured into this space. And, while at Messung, we also don't manufacture robots, we provide motion controllers and servo motors that go into the robotic systems and synchronisation. There are companies who are in the field of material handling, but this is different from manufacturing robots. FUTURE TRENDS IN AUTOMATION Wireless technology has advanced with the use of GSM, GPRS, Bluetooth and RFID devices. But automation is not far behind. Motors operated using gear boxes and shafts will soon be replaced with servo motors to enhance speed, accuracy and repeatability. Automated machines are also being modified to make them user-friendly. THE CHANGING PHASES OF AUTOMATION Earlier, companies would use mechanical gears, hydraulics and pneumatics, which due to their elctromechanical nature had 56 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 FLEXIBLE MANUFACTURING FLEXIBLE MANUFACTURING: Think `Flexible' Think `Robots' .....................................................62 LOW-COST ROBOTICS: Equipping SMEs with Affordable Solutions .............................................66 OPTIMAL TEMPERATURE SENSOR SELECTION: Achieving Accurate Temperature Measurement ...71 SENSORS: Preventing Product Defects Through Error-proofing ....................................................76 TIPS & TRICKS: SENSORS: Taking `Stock' Of Inventory .................................................................80 D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 61 FLEXIBLE MANUFACTURING TH NK `FLEXIBLE' TH NK `ROBOTS' With rising cost concerns and lack of trained manpower, companies are now adopting robotic technology as part of flexible manufacturing systems or flexible automation. Today, these robots have become intelligent through the means of advanced technology such as sensors that support `flexibility' of production lines. The increasing robotisation on the shop floor has led to cost benefits, but is also posing several challenges for the industry. SHIVANI MODY istinctive competencies and core competencies or competitive priorities are the two areas of strength, which determine the success of any company. Price (cost), quality, delivery, service and flexibility are five distinct factors that can provide a competitive edge to companies. This implies that a firm's major strength lies in flexibility of product (ability to easily make changes in a product) and flexibility of volume (ability to easily absorb large shifts in demand). Firms that are able to achieve this are said to have flexible capacity, the ability to operate manufacturing equipment at D different production rates by varying staffing levels and operating hours. This is what is known as flexible manufacturing, which consists of three components: (1) the flexibility to produce a variety of products using the same machines and to produce the same products on different machines; (2) the flexibility to produce new products on existing machines; and (3) the flexibility of the machines to accommodate changes in the design of products. Literally, a flexible manufacturing system (FMS) is a group of numerically-controlled machine tools, interconnected by a central control system. The various machining cells are interconnected, via loading and unloading stations, by an automated transport system. Operational flexibility is enhanced by the ability to execute all manufacturing tasks on numerous product designs in small quantities and with faster delivery. In the age of stiff competition, this presents the possibility of producing non-standard parts to create a competitive advantage. The concept of flexible manufacturing systems were evolved during the 1960s when robots, programmable controllers and computerised numerical controls brought a controlled environment to the factory floor in the form of numerically controlled and direct numerically controlled 62 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 FLEXIBLE MANUFACTURING machines. This reflects the crucial role of robotics in manufacturing. But what makes it critical is noteworthy. This is all because of its programmable controls, end-of-arm tooling and machine vision systems � devices that can perform a wide variety of repeatable tasks. Ramadas Nambi, General Manager � Robot Sales, Fanuc India, says, "Today, it is possible to automate every operation to get the desired outcome. In order to ensure optimal functioning of such a system, it is necessary to apply special decision-making structures, proper planning, quality control system of production and execution. This is possible by robotisation, an advanced technology mechanism." Apart from bringing in flexibility in production, robotic technology is beneficial as it helps to reduce total batch production time; minimise running production volume; reduce the time necessary to change the assortment being produced; communicate better with planning system & scheduling system; and enable better utilisation of machines. Nambi says, "The aim of flexible manufacturing includes obtaining highly productive output, reducing non-productive time, preventing rejection/wastage, ensuring process precision & on-line process correction, and delivering good quality parts every time. The outcome of this will be low manufacturing cost, high quality product, consistent results and high reliability 24x7. To get the significant outcome, one has to ensure consistent, good input all the time. This is possible by using reliable machinery, which addresses the repeatability element. One such machine used to address this issue is the robot." One of the other benefits of robotic technology is reduction in overall manufacturing cost by lowering direct labour cost and minimising scrap, rework and raw material waste. Such systems require less skilled labour, though there needs to be trained employees to support the operation of the system. There is a reduction in manufacturing lead-time, so that manufacturers can respond more quickly to the demands in the marketplace. Also with better process control, one can create consistent quality. With the rapidly evolving robotic technology � increasing power of the microprocessor and artificial intelligence techniques � robots have dramatically increased their potential as flexible automation tools. The new surge of this technology is in applications demanding advanced intelligence. Robotic technology is converging with a wide variety of complementary technologies � machine vision, force sensing (touch), speech recognition and advanced mechanics. This results in exciting new levels of functionality for jobs that were never before considered practical for robots. The introduction of robots with integrated vision and touch dramatically changes the speed and efficiency of new production and delivery systems. Robots have become so accurate that they can be applied where manual operations are no longer a viable option. In addition, significant gains are achieved through enabling rapid product changeover and evolution that cannot be matched with conventional hard tooling. Sunil Raibagi, MD, Gudel India, avers, "Due to the changing market trends, the use of robotic technology has now become the norm. Considering the automobile industry, consumers demand choice, and this forces manufacturers to produce many variants and multiple models of cars within a limited time. To meet the time to market, manufacturers need to produce different parts � differing in shapes and sizes, for different models on the same production line. For the production line, robots handle loading & unloading of parts. In order to handle different parts, the robot has to make changes for fixtures, tools and dies. This has to be done efficiently and without much changeover time. There is also a need to build flexible lines to incorporate the robotic technology." TECHNOLOGICAL ADVANCEMENTS With a focus on flexible automation, robotic technology too is evolving in its intelligence. These advanced technologies use latest sensor technology and advanced technology for robotic arms. The vision and force sensors in combination with the robotic arm control the grip of the fingers for different parts, depending on the shape and size of the products. These also control the speed of the robot on the shop floor. The other feature that makes robots suitable for flexible automation systems is the open architecture that allows easy integration with commonly used PLC platforms and offline simulation from desktop computers. Further, networking, continued standardisation in protocols and enhanced predictive maintenance tools, will make future generation of robots more flexible. Yogesh Kumar, Head - Robot Engineering Services, DiFACTO Robotics & Automation, observes, "Currently, the standard equipment used by the industry is robots with six or more axis of motion. These are flexible and can be used interchangeably depending on the production range. Flexible systems are important as they support production of parts, which may not be high volume products. This allows for multi modelling � mixing of production of two products as per a set batch production time � which ensures improved productivity and optimisation of the same production lines. Added to making changes in the external features, controlling the internal programming too is becoming easy for operators. An operator can comfortably change the software programming to suit the production." The gripper of the robotic arm is equipped to handle different products and is designed to suit the production. The grippers undergo an automatic tool change, in a short time, depending on the production. Kumar informs, "The system is set up in a way that it runs smoothly in an automatic mode. The robot changes the tools based on the part that is to be worked upon. It will automatically go to the parking stand and select the suitable gripper." Elaborating on the significance of grippers, Gopal K, MD, GK Technosynergies, states, "The use of grippers requires sufficient planning. Other than the shapes and sizes of products, even the element of material and weight is to be factored in while selecting robots. Further, the grippers are used with pneumatic cylinders, which help to control the speed of the arm. With the increasing number of robots on the shop floor, companies are looking at one control system instead of many controllers. There can be more flexibility using a parallel connection." SENSOR CAPABILITIES One of the potential growth markets for the present and near future is assembly and machining, where vision and force sensing continue to be the enabling technologies. Today, the robots are fitted with sensors � vision and force sensors that help in identifying products, and thereafter, picking and handling the function. Kumar says, "The use of vision and tactile sensors have helped in carrying out repetitive tasks. The sensor technology is D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 63 FLEXIBLE MANUFACTURING useful for reducing errors and rejections. This improves the quality and saves valuable time in the process. With the focus on quality and improved productivity, inspection using machine vision systems is becoming a critical application for the industry. Along with reducing errors, the system is quick to report any variations." Also a camera used in the machine helps in reporting variations and reducing errors of products. The addition of sensor technology has helped in improving performance and quality of parts. Moreover, the 3D vision systems are becoming prevalent, especially in applications where parts have contours or where they vary in dimension. Nambi informs, "Our patented 3D laser vision sensor allows the robot to intelligently recognise objects and handle them accordingly. The laser sensor helps the robot to detect objects whether they are placed in order in a stack or randomly grouped together. The force sensor provides good tolerance to overloading, detects both torque and force applied to a robot wrist in arbitrary directions and realises compliant robot motion to external force. This is useful, for instance, while doing multi-layered (4 to 6) spline insertion by force sensor." Additionally, the vision sensor helps in detecting parts on the conveyor and takes action accordingly. The system moves conveyor by I/O signal from robot and detect parts on the conveyor by the vision sensor. The system helps in detecting multiple parts; and new parts are handled by vision programme modification. the accuracy of distance needs to improve over time." He adds, "In the future, we will see multi-functionality in robots and already experiments are on using an additional axis � the seven-axis robot." Nambi says, "Installing robotic solution calls for a structured, practical approach and a good quality production set up. The output that a robot produces is dependent on the quality of the input. Currently, this concept is missing in the industry. Moreover, there needs to be standardisation of the input to achieve consistent output." As of now, the use of safety devices in the industry is limited. The number of robots that has minimal barrier or is completely enclosed is limited in the country. Also the awareness related to optimal work range and response to error condition is not up to the mark. Some of the widely used active safety devices are light curtains and floor mats. On the same lines, Raibagi notes, "The speed of the robot and safety are among the primary concerns when it comes to robot usage. With the space constraints on the shop floor, the movement of people and operator working on the robots can lead to problems." PROMISING LANDSCAPE Several companies have been able to address the issue of lack of manpower by adopting flexible automation. This has resulted in cost savings for companies. Citing an example, Nambi says, "One of the companies needed to automate 20 machines (15 CNC lathes and 5 autolathes) to perform turning operations on bearing parts. The management faced issues pertaining to output � inconsistent production volume per day, lesser efficiency in unloading/loading process on machines, availability of trained manpower, drastic reduction of output during absence of trained manpower, time required to train the newly recruited manpower among others." He adds, "With proper planning, we modified the machine layout on the shop floor and installed five robots, leaving space for an additional one in the future. This enabled consistent production volume for a particular month and was not dependent on manpower. The transportation from autolathe is totally eliminated by adopting direct supply to the robot cell by using feeder unit and considerable improvement is achieved (approximately more than 25 per cent). The SURMOUNTING CHALLENGES One of the major challenges in the adoption of robotic technology is the issue of developing the software. The advances in hardware have not automatically translated into better software for controlling complex robots. Kumar informs, "Being a complex machine, manufacturing robot itself is a challenging task. The robotic arm is designed for a particular application, while the software can be entirely for another application. In such a case, the operator can spend hours trying to re-programme the system. The right combination and development of software is essential. Further, there needs to be development in the robot mechanical unit. However, a robot may not be the most accurate device though it enables repeatability. For instance, number of manpower drastically reduced to five per shift instead of 20 per shift. The production per day could be managed with 15 workers instead of 60." Looking at the advantages of flexible management system, even the SMEs are adopting robotic technology. Gopal states, "Currently, SMEs are realising the need to adopt robotic technology. But the hindrance here is the cost of re-configuring the process and implementing robotic technology. For these solutions to be used widely, the cost needs to reduce in the long run." Raibagi informs, "Moving forward, there are three major changes that will take place in the flexible automation space. Firstly, there will be need for companies to analyse their shop floor configuration and make changes accordingly. The safety factor will gain importance owing to the high speed and movement of robots in limited space. Secondly, automation will become a commodity and the intellectual property issues will become critical in this case. And lastly, there will be focus on environmental concerns and `green' products and solutions will see momentum." With greater flexible automation on the shop floor, companies are now looking at unmanned operations. Experiments are already on for 72 hours of unmanned operations, where robots perform the tasks uninterrupted. Nambi says, "There is a great deal of R&D happening in the field of artificial intelligence, which will lead to advancements in sensor technology. Flexible automation will grow at a fast pace, and we may even witness one month of unmanned operations." The changing dynamics of the market is demanding new features such as new programming approaches, safe industrial robots with minimal required space, integrated gripper solutions, new control possibilities and assistance behaviour. The use of robotic technology can help solve these issues to a great extent. Additionally, faster equipment changeover between production jobs will have a direct bearing on the improvement of capital utilisation. This will also reduce costs per production job due to the decrease in manhours needed for set up of equipment. There are significant savings from the reduced indirect labour cost, less error in production and number of repairs, and product rejects. With companies in India looking to increase efficiency and enhanced productivity, robotisation will see greater adoption in the near future. 64 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 LOW-COST ROBOTICS EQUIPPING SMEs WITH SMEs AFFORDABLE SOLUTIONS The use of robots has imparted the manufacturing industry with a job efficiency that is unlikely to be duplicated by humans. Costeffectiveness, efficiency and safety are the main reasons why robots have become an integral part of this industry. However, there is a perception that robotic solutions come at a very high cost and is difficult for every company to adopt. Nevertheless, R&D and innovations have made low-cost robotic solutions a reality, which has proved to be a boon to companies, especially SMEs. PURNA PARMAR obotic solutions have revolutionised the Indian manufacturing industry, with robots outperforming humans in jobs that require precision, speed, endurance and reliability. Robots safely perform dangerous jobs. Robotic applications in traditional manufacturing include material handling (pick and place), assembling, painting, welding, packaging, palletising, product inspection and testing. R However, robotic applications are perceived to be more expensive and so the penetration of robotic solutions in the Indian manufacturing industry is limited to few large-scale industries in sectors including automotive, electronics, medical, food production, biotech, pharmaceutical and machinery. Small and Medium Enterprises (SMEs) lie on the other side of the technological divide. However, with several companies undertaking innovation and designing robotic programmes, robotic solutions are now available at a low cost. These low-cost robotic solutions are easy to adopt and highly cost-effective. ADVANTAGES OF ROBOTICS Robotic solutions have proved to be key drivers in terms of low-cost automation with higher degree of flexibility and return on investment (ROI). As the Indian market is witnessing a transition from being a medium quality market to a high quality 66 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 LOW-COST ROBOTICS the growth of adoption of robotic solutions in manufacturing industry. One of the biggest factors that has intensified the use of robotic solutions in manufacturing industry and SMEs is the consciousness towards quality. They have started entering into the export domain, and consistent quality is a vital attribute that international customers demand. So these enterprises are focussing install the robot. Today, there are many companies, which provide such programs and services in India. This has made adoption of robotics not just easily available but also affordable." Creating awareness on availability of low-cost robotics solutions can help companies expand their markets. It is more about ROI than cost, and this has been one Advantages of deploying robotics: Reduce operating costs Improve product quality & consistency Improve quality of work for employees Increase production output rates Increase product manufacturing flexibility Reduce material waste and increase yield Comply with safety rules and improve workplace health & safety Reduce labour turnover and difficulty of recruiting workers Reduce capital costs (inventory, work in progress) Save space in high value manufacturing areas. on consistent quality output & first time right delivery and robotic solutions helps in achieving this. Hence, the adoption of robotics solution has increased amongst SMEs." OVERCOMING THE COST BARRIER Robotics industry has been suffering on account of cost issues, where the perceived cost is more than actual cost. Latest technological innovations in production line and usage of robotics in manufacturing the robots have resulted in a considerable decline in their costs. Robots are more affordable now compared to the previous decade. Robotics industry is still in the growth stage, thereby driving robot manufacturers to reduce the costs. According to Joshi, the cost of ownership of robotics has reduced over the last five years. This is mainly due to the increase in the volume of production and growing customer demand for quality products. So buying a robot these days is not an expensive affair. "A few years back, the implementation of robots on the existing shop floor was expensive. In a robotic application, there is a huge aspect of service, not just with regard to the equipment (robot) that is bought but also the configuration system required to products-oriented market, there has been a need for better quality, higher productivity and greater flexibility. Workforce, health and safety issues are among other major reasons for increasing demand for robots. Anil Chaudhry, BU Manager-Robotics, ABB, avers, "Robots can work in harsh conditions where the working temperature and the environment are beyond the normal tolerable limits. However, it is perceived that increasing cost of labour and nonavailability of skilled labour is the main force driving the growth of robotics among SMEs. On the contrary, the urge to match the international quality standards and surmount global competition is among the growth drivers of robotics among Indian SMEs." Meanwhile, Prashant Joshi, Business Head, Hi-Tech Group, further explains, "There are various factors that have led to of the factors leading to rise in adoption of robotics solutions. "Awareness regarding the cost of error has helped people overcome the cost barrier. For instance, imagine a situation where a company needs to produce a huge quantity of assembled machines and the work is done manually. And for some reason, one of the employees makes a mistake and the faulty product reaches the customer who rejects the whole consignment. The error made by one employee could result in the loss of entire business and ultimately the cost of error may increase. Instead, if the company deploys robotic applications, then the chances of error are eliminated and the cost of error comes down drastically. This way the company can ensure delivery of consistent quality products. Robotics also helps in saving manpower cost. Even with the expenses of maintenance and occasional breakdowns, robots just make more sense economically for the manufacturing industry," says Joshi. LATEST TECHNOLOGIES There are multiple technologies, launched every year, in the arena of robotics. Earlier only original equipment manufacturers (OEMs) were using robotics, but robotics D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 67 LOW-COST ROBOTICS applications span across all sectors expensive; they come in multiple of manufacturing. options and can be easily "Robot manufacturers are customised. Another robotic coming out with technologies like One of the biggest factors that has intensified the use of application that first-time users can offline simulation tools and others robotic solutions in manufacturing industry and SMEs is adopt is Scara robots. They are that make it much easier to industry, the consciousness towards quality. They have started prevalent in electronics in other understand and operate robots. but can be applied entering into the export domain, and consistent quality is manufacturing sectors as well. Designer software takes robot a vital attribute that international customers demand. programming to an optimum level, They can be used in precision which increases the manufacturing machines as well and cost is not a flexibility and lower installation hindrance here as these are easily PRASHANT JOSHI, periods. Then there are robots available and are not very Business Head, Hi-Tech Group that can be monitored remotely expensive to install. Another with remote service. The robots application is the AGVs that are of today are much more userwidely used by SMEs." friendly than its predecessor," says helping to device the right robotic application SUCCESS STORIES Chaudhry. depending on your requirement," says Robotics has not just enabled to attain high According to Joshi, smart robotic Joshi. quality products, but also helped in achieving solutions are one of the latest technologies ROLE OF R&D AND cost effectiveness. Through various that are gaining ground across industrial INNOVATION innovations and research, companies are segments. The robots have a great sense of Changing technology in the processes and able to produce low-cost robots that deliver adaptability. For instance, earlier if a end-products calls for newer applications in same output as other sophisticated robots component had to be picked up from one designing and product development. would deliver. Joshi shared an example of place and placed on a machine, the robot "Highly flexible automation robots are being low-cost robotics being deployed by an would just pick up the component from a continuously developed and innovations SME, which has immensely benefited out of pre-decided location and place it on the are happening in the R&D labs to match it. He elaborates, "One of our SME client machine and do the job. But now, the changes in the production environment, was into assembly processes and they robots have a great sense of adaptability � customer requirements and technologies," constantly received complaints from their they can pick up the right component from says Chaudhry. clients and often had to suffer huge losses on any location and place it on the machine." According to Joshi, today there are account of rejection of consignments due to Another technology introduced is highly sophisticated robots available but errors found in the products. The problem mobile robotics solutions � these robots these robots are not customised. He diagnosed was the components were not are not static, they can move from one believes that if a mass customisable product assembled properly, and hence customers place to other and are not confined to one can be created for Indian companies, it will complained that the machine parts were not place. They are also called automated help companies to adopt robotics easily. For working properly. We designed a poka guided vehicles (AGV). instance, a company might need only a yoke solution for them. We installed a PARAMETERS FOR SELECTING two-axis robot, but there are only five-axis camera-based poka yoke that did not allow THE RIGHT ROBOT robots available in the market. Here comes the machine to install the components, if A wrong selection of robot can hamper the the role of innovation through which a they were not aligned in the right direction. productivity of a process. Hence, the usage company can attain a customised robot to This helped the customer obtain higher of simulation tools will provide the user the meet its specific requirement. This will also quality products and the production time benefit of choosing the apt robot for a help in reducing cost for the overall robot was also reduced. These poka yoke solutions particular application. The selection can be and its installation. are not expensive and so the client did not based on various parameters, for instance have to spend much on the cost." FIRST STEP TOWARDS the payload carrying capacity of the robot ADOPTING ROBOTICS THE WAY FORWARD or the reachability of the robot. Here, While adoption of automation has been The use of robotics is spreading wide and designing plays a vital role in attaining lowrapid, robotics is still in its nascent stage. fast; high consciousness for quality has cost robotic solutions. The perceived cost of robotics application is compelled SMEs and other companies to "The biggest criteria that needs to be high while the actual cost is relatively low. adopt robotic solutions. There are various kept in mind while selecting the right robotic Talking about how SMEs can take their first advantages attributed to robotics and their solution is the consistency of deliverability step towards adoption of robotics, Joshi importance in achieving high quality be it quality or time. The company needs to opines, "There are some innovative gantry products and cost-efficient jobs cannot be be sure how much additional business they solutions available in the market. It is the over-emphasised. It would be of paramount can manage within their existing simplest form of robots, these gantries are importance to see how SMEs can leverage infrastructure. Accordingly, they need to like a robotic arm used for a gripper that on this growth through adoption of lowpredict the daily production capacity, and moves in two directions at the most. These cost robotic solutions backed by innovation hence, prepare their forecasting plan are easy to adopt and now they are not and R&D. accurately. Design plays a critical role in 68 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 OPTIMAL TEMPERATURE SENSOR SELECTION ACCURATE MEASUREMENT Sensor selection goes beyond having a sound knowledge of the inherent accuracy of particular sensor types. In selecting the best sensor for an application, environmental factors need to be considered for potential sources of error. In order to deal with uncertainties, it is also important to have in-depth information about sensor calibration techniques. hen building a knowledge base on sensors, one should consider inherent accuracy in terms of durability, range of operation and susceptibility to external noise influences. Besides, it is also necessary to examine how a particular sensor will be used in terms of temperature range, the required level of accuracy and repeatability, handling/installation endurance, whether it will be calibrated/grounded, and the type of environment it will be used in. Some of the widely used sensors include thermocouples, thermistors and resistance temperature detectors (RTDs). close to the desired point of measurement. The durability and simplicity of this sensor type makes it ideal for embedding into other devices. However, thermocouples have certain drawbacks pertaining to accuracy, noise and precision. When extreme accuracy and precision is required, many of these shortcomings can be compensated for -- simply by using short runs of insulated and shielded thermocouple wires with balanced, low-pass filtered differential amplifiers (to avoid common-mode voltage offsets), as well as through relatively complex calibration procedures. Lack of alloy homogeneity poses additional challenges. Deviations in metal purity and alloy homogeneity result in thermocouple temperature profiles are not in sync with the National Institute of Standards and Technology (NIST), which become particularly problematic when long runs are required. When high accuracy is required without calibration, a thermocouple type that consists of a minimum number of elements should be used. W THERMISTORS Thermistors are ideal for measuring applications that require high accuracy sensitivity over a relatively narrow range of temperatures (typically less than 300�C). However, unlike thermocouples they cannot endure high temperatures or mechanical stresses, which makes it difficult to use them in applications and assembly operations where these influences are not well-controlled. To compensate for this limitation, the sensor can be encased in a protective metal enclosure -- but this will be at the cost of thermal responsiveness. Some special version thermistors are capable of working to temperatures of 1,000�C. Despite being less subject to different types of errors, local signal conditioning is still recommended for thermistors (though it is much simpler than that required for thermocouples). Thermistors tend to be THERMOCOUPLES Thermocouple is the smallest, fastest and most durable temperature measurement solution. They can withstand very high temperatures, harsh mechanical treatment and are simple to operate. Their size allows for rapid temperature response times and the sensing junction can often be placed D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 71 OPTIMAL TEMPERATURE SENSOR SELECTION QUICK TAKE Thermocouples are generally the most durable as compared to thermistors and RTDs Thermocouples and RTDs generally have the lowest noise immunity Generally, thermistors and RTDs have better inherent accuracy than thermocouples Thermistors usually exhibit some initial drift, but are generally stable after initial aging Thermocouples exhibit more complex behaviour because the voltages produced are a direct result of the dissimilar metals used, as well as their alloy formulation, which both change as the metal ages and deteriorates The accuracy and precision of an RTD often exceeds that of both a thermistor and thermocouple. larger than thermocouples and so they have correspondingly slower response, and may also be subject to additional location and heat transfer error than equivalently placed thermocouples. Near their maximum sensitivity point, small changes in temperature produce relatively high changes in resistance (a nonlinear response). However, away from the maximum sensitivity point, thermistors are less able to resolve changes in temperature. Padding resistors may be added in a voltage divider circuit to obtain a more linear response. Thermistors are capable of being made relatively uniform in batches, but batch-tobatch variations can be problematic when high precision or accuracy is required. Additionally, there are no NIST standards for thermistors, so there may be additional manufacturer-to-manufacturer response variations. which results in them being difficult to embed into custom-made mechanical devices. This limitation can be reduced through the use of metal-sheathed assemblies that remove the fragility, but this is at the cost of response time. Additionally, their larger size typically results in slower response times than comparable thermocouples. For a typical 100 ohm RTD, wire and termination resistance associated with long lead lengths and multiple connections can become a significant source of error. To achieve the highest accuracy, three or fourwire RTDs are often used. The electronics can be constructed to dynamically remove error associated with lead resistance, but there is also a trade-off in terms of cost and the number of wires required to perform the measurement. Noise from external sources can create additional measurement problems, but can be mitigated in much the same way as thermocouples -- by using differential, ungrounded, and shielded elements. These effects can also be limited through optional electronics that perform 10 per cent duty cycle measurements to limit self-heating of particular sensor types is important, but it goes only a short way towards the goal of achieving optimally accurate temperature measurement. It is the broader knowledge of how sensor choice, sensor placement and a wide variety of environmental factors can contribute to sensor error, as well as having a familiarity with calibration techniques that can be used to reduce this uncertainty, which ultimately leads to optimum sensor selection and measurement accuracy. There are several considerations to be taken into account while choosing a sensor for a particular application. LOCATION AND TRANSIENT ERRORS It is nearly impossible to sense temperature exactly where you need it. At the very least, the sensor itself has a finite size that displaces the sensing element from its attachment -- resulting in the sensor being at a different location than the desired measurement location. Thermistors and RTDs are more prone to location error than an equivalently placed thermocouple -- simply because of their size. If surrounding heat sources and sinks are known, location errors can be compensated for. However, this can be difficult in many systems and will result in location errors resisting calibration. The simplest solution, which avoids complex calibration techniques, is to utilise a small sensor and place it as close to the temperature source as possible. Figure 1 illustrates how errors in sensor location can affect temperature RTDs measurement accuracy. Location error `A' is RTDs are suitable when extremely stable a direct result of the entire sensor being and precise measurements are required, or displaced from its desired location, typically when accuracy over a prolonged time is the because of interference. Location error `B' most important factor (the accuracy and is a direct result of the sensor element being precision of RTDs often displaced from the intended exceeds that of both thermistors surface by its encasement. A common way to correct inherent accuracy errors is to and thermocouples). RTDs Transient errors are dynamic calibrate the sensor in a controlled isothermal liquid bath follow Deutsche Industrie thermal errors, which are and compare temperature readings against a standard Norm (DIN) and/or Joint typically difficult to compensate Information Systems for. This is because every reference. Committee (JISC) national material within the thermal power without reducing signal strength. standards and with good tolerance system has its own unique thermal However, the trade-off for utilising low-level specifications, off-the-shelf RTDs are conductivity and capacity. Of the three most signals (power) to drive an RTD is that even consistent regardless of their batch number. popular sensor types, it is the thermocouple RTDs are delicate, and while the melting further measures may then be required to that best minimises transient errors because temperature of an RTD element is minimise the effect of external noise. it is the smallest sensor with the smallest sufficiently high enough to survive many time constant. SELECTING THE high-temperature manufacturing operations, APPROPRIATE SENSOR HEAT TRANSFER ERROR they do not tend to survive aggressive A basic awareness of the inherent accuracy Sensors receive conductive, convective mechanical operations (such as compaction), 72 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 OPTIMAL TEMPERATURE SENSOR SELECTION Cool Air Actual Sensing Element Location B Ideal Sensor Location Heat Source Heat Sink A Figure 1: Location Error and/or radiative inputs that contribute to lead-wire deterioration. measurement inaccuracy. In figure 1, these For RTDs, the lead-wire corrosion types of errors can be represented by problem is mitigated by using three-wire or ambient conditions that heat up or cool four-wire units that effectively measure the MAGNETIC, CAPACITIVE, RF down the sensor -- often along specific resistance of the sensing element versus the AND GROUNDING EFFECTS pathways such as along the thermally connection wire. This provides RTDs the Thermocouples and RTDs generally have conductive electrical wires used in greatest overall stability of the three sensor the lowest noise immunity of the three thermistors, RTDs and some thermocouples, types. Thermistors usually exhibit some sensor types. By shielding and properly from a nearby heating element. In this initial drift, but are generally stable after grounding these sensors, their immunity instance, heat from a local source travels up initial aging. Thermocouples exhibit more from potential noise offsets can be further the copper wire to the sensing element and complex behaviour because the voltages improved. This is true for offsets caused by distorts the measurement. A few types of produced are a direct result of the dissimilar capacitive, radio frequency (RF), thermocouples use alloys that and offset currents, but immunity are less conductive, which makes There is no simple solution to achieving accurate from magnetic sources is not so them ideal for mitigating this kind temperature measurement through sensors. The key easily achieved. of error. lies in choosing the appropriate sensors taking into The environment in which account various factors, be it pertaining to the given SELF-HEATING ERROR sensors operate can often One form of measurement error contain large motors and application or environmental impact among others. applies to thermistors and RTDs, solenoids, or high current and results from heat dissipating inside the devices that can cause transient currents or metals used, as well as their alloy sensing element itself. This causes the magnetic surges. For sensor types that formulation, which both change as the temperature inside the sensor to rise, which require stimulating electronics (thermistors metal ages and deteriorates. makes the measured temperature less and RTDs), these power droops could When attempting to measure indicative of the environment. Strategies for potentially affect the power supplies temperature on a surface, forced airflow on minimising this include keeping the current and sensing circuits inside the sensor and around a sensor can contribute to a low or pulsing the sensor with a low-duty electronics, which subsequently affects false reading due to heat transfer error. This cycle to keep the average power dissipated temperature readings. Additionally, large is because convective currents add or in the sensor low. inductive spikes can create circulating remove heat from the sensor and/or currents that alter ground potentials near measurement surface. If the atmosphere is ENVIRONMENTAL the sensors. This effect then biases the at a different temperature than the surface, INFLUENCES: MOISTURE, voltage reading from the sensor and creates or the measurement environment is moist, OXIDATION & REDUCTION a false reading. the heat flow associated with convection For all the three sensor types, operating or When thermistors are used to measure must be considered as if it were another cycling them near their temperature limits temperatures near their lower extremes, heat source or sink. can cause deterioration, which then results the resistance may approach 100 K or MECHANICS, ACOUSTICS, in a drift from the initial profile. Thermistors more. When this happens, long runs of VIBRATION AND and RTDs are usually well-sealed from the thermistor wire can create an antenna that TRIBOELECTRIC EFFECTS environment, which makes them less adds noise to the measurement system. Small wire gauges and fragile sensors should susceptible to internal corrosion. However, While most of this can be filtered out, the be avoided in applications that subject them these sensors are usually connected to potential for biasing the measurement to extreme mechanical motion, vibration or copper wires, which increase the risk of becomes greater because direct current high-intensity acoustics. The most common wire failures occur near connection points, where there is the greatest amount of flexure. However, mechanical motion or vibration can also stimulate internal resonances inside the sensor -- leading to early failure. Thermocouples are generally the most durable of the three sensor types because many of the alloys used in the wires are more ductile -- allowing them to handle additional motion. Besides fatigue, cables in motion can also generate low voltage triboelectric effects. For microvolt sensors such as thermocouples or RTDs, these effects could become another contributor to measurement uncertainty, if the motion stimulating the effect is of the same order as the thermal responsiveness that one intends to measure. D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 73 OPTIMAL TEMPERATURE SENSOR SELECTION Thermocouple is the smallest, fastest and most durable temperature measurement solution. They can withstand very high temperatures, harsh mechanical treatment and are simple to operate. Their size allows for rapid temperature response times and the sensing junction can often be placed close to the desired point of measurement. The durability and simplicity of this sensor type makes it ideal for embedding into other devices. standardised freeze point (such as a gallium freeze bath at 29.7646�C) -- is an alternative way to characterise accuracy. Assumptions can be made as to how the accuracy at the calibration points can be extrapolated to predict the accuracy at other temperatures. If only relative accuracy is important, an array of sensors can be calibrated to each other by immersing them in a common bath at a known temperature (0�C for an ice bath). The temperature in the bath can then be slowly raised, while tracking all sensor responses. To achieve the best results, the calibration bath should span the same temperature range as the intended measurement. Additionally, the rate of temperature increase should be slow, relative to sensor responsiveness, which will reduce time-transient errors. The limiting factor for minimising (DC) charge collects (known as the `electret effect'). The best method for protection from outside electrical and magnetic sources is to keep the sensor and lead wires away from them, shield them, and/or pay close attention to electronics isolation and grounding. Keeping sensor lead wires short and converting the signals into digital form, as close to the measurement point as possible, can also help minimise noise. inherent sensor error is the uncertainty (including both the accuracy and precision) of the calibration process. Generally, thermistors and RTDs have better inherent accuracy than thermocouples, but all three types of sensors will require calibration to achieve accuracies down to 0.1�C. However, it is more challenging to calibrate thermocouples than thermistors and RTDs because calibration must consider both hot and cold junction temperature errors. FAC T FACT PUTTING IT ALL TOGETHER There is no simple solution to achieving accurate temperature measurement through sensors. The key lies in choosing the appropriate sensors taking into account various factors, be it pertaining to the given application or environmental impact among others. It is also equally important to be familiar with the strategies that can be used to minimise environmental influences and maintain the best level of temperature accuracy. Cal Swanson, Senior Principal Engineer, Single Iteration (a division of Watlow Electric Manufacturing Company) SENSOR CALIBRATION TECHNIQUES A common way to correct inherent accuracy errors is to calibrate the sensor in a controlled isothermal liquid bath and compare temperature readings against a standard reference. Alternatively, point calibration -- immersing sensors in an ice bath (0.01�C is standard) or other 74 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 SENSORS PREVENTING PRODUCT DEFECTS THROUGH ERROR-PROOFING In today's marketplace, it is not good enough to simply make parts. Manufacturers and customers demand high quality that is measurable and verifiable, for each and every part or assembly. Error proofing reduces the time spent on quality inspections and rework, in addition to lowering the reject and scrap percentages. This adds up to reduced manufacturing costs and higher plant profitability. With these added benefits, manufacturers are now able to optimise their production speeds and produce quality products faster than ever before. o err is part of human nature, and when it comes to manufacturing, mistakes equate to lost time, money and ultimately lost customers. In today's globally competitive market, product quality has emerged as a key differentiator. But if errors are so common and made often, the question that arises is how does a manufacturer guarantee that they deliver T Sensors are employed at various stages throughout the manufacturing process to either initiate warnings such as audible or visual alarms (for low defect processes and those where part repairs can be made), process shutdown. quality products all the time. The answer lies in designing fool-proof products and processes that minimise the possibilities of mistakes in the first place. And the concept of error-proofing becomes relevant here. ERROR-PROOFING Error-proofing is an industry term that relates to the implementation of mechanisms to prevent product defects. Also known as `poka yoke' from the Japanese `poke' 76 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 SENSORS (inadvertent errors) and `yokeru' (to avoid), error-proofing is a concept developed and popularised in that country. Based on the philosophy that even the smallest number of defects is unacceptable, poka yoke maintains that the best way to eliminate defects is to prevent them from happening. In general, there are three keys to stopping the proliferation of defects: awareness, detection and prevention. Awareness involves the acknowledgement of breakdowns in the manufacturing/assembly process, and employing training, audio-visual aids and general assistance for personnel to combat those issues. Detection introduces manual or automated inspection techniques to filter out defects. Prevention includes process improvements or automation to ensure that no errors are (or can be) made. Essentially, error-proofing drastically reduces defects through a combined effort of preventing errors and catching those that have been made as soon as possible. Awareness and detection techniques are crucial but, ideally, this effort is focussed on prevention. Sensors play a key role in errorproofing, and while most are used as simple detection devices, there are also a few sensors designed to be used as preventive measures. QUICK TAKE Everyday examples of prevention-centric error-proofing include a dialogue box on a computer asking if you want to save a file before closing it, childproof caps on medicine bottles or speed-dial buttons on phone that improve accuracy as well as speed. Industry examples range from simple colour-coding to distinguish between components that otherwise look similar to a sensor connected to the electric nut-runner in an automobile plant that triggers a horn, if a suspension assembly is moved to the next operation before a bolt is properly tightened. aspect of error-proofing applications. Discrete output (standard on/off) sensors are the most common in error-proofing applications, used primarily to determine presence and positioning of a part or a feature on a part. Limit switches are costeffective and easy to apply, but the fact that their operation requires contact with the part prohibits their use in many applications. Inductive sensors are generally the most economical, non-contact solution, assuming the parts to be detected are metallic and the sensor can be mounted close enough to the workpiece for the relatively small sensing ranges (less than 40 mm) associated with inductive sensing technology. Available foreground suppression, wide angle and fixed-focus modes, address a major amount of error-proofing applications. Laser-based models are also available for sensing extremely small parts and part features at a relatively greater distance. PHOTOELECTRIC AND ANALOG OUTPUT SENSORS The scanning technology employing 42EF RightSight photoelectric transmitted beam pair is used in parts verification arrays (PVA) that are specifically geared toward error prevention, notably in bin picking applications. By spanning the sensing fields of multiple PVAs across assembly station bins and wiring them into a controller programmed with the necessary logic, a virtually error-free bin-picking process Error-proofing drastically reduces defects through a SENSORS IN ERRORcan be achieved. `Job lights' on combined effort of preventing errors and catching those PROOFING the sensors not only show the that have been made as soon as possible. Awareness Sensors are employed at various assembler the bins required to and detection techniques are crucial but, ideally, this stages throughout the complete the current process, manufacturing process to either but will also indicate the effort is focussed on prevention. initiate warnings such as audible correct picking sequence. In or visual alarms (for low defect the event the assembler processes and those where part repairs can attempts to pick an incorrect part, a in a broad range of sizes, barrel/body be made), process shutdown (for selectable warning light illuminates to materials and wiring configurations, inductive applications where problems must be indicate the error; additional fault sensors are available in small barrel models corrected before production can resume; enunciation can be achieved via controller ideal for space-critical applications, as well processes with higher defect rates and logic in conjunction with a tower light or as flat pack and extended range versions for those where part repair is not possible), or audible alarm. those applications where maximum sensing Analog output sensors, on the other auto-correction controls to provide an distance is key. Inductive proximity sensors hand, are used for precise part positioning integrated test-feedback-repair loop. In are also extremely rugged � especially with continuous monitoring. Associated manufacturing and assembly, there are four stainless steel-bodied and cube-style models with true distance/position measurement, basic types of errors. These include missing � making them a good all-round erroranalog output sensors provide a linear parts, misassembled parts, incorrect proofing solution in harsh industrial current or voltage output (4-20 mA or 0-10 processing and incorrect parts. environments. For applications requiring V, respectively), often in conjunction with The sensors used to detect these increased sensing distances and/or detection discrete switch points. While many mishaps are of all shapes, sizes and of non-metallic parts, discrete photoelectric inductive, ultrasonic and photoelectric technologies. These range from standard sensors are often the best and simplest sensors are offered in analog versions, the inductive proximity and photoelectric solutions. precision of laser measurement sensors has sensors to vision sensors capable of Infrared sensors in standard sensing made them the predominant technology analysing a complex image and providing modes (diffuse, retro-reflective and for error-proofing applications including simple feedback, as well as specialty sensors transmitted beam) as well as more distance measurement and position designed specifically for the prevention specialised sensors in background/ D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 77 SENSORS verification, and several diverse functions such as part profiling, thickness measurement, hole depth checking and material warpage detection. At the high-end of the sensing spectrum for error-proofing applications is vision technology, ranging from standalone vision sensors to complete vision systems. Complete vision systems are used for complex inspection applications and require the integration of a camera, lighting, a processor (usually a PC) and software, typically involving a fair degree of customisation and programming expertise. But for many error-proofing applications, vision systems can be overkill and cost-prohibitive. As a result, vision sensors have emerged as the preferred technology for applications requiring economical yet advanced sensing for determining presence or absence, completeness, position, markings, labelling, packaging and components. Vision sensors combine an imaging device, lighting and the necessary logic into a At the high-end of the sensing spectrum for errorproofing applications is vision technology, ranging from standalone vision sensors to complete vision systems. single, self-contained unit that provides a simple pass/fail output. Using multiple methods of evaluation (pattern matching, contrast and brightness) to detect or differentiate objects by means of previously defined optical characteristics, this pass/fail output is used to separate good parts from defective ones. Detection parameters are set up through simple configuration of predefined functions as opposed to the detailed software programming associated with vision systems. DRIVING PRODUCT QUALITY No matter what you call it � error-proofing or poka yoke � sensors are an integral part of the quality control process. And there is no shortage of sensing technologies to effectively address various error-proofing applications, whether it is simple presence sensing or complex inspection. A complete error-proofing effort will most likely involve a mix of these sensing technologies as well as audio-visual aids, awareness training for personnel and some creative thinking in the development of new preventative processes. All are key to driving not only product quality, but also customer satisfaction. Manufacturing errors only become product defects, if they make it out of the door � and into customers' hands. Courtesy: Rockwell Automation 78 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 FAC T FACT The benefits of error proofing to improve quality and increase productivity in automated and manual assembly procedures are evident in all industries. In conjuction with this, adoption of new sensor technologies will ensure that increased productivity does not come at the cost of quality, as assemblies will be validated and automatically error-proofed in-process rather than post-process. This will not only save steps in the manufacturing process, but also save on costs. TIPS & TRICKS: SENSORS TAKING `STOCK' OF INVENTORY Sensors are integral elements of the automation era. Recent advancements in sensor technology have improved their accuracy and reliability, while reducing the cost. However, sensors are prone to failure due to various reasons, thereby resulting in the need for stocking huge amount of replacement sensors. Hence, companies are now aiming at reducing the sensor stock. One just needs to master the tricks provided herewith. sensors required to do the job. A smaller sensor also offers increased mounting flexibility, as it can fit in places where larger sensors cannot. If the targets are non-ferrous, the use of Factor 1 sensors is recommended. These sensors achieve longer sensing ranges than traditional sensors, because these n a perfect automation world, sensors never need to be replaced. They never die or suffer the effects of their environment. But in the real world, this is not the case. Such things happen often and increase the amount of sensors needed at any given point in time. Stocking replacement sensors for applications can pose a problem, as a result of the time it takes to find the right replacement; the confusion that goes along with finding the appropriate shape with the correct sensing range; the space it takes to stock all this inventory and, of course, the huge amount of capital invested. This brings us to the question of how to reduce the need for spare stock. Electromagnetic interference (EMI)/ radio frequency interference (RFI) can interact with sensing elements, causing the sensor to lock on or `chatter'. Noise emitting devices can range from two-way radios to motors and drives, so the possibility that a sensor will be exposed to EMI/RFI is relatively high. This will only increase with the increasing use of wireless communication. Several sensors have been I QUICK TAKE Factor 1 sensors achieve longer sensing ranges than traditional sensors, because these can detect non-ferrous metals at the same rated distance as steel. Many Factor 1 sensors also lack a ferrite core, allowing them to be incorporated into unique and non-traditional housings that may easily replace other sensors. can detect non-ferrous metals at the same rated distance as steel. Many Factor 1 sensors also lack a ferrite core, allowing them to be incorporated into unique and non-traditional housings that may easily replace other sensors, therefore reducing the amount of sensors should be kept in hand. designed for noise immunity, including Factor 1 sensors. If Factor 1 sensors are used, stocking noise-immune sensors can be ruled out. Another way to reduce overall stock levels is to standardise the sensor's connector sizes, along with corresponding cables/cordsets. Choosing a quick disconnect sensor/cable combination will also lessen installation time. This might sound basic, but make sure the sensor supplier has local support or is willing to visit a given location � wherever it is. Sometimes sensors need to be applied in tricky situations and remote support from the supplier just would not cut it. Even the best sensors sometimes need onsite troubleshooting. When issues arise, it is in the best interest of one and all to ensure reliable support wherever it is needed and fast. Courtesy: TURCK Inc. BEST PRACTICES It would be a good practice to mount a sensor, and then there would be little likelihood that it will be hit by the target. A target hitting a sensor is one of the major causes of sensor failure. If the application or location requires a sensor to be very close to the target, one must try to use a sensor that can be recessed in its mounting apparatus to promote a higher degree of protection from the target. It is vital to choose a sensor that has been designed for recessed mounting, as a conventional proximity sensor will lock on, if recessed in metal. RESOLVING ISSUES There are several ways to bring down sensor stock levels, but one of the easiest and most efficient ways is standardisation. Standardising on styles, sizes and brands is the first step in reducing the sensor stock. Using smaller sensors with extended range is another great way to reduce it. Sensors that are specified for extended range can replace several (often bulkier) other sensors, thereby reducing the number and type of 80 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 HITECH AUTOMATION SHOW TAKING MANUFACTURING TO THE NEXT LEVEL With fast-paced changes taking place in the manufacturing sector, the need for automation cannot be undermined. With India catching up on the adoption of automation solutions, manufacturing will soon witness a dramatic change in the way it is being operated today. Aimed at offering automation solutions for the entire manufacturing fraternity, HiTech Automation Show is designed to provide a fertile ground for GenX manufacturing. Mumbai | 17-19 Feb, 2011 hat are the few things that a future factory will have and must have beyond doubt? The answer lies in automation! It is automation that will drive manufacturing, growth, productivity, quality, innovation and technology. Supporting this, R Narayanan, Head � Discrete Automation & Motion Division, ABB India, avers, "Automation will be vital in helping manufacturing companies achieve economies of scale, global competitiveness and meet stringent quality/safety standards. Automation products, systems, solutions and services are designed to improve customers' business, centered on increasing industrial productivity, while lowering environmental impact." SHIBANI GHARAT W diverse range of industries including automotive, electronics, medical, food production, pharmaceutical and machinery. INCREASE IN DEMAND High efficiency and productivity have taken centre-stage in today's manufacturing scenario. To match the demands of increased quality at lower cost, several industries are opting for automation. "The demand for ERP/MIS integration with factory floor, which was more of theory, is fast becoming a reality," says Narayanan. He also mentions that technologies for equipment, products, systems with PLCs, DCS, drives, field buses, sensors, robotics as well as high level software integration between these discrete automation islands are being developed. "All manufacturing industry verticals have seen a huge demand for automation in the last decade. Process industries like steel, cement, refineries, petrochemicals, power, etc, and discrete manufacturing industries like automobile, pharma, building segment, food & beverages, rubber & plastics will continue to drive demand for automation," asserts Narayanan. "Automation is the key to success. Typical automation capabilities, relative to the use of technological interventions such as advanced planning, measurement, robotics and MES, continue to grow. However, new advancements in making supply chain operations and various stakeholders operate more collaboratively and seamlessly will drive further benefits. The focus of the emerging trends will be on reducing variability, increasing velocity, increasing visibility, guaranteeing full compliance and increasing collaboration," asserts Frank MINIMAL HUMAN INTERVENTION The introduction of automation in Indian manufacturing has dramatically changed the speed & efficiency of production and delivery systems for the industry. It is a smart muscle that smoothly integrates and executes activities in an industrial environment. "An ideal factory in the future would have minimal human intervention besides being increasingly environmentfriendly," says Shekar Viswanathan, Deputy Managing Director, Toyota Kirloskar Motor. Industrial automation has replaced human beings across industries. Automation proves to be an apt solution for jobs that require precision, speed, endurance and reliability. Traditional applications of industrial automation include material handling, assembling, painting, welding, packaging, palletising, product inspection and testing. Industrial robots are used in a Khoshnoud, Sr VP & Head � Manufacturing, Retail & Distribution (MRD), Patni. Looking at such promising prospects, Network18 Group will be organising HiTech Automation Show from February 17-19, 2011, in Mumbai concurrently with HiTech Material Handling, under the umbrella show HiTech Manufacturing. HiTech Automation is a first-of-its-kind event showcasing latest innovations under one roof. From factory automation, process automation & control systems, field instrumentation and smart sensor, robotics & drives, software solutions to hydraulic and pneumatics, the event will display the best among the new-age automation solutions. "HiTech Automation showcases the best and the latest in the industry. This show is a must attend for all small and medium enterprises. For those who will be a part of this extravaganza, the exhibit will provide tremendous networking opportunities and scope for business generation," asserts Sudhanva Jategaonkar, Associate VP�B2B Publishing, Infomedia18. ONE-STOP AUTOMATION SHOP Displaying cutting-edge technology, breakthrough innovations and interactive demonstrations from the leaders in the automation industry, HiTech Automation Show has been designed to provide an ideal platform for the growth of the automation industry in India. HiTech Automation will help the entire automation industry converge into a single lucrative platform that will serve as a foundation for the future growth of this industry and drive it towards a promising automated future. 82 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 NEW-AGE WELDING TECHNOLOGIES NEW-AGE WELDING TECHNOLOGIES: Imparting Coalescence For Optimal Performance .......84 ROBOTICS IN WELDING: Extending A `Tech' Arm For Efficient Functioning ................................90 SENSORS FOR WELDING: Withstanding Temperature Extremities ...............................................94 D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 83 NEW-AGE WELDING TECHNOLOGIES OPTIMAL PERFORMANCE New-age technologies in welding or metal joining are many, which are finding applications across various industrial segments. However, the most significant among the welding techniques are micro-plasma arc welding, laser beam welding and friction welding that have opened up a new world of opportunities. Though these have been around for a while, it's now time to explore their advancements. ith welding being universally accepted as the method of permanently joining all metals, its importance in the manufacturing sector can clearly be understood. However, welding tools and techniques have seen advancements in terms of technological innovation over the last few years. These new welding tools and techniques help to provide a manufacturer with the best performance. Amongst them, micro-plasma welding (MPW) is a variant of the generic plasma arc welding (PAW) technique. This is a process similar to gas tungsten arc welding (GTAW). The electric arc is formed between an electrode (which is usually but not always made of sintered tungsten) and the workpiece. The key difference between PAW and GTAW is that in PAW, with the electrode within the torch, the plasma arc is kept separate from the shielding gas envelope. The plasma is then forced through a fine-bore copper nozzle that constricts the arc and the plasma exits the orifice at high velocities (nearly the speed of sound) and a temperature of around 20,000� C. The micro-plasma arc can be as thin as 0/01 mm in diameter. `controlled atmosphere chambers' may be used in some high precision application of the reactive or refractory metals/alloys. Several basic PAW process variations are possible by varying the current plasma gas flow rate, and the orifice diameter, including micro-plasma (< 15 Amperes); melt-in mode (15-400 Amperes); and keyhole mode (>100 Amperes). Plasma arc welding has far better energy concentration than GTAW. A deep, narrow penetration is achievable, with a maximum depth of 12-18 mm (0.47 to 0.71 in) depending on the material. Such a joint is stronger than the wider tungsten inert gas (TIG) welded joint. Greater arc stability allows a much longer arc length (stand-off) and much greater tolerance to arc length changes. IMPARTING COALESCENCE FOR W PLASMA ARC WELDING Plasma arc welding is an advancement over the GTAW process and can be used to join most commercial metals and alloys. Titanium, tantalum, molybdenum and zirconium metals and alloys can be welded. Some special accessories like the `trailing shield' to provide additional shielding or 84 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 NEW-AGE WELDING TECHNOLOGIES QUICK TAKE Often high precision plastic moulding dies, e.g. those used for making tiny but dimensionally precise parts for camera, computers and other such applications � especially when such dies are dented or chipped off � calls for a MPW technique, also referred to as needle arc welding (since the arc is so thin, it can pass through the eye of a needle). Gas flow rate (this is a critical variable). These days high precision welding of 0.01 mm thick sheets is also carried out, for instance in filter fabrication, welding of stainless steel bellows, or wire-mesh grids, etc. Automated welding units are usually employed for various applications. However, aerospace & nuclear engineering, and biomedical engineering are some areas where micro-plasma welding is a mandatory solution to tricky welding configurations. Sheets as thin as 0.076 mm have been welded reliably. Given below are a few welding techniques employed across industries: Milliseconds long pulses are used to weld thin materials such as razor blades while continuous laser systems are employed for deep welds. LBW is a versatile process, capable of welding carbon steels, high-strength lowalloy (HSLA) steels, stainless steel, aluminium and titanium. Due to high cooling rates, cracking is a concern while welding high carbon steels. Proper pre-heat and postheat can eliminate this problem. The weld quality is high, similar to that of electron beam welding. The speed of welding is proportional to the amount of power supplied and depends on the type and thickness of the workpieces. The high power capability of gas lasers make them, especially suitable for high volume applications. LBW is particularly dominant in the automotive industry. Some of the advantages of LBW over EBW are : The laser beam can be transmitted through air rather than requiring a vacuum The process is easily automated with robotic machinery X-rays are not generated LBW results in high quality welds. Plasma welded products used in architecture and paper processing Hence, the longer PAW arc is more stable and tolerant of unsteady torch manipulation by novice welders. PAW requires relatively expensive and complex equipment as compared to GTAW; meticulous and timely torch maintenance is critical. Welding procedures tend to be more complex and less tolerant to variations in fitup. Automation is desirable. All this is worth the trouble as impossible-seeming welds can be performed. There are various process variables when it comes to PAW. One of them include gases. At least two separate (and possibly three) flows of gas are used in PAW: Plasma gas that flows through the orifice and becomes ionised Shielding gas that flows through the outer nozzle and shields the molten weld from the atmosphere Back-purge and trailing gas required for certain materials and applications, e.g. titanium/alloy welding. These gases can all be same or of differing composition. argon, hydrogen and helium gases are most commonly used. Some other important variables include: Current type (pure DC or square wave/ pulsed) Polarity is another factor. Direct current electrode negative (DCEN) from a constant current (CC) power source is a standard requirement. AC square-wave is common in aluminium and magnesium, which provides better cleaning of the nearly transparent surface oxide films that can hamper welding. Welding current and pulsing current can vary from 0.5 A to 1200 A; Current can be constant or pulsed at frequencies up to 20 kHz. LASER BEAM WELDING (LBW) It is a welding technique used to join multiple pieces of metal through the use of a laser. The beam provides a concentrated heat source, allowing for narrow, deep welds and high welding rates. The process is frequently used in high volume applications, such as in the automotive industry. Like electron beam welding (EBW), LBW has high power density (in the order of 1 megawatt/cm�) resulting in small heataffected zones and high heating and cooling LBW EQUIPMENT The two types of lasers commonly used are solid-state lasers and gas lasers (especially carbon dioxide lasers and Nd:YAG lasers). The first type uses one of the several solid media, including synthetic ruby and chromium in aluminium oxide, neodymium in glass, and the most common type, crystal composed of yttrium aluminium garnet Micro-plasma welded Palladium strips rates. The spot size of the laser can vary between 0.2 mm and 13 mm, though only smaller sizes are used for welding. The depth of penetration is proportional to the amount of power supplied, also dependent on the location of the focal point: penetration is maximised when the focal point is slightly below the surface of the workpiece. A continuous or pulsed laser beam may be used depending upon the application. High precision plasma welded s.s. bellows D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 85 NEW-AGE WELDING TECHNOLOGIES doped with neodymium. Gas lasers use mixtures of gases like helium, nitrogen and carbon dioxide (CO2 laser) as a medium. High power lasers are usually gas lasers and invisible, hence risky when used in open workshops. Regardless of type, however, when the medium is excited, it emits photons and forms the laser beam. Then there is the fibre laser. Solid-state laser: It operates at wavelengths in the order of 1 micrometre, much shorter than gas lasers, and as a result require that operators wear special eyewear or use special screens to prevent retina damage. Nd:YAG lasers can operate in both pulsed and continuous mode, but the other types are limited to pulsed mode. The original and still popular solid-state design is a single crystal shaped as a rod approximately 20 power up to 50 kW and are increasingly being used for robotic industrial welding. FRICTION WELDING Friction welding (FW) is a class of solid-state welding process that generates heat through mechanical friction between a moving work piece and a stationary component, with the addition of a lateral force called `upset' to plastically displace and fuse the materials. Technically, because no melt occurs, friction welding is not actually a welding process in the traditional sense, but a forging technique. However, due to the similarities between these techniques and traditional welding, the term has become common. Friction welding is used with metals and thermoplastics in a wide variety of aviation and automotive applications. The combination of fast joining times in the order of a few seconds and the direct heat input at the weld interface gives rise to relatively small heat-affected zones. Friction welding techniques are generally melt-free, which offer the advantage of avoiding grain growth in engineered materials such as high-strength heat-treated steels. Another advantage is that the motion tends to `clean' the surface between the materials being welded, which means they can be joined without as much prior preparation. During the welding process, depending on the method being used, small pieces of the `plastic' metal will be forced out of the working mass in rippled sheets of metal known as `flash'. It is believed that the flash carries away debris and dirt. Another advantage of friction welding is that it allows dissimilar materials to be joined. This is particularly useful in the aerospace field, where it is used to join lightweight aluminium stock to high strength steels. Normally, the wide difference in melting points of the two materials would make it impossible to weld using traditional techniques, and would require some sort of mechanical connection instead (bolts, etc). Friction welding provides a `full strength' bond with no additional weight. Another common use for these sorts of bi-metal joining is in the nuclear industry, where copper-steel joints are common in the reactor cooling systems. Friction welding is also used with thermoplastics, which act in a fashion analogous to metals under heat and pressure. The amounts of heat and pressure used on these materials are much lower than on metals, but the technique can be used to join metals to plastics with the metal interface being machined. For instance, the Laser welds can be very narrow and deep using the keyhole technique. Robotic laser beam welding of an automotive part mm in diameter and 200 mm long, and the ends are ground flat. This rod is surrounded by a flash tube containing xenon or krypton. When flashed, a pulse of light lasting about two milliseconds is emitted by the laser. Disk shaped crystals are growing in popularity in the industry, and flash-lamps are giving way to diodes due to their high efficiency. Typical power output for ruby lasers is 10-20 W, while the Nd:YAG laser outputs between 0.04-6,000 W. To deliver the laser beam to the weld area, fibre optics are usually employed. Gas laser: It uses high-voltage, low-current power sources to supply the energy needed to excite the gas mixture used as a lasing medium. These lasers can operate in both continuous and pulsed mode, and the wavelength of the laser beam is 10.6 m. Fibre optic cable absorbs and is destroyed by this wavelength, so a rigid lens and mirror delivery system is used. Power outputs for gas lasers can be much higher than solidstate lasers, reaching 25 kWs. Fibre laser: In fibre lasers, the gain medium is the optical fibre itself. They are capable of LBW in action technique can be used to join eyeglass frames to the pins in their hinges. The lower energies and pressures used allows for a wider variety of techniques to be used. The variants include: Spin welding: Spin welding systems consist of two chucks for holding the materials to be welded, one of which is fixed and the other rotating. Before welding one of the work pieces is attached to the rotating chuck along with a flywheel of a given weight. The piece is then spun up to a high rate of rotation to store the required energy in the flywheel. Once it starts spinning at the proper speed, the motor is removed and the pieces forced together under pressure. The force is kept on the pieces after the spinning stops to allow the weld to `set'. This technique is also known as inertia welding, rotational welding or inertia friction welding. Linear friction welding (LFW): It is similar to spin welding except that the moving chuck oscillates laterally instead of spinning. The speeds are much lower in general, which require the pieces to be kept under pressure at all times. This also requires the parts to have high shear strength. LFW requires more complex machinery than spin welding, but has the advantage that parts of any shape can be joined, as opposed 86 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 NEW-AGE WELDING TECHNOLOGIES Laser beam welded 0.5mm thick s.s. sheet, welded at 1.0 metre/minute A complex vane friction welded by TWI to parts with a circular meeting point. Friction surfacing: It is a process derived from friction welding wherein a coating material is applied to a substrate. A rod composed of the coating material (called a mechtrode) is rotated under pressure, generating a plasticised layer in the rod at the interface with the substrate. By moving a substrate across the face of the rotating rod, a plasticised layer is deposited between 0.2-2.5 mm thick depending on mechtrode for several decades, thus diameter and coating material. proving their mettle and This technique is rather utilitarian indispensability. more costly than arc stud An endless number of welding and is, therefore, used variants, spin-offs and for special applications where derivatives, especially in arc welding may present automated welding problems, such as welding applications have underwater or on live subsea emerged, which pipelines to attach anodes or in together cover an explosive environments and impressive gamut of zoned areas. In addition, it can industrial problemalso be used for friction plug A typical stud to base weld made with solving from sports welding or welding materials stud welding goods to aerospace that are difficult to join by fusion components. The future for all these welding processes or welding pipe fittings processes appear bright. onto flat or curved surfaces. Portable equipment for friction stud MAK Babi, Metallurgist & Plasma Technologist welding is used at construction worksites, E-mail: email@example.com offshore, underwater and in workshops. These portable units are much lighter and smaller than the large static friction welding machines that are used, for example, in EXTREME ENGINEERING: factories to weld engine components such Solar Impulse as drive shafts. GROWING FROM STRENGTH TO STRENGTH All the new-age metal joining methods briefly described here have been around The Meridian Hour In Aviation on pg. 100 D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 89 ROBOTICS IN WELDING EXTENDING A `TECH' ARM FOR EFFICIENT FUNCTIONING GEETHA JAYARAMAN devices from end-users, as welding process demands utmost concentration to develop a perfect product. Welding needs to be precise and accurate. Vikas Swami, VP , KUKA Robotics, says, "Generally welding is considered to be a labour-intensive job, which is performed in a polluted environment. In order to ensure a good weld, it calls for efficient operator skills. However, with the use of robotics in welding, one can assure quality and consistency of products. The deployment of robotics helps manufacturers to achieve better product quality and attract more skilled labourers into the industry." Welding is a high-precision work that calls for accuracy. With the lack of skilled labourers, the industry is shifting towards utilising more robotic applications. The right usage of robots in appropriate areas of welding will ensure best-in-class output, which in turn will lead to manufacturing of world-class products. ith the increasing customer demand for a wide range of products and simultaneous shortage of skilled workers, automation and robotics play an important role in the welding industry. Robots are deployed to handle the parts that need to be welded as well as perform the process. These are generally used in resistance spot welding or arc welding where there is a need for high productivity. Although robotic welding is still emerging, it was introduced during the 1980s when the automotive industry discovered that robots could be employed for spot welding. Over the years, the use of robotics in welding has evolved continually. Since 2001, there has been a steady growth in the demand for quality robotic W THE MYTH Generally, companies purchase robotic welding equipment with the expectation that robots will solve all their productivity and quality problems. But after installation, the actual results often do not meet the end-users' need and expectations. Thus, they come to a conclusion that the company has sold them the wrong system. Agreeing to this, Swami avers, "In India, most of the industry people have the right kind of knowledge, yet use robots for wrong applications. The ultimate conclusion is that the company sold the wrong model. Therefore, before purchasing a robot, manufacturers should specify the purpose of installing the robot in their facility, so that the company can suggest the appropriate robot for a particular application." He adds, "Such guidelines can not only prevent disappointments resulting from false expectations, but also can help make a robotic welding project more profitable and dependable." 90 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 ROBOTICS IN WELDING THE NEED TO DEFINE The exact requirements of the robotic welding system need to be defined clearly before designing a system. This will ensure high quality, operator safety and increase in productivity in the final output. Ramadas Nambi, GM � Robot Sales, Fanuc India, suggests, "Be clear about the reasons you are interested in robotic welding. This will help towards guiding a project along a predictable path. When it is time to specify and purchase a system, be involved in its design and functionality. This does not mean that the end-users are responsible for the actual design, but one must become intimately familiar with the system before it is built and stay updated on design changes as they happen. This will prevent surprises and failures in the future � for instance, in case the system becomes too big to fit into the floor space the customer has provided for it or cannot reach certain weld spots." When applying robotics to a welding system, it is important to realise that it is not the same as performing welding manually. Many factors have to be taken into consideration with regard to reliability, the number of axes needed and the space where the robots will be installed. Manufacturers should employ well-trained workers on the shop floor who have the knowledge on robot handling. They should keep a check on the weld to make sure that seamless work is in place. Swami says, "Robotics has advantages and disadvantages. For example, many manufacturers use robots to do monotonous tasks that are difficult for humans to perform over a period on a continual basis. However, robots need recalibration, reprogramming and regular maintenance. Hence, it should be ensured that the robots are placed in proper position to perform all tasks perfectly. There must always be a back-up system if in case something goes wrong." Engineering, Robotics & Automation, explains, "For any application involving voluminous production combined with critical & substantial welds, robots will be of paramount importance in the welding process. It is virtually impossible for each robot to deliver the perfect weld. There have been constant improvements taking place in the area of electronics for ensuring the growth of robotics, and thus save production time. "If we can take those same few welders and train them to employ robotic technology that accelerates the welding process, it would certainly lead to increase in the returns on investment for companies," informs Nambi. One of the other trends witnessed in recent years is the application of laser TIPS AND TRICKS Robotic welding systems are able to operate continuously, provided appropriate maintenance procedures are adhered to. Continuous production line interruptions can be minimised with proper robotic system design. Planning needs to be completed for the following contingencies: Rapid substitution of the inoperable robots. Installing back-up robots in the production line Redistributing the welding of broken robots to functioning robots close by. Robots are the most effective when it comes to medium-scale production of a moderate variety of products. TECHNOLOGY FOR FUTURE Welds are complex pieces of engineering involving several parameters under consideration at each time a weld is under process. Akshat Sinha, Executive Director, ATE Welding human-like precision and observation during welding." While making robots, manufacturers should ensure that the robots are easier to use and simpler to program. For this to happen, manufacturers are partnering with customers to demonstrate how robotic work affects quality and productivity. Swami points out, "Because robots have matured to the point where they can achieve r e p e a t a b i l i t y, consistent joint location and touchsensing, operators have more time to spend on weldment design and dimensional data, fixture tooling and gauging." Training welders to use higher technology can aid welding, which is being widely used in recent years. This is because, like laser cutting, the advantages of laser processing are being recognised and exploited to manufacture better products at lower cost. "Because the capital cost for laser welding equipment is relatively high, economic justification must be carefully analysed and aggressively pursued in exploiting the potential benefits of the process. The major benefits of laser welding, such as high speed, high productivity, and low heat input, are similar to those offered by laser cutting," points out Swami. ADVANTAGES Robots are the most effective when it comes to medium-scale production of a moderate variety of products, as opposed to mass production of a small variety of products. They increase labour efficiency, stabilise product quality, increase the rate of yield, and even improve the rate of capacity utilisation. Swami avers, "Robotics helps to ensure repeatability, precise heat control and exact penetration to meet challenging quality standards. It reduces operator training time, inspection costs, and improves weld quality. It also has the ability to save multiple weld schedules and several welding programmes for easy retrieval." Adding to this, Nambi says, "Another advantage of using robots is that they can perform jobs in poor working environments, D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 91 ROBOTICS IN WELDING parameters. Sinha says, "Automation usually helps in maintaining these values. Humans are bound to face issues like stress, anxiety and a host of other emotions that tend to affect the weld in some or the other way. It is impossible to neglect these emotional imbalances, if one has to achieve utmost accuracy at work." He further adds, "With automation, there is no such emotion quotient and all that one can expect is consistent high performance welds. But with the use of automation and robotics in every area of the production, the manufacturer has to ensure continuous flow of electricity. One of the most important challenges faced by the manufacturer in India is the inconsistent flow of power in the industrial areas, which needs to be tackled for successful development of robotics in welding." In future, robots will allow more production processes to be automated and unmanned factories will become a reality. WAY FORWARD Realistic expectations begin at the concept stage of a project. If the system is conceptualised and designed properly, there is a better chance that it will work as expected. Despite the challenges of a welder shortage, robotics and welding automation industries are moving ahead with more convenient technology. By partnering with end-users, equipment manufacturers are assisting in enhancing the flexibility of automated systems used in a variety of markets. "Robotics in welding is inevitable, similar to man finding fire, wheel and eventually integrating those with the system to such an extent that it does not even seem like an invention any more. The future of welding is robotics," says Sinha. In future, robots will allow more production processes to be automated and unmanned factories will become a reality. Robots will find enormous use by smaller businesses as robots are getting cheaper and skilled workers are getting more expensive and harder to find. This makes robots an attractive alternative even to small and micro enterprises," says Swami. He also adds that robots will be replacing human workers at a substantial rate by the end of the decade. This will in turn increase productivity and add value, thus, creating wealth. Through careful planning and extensive research and development, robotics could play an important role in the industrialised society of India in the coming years. Images Courtesy: Kuka Robotics such as dark or noisy areas, and liberate people from monotonous, repetitive tasks such as component insertion on an assembly line. At the same time, automated parts inspection dramatically reduces rework and repair costs that can occur from inconsistent or failed manual inspection." Apart from these, manufacturers have also overcome the challenge of employee robot welding improves weld repeatability � robots will give precisely the same welds every time on work pieces of the same dimensions and specifications � many manufacturing plants use robotics welding systems to improve productivity and product quality." EFFICIENT COMMUNICATION With the help of proper communication and co-operation from vendors and the growing use of Internet, robot manufacturers are able to provide the apt robot for better productivity. "Today, the customer wants to get all the necessary information instantly and Internet is one mode, which acts as a one-stop shop. Robotic welding equipment manufacturers are using Internet to solve problems (instead of using trial-and-error techniques). Many a time, we get enquiries on the basis of our website wherein customers ask us about a specific model of robot they think will suit their business. In addition, they use the Internet to work with distributor networks, source spare parts, and register customers for training. In future, some manufacturers plan to extend their customer base by using the Internet," Swami observes. Welding is considered to be a labourintensive job, which is performed in a polluted environment. In order to ensure a good weld, it calls for efficient operator skills. However, with the use of robotics in welding one can assure quality and consistency of products. VIKAS SWAMI, VP KUKA Robotics , retention and training labourers. Ergonomic and safety issues are some reasons why manufacturers are opting for automating their welding operations with robotic installations. Thus, the new controller technology allows the motion of the welding robot to be co-ordinated with handling robots. This results in faster travel speeds and better quality. Nambi says, "Because HURDLES ON THE WAY Some of the key challenges faced by robotic welding equipment manufacturer are the duty cycles delivery of the power source, consistent delivery of current, constant control of complex weld 92 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 SENSORS FOR WELDING WITHSTANDING TEMPERATURE EXTREMITIES Sensing the sensitivity of sensors in harsh welding environments and its hampering effect on productivity due to the accumulation of weld slag and splatter, the automotive industry has opted for more rugged and durable sensors. Sensors coated with weld flash resistant materials such as Teflon and stainless steel have now become the preferred choice for manufacturers in the automotive industry. ensors play an important role in ensuring production quality in welding environments. A machine can use even a hundred sensors depending on the degree of exposure to welding operations. One of the most common areas where resistance welding occurs is in the automotive industry. Here, sensors are used to confirm proper placement of metal car parts before they are fused together. The welding temperatures here are very high, often more than 1,200OF, and currents can range from 15,000-35,000 Amps. In such a scenario, if a sensor fails, it will cause just a few minutes of downtime. However, if several sensors of several machines fail due to the harsh welding conditions, it will hamper productivity levels, which will cost the company much more. can fail to generate correct output at least three to four times a day depending on the amount of welding involved in the application and location of the sensor. Sensors mounted close to the weld tips are frequently subject to weld flashes. A sensor within 10 inches from weld tips can easily experience 1,0002,000 flashes per day per switch. In the automotive industry, sensors are used for multiple operations, including detecting where metal car parts are located to ensure proper placement prior to S REASONS FOR MALFUNCTION Sensors in severe welding environments 94 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 SENSORS FOR WELDING CABLE GUIDE Weld slag affects cordsets Accumulation of weld slag can significantly affect the cordsets used to connect the sensors to high-level control systems. Replacing a cordset may not sound like a big deal, but it can be very time consuming. Imagine removing 20 feet of tie-wrapped cable � some of which is covered in solidified weld slag � and installing and tie-wrapping 20 feet of new cable. THE SOLUTION There are ways to avoid some of these cabling pitfalls. Depending on the application, there are different levels of protection to choose from. Cable jackets, plug bodies and coupling nuts are all components of the cordset that can be altered to provide protection from weld slag. For instance, coupling nuts may be coated with Teflon to improve weld resistance. However, when selecting a cable jacket, it is essential to choose cable jackets made from materials that are more resistant to weld slag build up or else the slag will cause the cordset to melt or burn on contact. Cable jackets most commonly used for welding environments are made from rubber (chlorinated polyethylene or CPE) for their ruggedness and durability. A thermo-set CPE jacket over ethylene-propylene-diene elastomer (EPDM) rubber insulation is impervious to flame and temperature extremes. CPE jackets also provide superior resistance to tears, cuts and abrasions. The drawback of this cable type jacket, however, is that it is more difficult to strip and is not recyclable. If the welding environment does not require cable as rugged as CPE, thermoplastic elastomer (TPE) jacket material may also be used. TPE cable, sometimes called thermoplastic rubber (TPR), offers good resistance to weld slag accumulation. It is also more flexible, less expensive than rubber, and easier to strip. TPE material may also be used as a moulding for the cordset plug body. If the weld slag has caused the coupling nut to fuse the sensor, a protective sleeve made from fibreglass is the first option one should consider. The sleeve is usually coated with another substance, so that it is better able to withstand the brunt of the damage from the weld slag. Moreover, sleeves can be made to fit most cordsets in lengths that are specific to the application. A second protection measure involves an expandable silicone rubbercoated fibreglass sleeve. This provides a `heat shrink'-type fit around the cordset and the coupling nut. Another option is to use a short extension cordset between the sensor and the second, longer cordset. Since most of the slag damage occurs near the sensor, adding the extension cordset to this area will ensure that you will not have to go through the hassle of replacing a 20-foot cable. welding. An automated (robotic) weld arm manoeuvres into place and welds in multiple locations around the vehicle. In the process, sensors are exposed to several thousands of weld flashes a day and eventually, begin to malfunction. Also, strong electromagnetic fields can cause a standard (ferrite core) proximity sensor to false trigger (output) or lock-on. Accumulated weld slag and/or splatter can also cause sensors to malfunction. Depending on the sensor's construction, it will withstand different levels of accumulation before malfunctioning. MODIFYING SENSORS Manufacturers have modified sensors to enable them to withstand varying degrees of weld slag and/or splatter. Some manufacturers use Teflon or stainless steel front caps, or use materials such as Teflon D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 95 SENSORS FOR WELDING QUICK TAKE Sensors in severe welding environments can fail to generate correct output at least three to four times a day depending on the amount of welding involved in the application and location of the sensor. Sensors mounted close to the weld tips are frequently subject to weld flashes. A sensor within 10 inches from weld tips can easily experience 1,000-2,000 flashes per day per switch. or copper for housing. It is essential that the front cap is made more resistant to weld field, slag and splatter. The housing can be less impervious to it. This is because the front cap is directly exposed to the weld flash and the slag/splatter is more likely to accumulate on it. COPING WITH MALFUNCTION Most manufacturers cope with sensor malfunction by simply replacing it. However, some prefer to repair the sensor by using a screwdriver to chip off accumulated slag. A sensor fixed this way will probably work for some time, but after being exposed to a few more weld flashes it will be rendered useless. Some sensors incorporate technology that makes them resistant to strong electromagnetic fields. Factor 1 sensors, which use separate, independent sender and receiver coils on a printed circuit board (PCB) and remove the ferrite core, are inherently immune to the magnetic field interference that often occurs during electric welding operations, lifts and electronic furnaces. Absence of the ferrite core also allows factor 1 sensors to operate at a higher switching frequency. Ironically, many sensors designed by manufacturers for welding applications fail to generate correct output after being exposed to very few weld flashes. Some sensors begin to malfunction after being exposed to 5,000 weld flashes. Sensors that can withstand 10,000-20,000 flashes are impressive on the low end and exceptional on the high end. A select few can function beyond 20,000 weld flashes without failure. Therefore, to determine if an application would benefit from sensors specially designed for welding applications, one must consider auditing the rate at which sensors are expended in current applications. How often do sensors fail to generate correct output? How often do you replace them? How much time does it take to diagnose or find a solution to the malfunctioning problem? The answers to these questions should help you determine how rugged a sensor one needs. It is, however, important to keep in mind that the effects of weld slag and splatter are not just harmful for sensors, but often affect surrounding components. Sensors may be susceptible to human and mechanical damage. Some manufacturers incorporate fitted steel covers into the sensor housing prior to sealing the sensor thus, making it impervious to physical damage from the side and weld damage from the front. In any sensing situation, it is important to examine all aspects that contribute to the success or failure of sensors to make an informed decision regarding which sensor is right for an application. Courtesy: TURCK Inc 96 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 SINGLE LARGEST CONVERGENCE BREAKTHROUGH INNOVATIONS O 360 PERSPECTIVE INTERACTIVE DEMONSTRATION NSTR NST ST S Inspiring Seamless Material Handling BREAKTHROUG INNOVATIONS CUTTING EDGE TECHNOLOGY Innovations and Solutions for an Automated Future H Envisioning The Future Of Manufacturing NS For the first time in India, there an event that promises to deliver future solutions for the complete manufacturing & engineering industry. HiTech Manufacturing Show is a first of its kind event bringing the entire industry under one roof. With HiTech Manufacturing as a backdrop for the entire value chain, the show also has HiTech Material Handling and HiTech Automation as concurrent shows to complement the growth process and future of the industry. GH S Factories of Tech Future | Future Designs | Business Strategies 17-19 Feb, 2011 | NSE Ground, Goregaon, Mumbai Contact: Prachi +91 9820373804 or firstname.lastname@example.org or SMS hitech to 51818 First in Business Worldwide SOLAR IMPULSE The MERIDIAN SUMEDHA MAHOREY nventions and innovations mark the progress and evolution of human race. Be it the wheel, the telephone, the steam engine or something that could fulfil the aspiration of every human � the aeroplane. Successfully tested by the Wright brothers, way back in 1903, today this invention holds immense significance in the way we travel. With drastic changes in the aviation landscape over the years � from helicopters Daring a technological challenge to create something that has never been thought about by anyone is an extreme case. Creating history, a big as an airbus but having just the weight of a car. Guiding a spurt in innovations and weaving the future around the theme of renewable H UR CONCEPT DEVELOPMENT I to fighter planes � the question that comes to one's mind is what would be the next level of innovation that will bring about a paradigm shift in the way we travel? A passenger aircraft, during a 1.5-2 hours flight, usually consumes somewhere between 3,000 to 4,000 kg of Air Traffic Fuel (ATF), the main reason behind the hefty sum that one pays for an air ticket. Can this cost be cut down, while saving the environment from the harmful emissions of the aircraft through a project that combines scientific exploration with the promotion of renewable energies? The answer lies in `Solar Impulse' � the plane that flies on solar energy day and night. The idea of developing a plane that doesnot consume a drop of fuel came to Bertrand Piccard, psychiatrist, aeronaut and Chairman, Solar Impulse, following his first round-the-world balloon flight with Brian Jones in 1999. A realisation that lack of fuel could have disrupted his adventure led him 100 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 SOLAR IMPULSE team of pioneers in the field of aviation has come up with the aspiration of encircling the world in a solar-fuelled plane with a wingspan as energy is the project ` Solar Impulse'. IN AVIATION the project to be officially launched on November 28, 2003. During this period, Piccard entrusted the management of the project to engineer and fighter pilot Andr� Borschberg, CEO & Co-founder, Solar Impulse. A core technology team was then put together and scientific partnership agreements were signed with the Ecole Polytechnique F�d�rale de Lausanne, the European Space Agency and Dassault Aviation. From then on, Solar Impulse climbed one ladder after the other with the help of to plan another adventure � to circumnavigate the world a second time, but without fuel or polluting emissions. Taking the first step towards this, Piccard and his teammate Brian Jones, criss-crossed the USA to investigate the status of research into solar energy in 2001. With encouragement from all quarters, Piccard turned to Ecole Polytechnique F�d�rale de Lausanne, one of the largest engineering schools in Switzerland, which agreed to conduct a feasibility study for the project. The conclusive results of this study enabled multiple out-of-the-box innovations to sustain flight solely on the basis of solar energy, making the plane an engineering marvel unimaginable for this century. THE COUNTDOWN: FROM DESIGN TO FIRST PROTOTYPE The first feasibility study done by Ecole Polytechnique F�d�rale de Lausanne reflected what researchers had discovered and dreamt about that a plane with a large wingspan and aerodynamically extremely D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 101 SOLAR IMPULSE TECHNICAL SPECIFICATIONS Wingspan: 63.40 m Length: 21.85 m Height: 6.40 m Motor power: 4x10 HP electric engines Solar cells: 11,628 (10,748 on the wing, 880 on the horizontal stabiliser) Average flying speed: 70 km/h Maximum altitude: 8,500 m (27,900 ft) Weight: 1,600 kg Take-off speed: 35 km/h efficient is indeed possible. However, at this stage, not all details had yet been taken into account, and the first images were only artist's views. In early 2004, more detailed studies led to the first prototype version, already significantly different. The engines had shifted to the leading edges, in order to balance the force of propulsion of the aircraft and the aerodynamic forces. The cockpit in this version was clearly detached under the wing. Finally, a third version was born from the work of the engineers who decided to start with a first prototype having a non-pressurised cabin. It took boldness and confidence in the projections to freeze the design and start construction. Partnering for perfection In November 2007, after four years of research, calculations, and simulations, Piccard and Borschberg presented the final design of the first prototype with a wingspan of 63 metre and weighing 1,600 kg, registration code HB-SIA. The construction of the prototype was the result of intense collaboration between the multidisciplinary Solar Impulse team, responsible for the design of the aircraft, and the various partners such as materials suppliers and component manufacturers. As the requirements of the new aircraft were compared with the potential solutions offered by everyone involved, new aeronautical solutions came to light. As Borschberg points out, "A challenge like Solar Impulse can be met only by bringing together engineers from every background. This diversity, sought at every level, stimulates their creativity and represents their strength. It is from comparing and confronting their experiences that new and original solutions have emerged." It is the summation of the strengths of over 50 staff supported by more than a hundred experts and advisers, which has made it possible to push back the boundaries of knowledge and achieve real technological progress. Virtual flights In May 2007, a virtual flight mission, made possible by software developed by Altran, provided confirmation that the dream to fly without fuel could indeed become a reality. Experimenting with the aircraft's reactions also provided much data leading to the adaptation of certain procedures and it proved to be of direct value during the actual flights. In May 2008, the flight simulator developed in collaboration with Dassault and EPFL enabled Borschberg and Piccard to pilot the HB-SIA for 25 hours the first time. It was equipped and harnessed like the way it would be during the actual flight � with helmet, safety harness, parachute, oxygen mask, food and accessories. Five projection screens, arranged 210� around the cockpit, gave the pilots the impression of live flight. Challenging human limits Preparing the pilots is also a major concern. During the various missions, human beings at the heart of the adventure have to demonstrate adaptability and mental resistance in the face of extreme flight conditions. To meet this unprecedented challenge, the Hirslanden Group of Clinics acted as medical adviser and developed a concept of permanent made-to-measure monitoring. By September 2008 after-assembly of the cockpit and the tail boom of the HB-SIA prototype, construction of the wing began. Three rectangular carbon fibre and honeycomb sandwich beams, the longest over 20 metre in length, made by Decision SA, were placed end-to-end to form the central wingspar, the backbone of the wing, with its total span of 63 metre. The Solar Impulse project then went through two further important test phases. In December, the Deutsches Zentrum f�r Luft-und Raumfahrt (DLR) in G�ttingen, an institute that specialises in aeroelasticity calculations, carried out a week of vibration tests. These were aimed at assessing the risks of resonance, defining the aircraft's specific frequencies, and verifying through physical experimentation the correspondence between the model the engineers had calculated and the technical characteristics of the actual aircraft. The fuselage, the wingspar and the horizontal and vertical stabilisers of the HB-SIA were assembled for the first time. Compared with the computer model developed by the engineers, the results showed only minimal differences. The modulus of elasticity of the whole turned out a little lower than expected, indicating a greater rigidity in the aircraft structure, which was good news. Mid-February 2009, a series of more robust tests put the wingspar through its paces. These were designed to directly test its resistance to high loads. Fully conclusive, these impressive load tests were conducted in an almost religious silence in order to be able to hear the slightest crack, and also enable the intense concentration and essential co-ordination of all involved. The electrical generating set and propulsion system also underwent detailed testing. The four engines, with their 3.5 metre diameter propellers, the lithium-polymer batteries, the optimisation and control circuits, the cabling, the power controls, and all the components of the aircraft were tested one by one, without exception. The combined efforts of each team member, the courage to undertake a completely new project and the trust of all the partners contributed to the construction of an aircraft, which was completed in June 2009. After its presentation to the public, the integration works were finalised in the autumn of the same year. HB-SIA prototype did its first ground tests in November and succeeded with its first `flea hop' on December 3, 2009 at D�bendorf Airfield. TASK: A PLANE WITHOUT FUEL The three basic and the most crucial 102 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 SOLAR IMPULSE challenges that project Solar Impulse faced were finding relevant partners who would be interested in the idea of creating a plane based on renewable energy, building a team that could work out-of-the-box and derive solutions to make the plane fly day & night, entirely propelled by solar energy, and reducing weight wherever possible as energy consumption had to be kept at the minimum. The search for the right partner ended with Solvay joining the team in 2004. "At the beginning, it was only Piccard, and myself who were involved in the project. During the first two years, we were looking for partners. We started to hire a couple of engineers and also started to identify the technologies, which could be integrated into the plane. In 2004, we had the first partner that came on board, Solvay, a Belgiumbased chemical company," says Borschberg. The company, till date, has developed many new solutions in areas like plastics for ultralight, ultra-resistant structures & mechanical parts, fixing and protection of the photovoltaic system, energy storage in optimised fuel cells, thermal insulation and computer simulation for the plane. After this came the expertise of the European Space Agency (ESA), which proved invaluable in several areas of technology such as batteries and solar cells, energy management systems and ultra-light construction materials. Another support came in the form of Dassault Aviation, the aviation adviser, which provided its expertise particularly in the fields of aeroelasticity, flight commands, safety and systems reliability. Developing a core team During the same period, Piccard and Borschberg were busy setting up the team that would change the thought behind an aircraft's flying capabilities. A team of engineers from different backgrounds and with varied skills was chosen and a network of technical partners, experts and specialists was created to back the project with technical know-how. With the expertise in place, Solar Impulse moved from being a dream to a virtual reality. The breakthrough The many strategies that were simulated in real-life weather conditions � in order to avoid the additional weight and congestion of a pressurised cabin, to limit energy consumption and reduce the control panel to the essentials � brought a wealth of lessons. Borschberg explains, "We mostly used carbon fibres for the structure and tried to replace metallic parts with plastic parts wherever possible. We also got rid of materials, which were not useful, and replaced most of the things with lighter ones. For finding the right material substitute, detailed research was done." The simulation demonstrated that, with the current design, it was possible to fly through the night with a solar airplane, by storing sufficient solar energy in the batteries during the day. This virtual flight mission soon became a reality on April 7, 2010, when the solar-powered aircraft Solar Impulse HB-SIA succeeded in its first and historic test flight from the Payerne Airfield, Switzerland. `ALL THAT IS IMPOSSIBLE REMAINS TO BE ACHIEVED' A famous saying by Jules Verne holds true for every innovation that was born with the success of Solar Impulse HB-SIA. The project's goal � to permit the plane to fly continuously even though it can only tap about eight hours of direct sunlight during every 24-hour period � was a formidable technological challenge that was overcome with the help of an ultra-light, highperformance solar skin. To optimise its exposure to the sun, Solar Impulse's wingspan is nearly the same as the new Airbus 380 (63.4 m) and the solar cells are not attached to the wings, they are the wings. Solar Impulse taking off for its first night flight Symbiotic communication between pilot and plane As the plane flies at very high altitudes non-stop for long period, extreme conditions arise for both the pilot as well as the plane. A device for communication between the pilot & the plane and between the support team on the ground has been developed to tackle this situation. A symbiotic system that would allow the pilot to `feel' the machine, and in turn enable the machine to detect when the pilot nods off or takes the plane outside safety limits has been developed for this flight. Energy storage One of the major challenges facing Solar Impulse was the storage of energy. For the plane to fly without touching down, it must be able to rely on the energy stored during just eight hours of usable sunlight in a 24hour period. Not only must the aircraft gather the necessary energy to fly, but also stock enough in its batteries to keep the plane aloft through the 16 dark hours ahead. Highlighting the criticality of energy storage for the plane to fly in night, Borschberg points out, "Meeting a challenge of this magnitude is possible only by taking maximum advantage of solar energy. Every watt counts and we are looking to track down every means to save energy. Only advanced solutions, most of them never applied before, will permit this." To achieve this, highly efficient and resistant energy management method was developed with the help of lithium-polymer batteries, optimisation of control circuits, cabling and power controls. Optimising the energy path in extreme conditions The precious solar energy collected on the wing eventually ends up turning the plane's propellers. In the process, more than 100 variables come into play that work together as efficiently as possible. The 11,628 monocrystalline silicon cells, each 150 microns thick, have been selected for their lightness, flexibility and efficiency. These cells are flexible so as to withstand the wings' deformations and vibrations in flight without breaking. These are also encapsulated in plastic film to protect them from extreme climates. At 22 per cent, their energy-efficiency could have been higher, but additional weight would have penalised the aircraft during night flight. Thus, the major constraint of the project has been pertaining to storing energy in the lithium polymer batteries. At 104 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 SOLAR IMPULSE the present stage, the maximum energy density is 220 Wh/kg. The accumulators needed for night flight weigh 400 kg, equal to � of the total weight of the aircraft. Success was therefore, possible only by maximising aerodynamic performance and optimising the energy chain. As light as a feather The Solar Impulse plane is as large as an Airbus, but no heavier than a car. The empty cockpit weighs no more than 10 kg. This extraordinary feat has been achieved with the right choice of materials and their optimisation. The plane's key structural elements have been built with a selection of composites and their weight. This has also played a key role in designing the sandwich structure of the plane, which is both robust and extremely lightweight, thanks to its honeycomb pattern. Solar Impulse HB-SIA has an unusual `skeleton' frame, also built in ultra-light materials that supports the 63.4 m wingspan and is sufficiently flexible to withstand some degree of deformation in flight, while offering great resistance. THE REALM OF INNOVATION With perseverance and passion riding high in the hearts of the pioneers, the solarpowered aircraft HB-SIA succeeded in its first and historic flight with professional test pilot Markus Scherdel at the controls on April 7, 2010. The prototype took off before the eyes of several thousand spectators. The HB-SIA flew for 87 minutes, reaching an altitude of 1,600 m. Today, Solar Impulse has received endorsements and appreciation from prominent personalities and organisations from world over for its commitment to seek concrete solutions to ensure the future of Earth. With successful test flights, this project is not only progressing technically, but its reputation and symbolic value are being affirmed well beyond the natural borders of Europe. This engineering marvel has well-demonstrated the fact that growth can be weaved around the theme of responsibility towards the environment and futuristic outlook. The applications of all the innovations that have come along the success of Solar Impulse can be imbibed in our daily lives. Supporting this, Borschberg avers, "The technologies that we have used in this plane can be used today on the ground. Solar energy, light materials for transportation, etc � all these allow us to save energy day by day." Elaborating on the applicability of the multitude of innovations that have come along the success of Solar Impulse, Piccard says, "If an aircraft is able to fly day and night without fuel, propelled only by solar energy, let no one claim that it is impossible to do the same thing for motor vehicles, heating and air conditioning systems and computers. This project voices our conviction that a pioneering spirit with political vision can together change society and bring about an end to fossil fuel dependency." What remains to be seen is how this technological development changes the future for the human race and overcomes the challenge of flying around the world uniquely on solar energy. Image Courtesy: Solar Impulse S.A. APPLICATION ZONE: Electric Rod-style Actuators Actuating Optimal Performance on pg. 122 D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 107 MANUFACTURING EXECUTION SYSTEM DRAWING THE LINE OF EXCELLENCE As Indian companies advance towards the next wave of manufacturing growth, plant solutions such as manufacturing execution system (MES) can become a key differentiator by improving product quality and enhancing plant efficiency. Focus on exports and growing awareness regarding its benefits will drive Indian manufacturing companies into adopting MES to maintain global competitiveness, thereby making a mark among others. he manufacturing industry in India is growing at 11 per cent annually and is expected to contribute to over 25 per cent of the country's GDP by 2020. Exports are likely to touch the $300-billion mark due to an increase in outsourced manufacturing. India will be a major hub for manufacturing automotive components, specialty chemicals and pharmaceutical products. The upcoming decade is being viewed as one of the most decisive periods for the progress of the Indian manufacturing industry. As the world economy evolves into a unified marketplace, competition from domestic and international companies will exert pressure on profit margins. The degree of automation in a manufacturing plant will play a pivotal role in driving the company's position in the global industry. Manufacturing execution system (MES) is a vital software element of plant automation. It integrates the plant equipment with enterprise resource planning (ERP) and other business applications. and data acquisition (SCADA) and ERP as isolated systems with minimal information exchange. This disconnect has created silos resulting in an inflexible supply chain and a lack of process visibility. MES integrates these disparate systems and provides a seamless flow of data between the shop floor and enterprise IT, improving the productivity of the manufacturing process. It reduces the production cycle time, workin process inventory, lead-time, paper work between shifts and the data entry effort. MES can also be used as a standalone system without ERP integration based on the need of the plant and the value that the T BENEFITS OF MES A majority of Indian manufacturing companies run their distributed control systems (DCS) or their supervisory control 108 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 MANUFACTURING EXECUTION SYSTEM end-user desires through its implementation. solutions may not be capable of supporting expenses charged for the system integration However, the factory management gets vast amounts of data generated from effort. Traditional automation companies better visibility of the entire plant floor multiple locations. have moved up the automation value chain operations by means of integration. Work The MES market in India was over $30 with their MES products, from levels one scheduling can be optimised through million in 2009 and is expected to grow at a and two to level three, while ERP analytical tools while tracking key compound annual growth rate (CAGR) of companies, lured by the opportunity, have performance indicators (KPIs) and overall over 18 per cent by 2016. India has gained moved down to include level three equipment effectiveness (OEE). substantially from enterprise solutions in applications within their product portfolios. Manufacturing Enterprise MES vendors include Solutions Association (MESA) automation companies such as Integration of MES with ERP and other applications International has defined 11 Honeywell, Rockwell, generic functions that most Siemens, AspenTech and GE; such as product lifecycle management (PLM) aiding MES products in the market niche MES product companies collaborative product design and manufacturing seem cater to: data collection and Werum, Performix and to be key focus areas for MES vendors. In developed acquisition, operations Posdata; and ERP companies economies, web-based MES products are gaining scheduling, resource allocation, such as SAP . Automation companies dispatching production units, popularity as they provide a real-time snapshot of have the largest share in the performance analysis, product equipment and an interactive interface. Indian market. Large Indian IT tracking and genealogy, services firms have, for the document control, process and most part, focussed on the global markets business processes in the telecom and maintenance management, and labour & due to higher revenue generation. financial services sectors. However, quality management. MES solutions utilise Noteworthy system integrators adoption of IT in the manufacturing sector the ISA-95 standard to integrate control implementing MES in India include TCS has been slow. The automotive and the oil systems and enterprise applications. This and Sarla Technologies among others. As & gas (O&G) industries have traditionally standard can be also used as a framework MES implementations require significant been the early adopters of manufacturing to define user requirements, develop process evaluation and customisation IT-related applications. systems and select vendors. efforts, the overall services revenues have A majority of the O&G refineries and ADOPTION OF MES been higher than licensing revenues. large automobile manufacturers have WORLDWIDE Occasionally, the vendors themselves may deployed MES or are in the process of Globally, the MES market is close to do the complete implementation. The implementing MES in their facilities. Due to $4 billion. North America and Europe each revenue share of software services an ongoing MES implementation by Steel account for about 40 per cent, while Asiacompanies is expected to increase as the Authority of India, the steel industry Pacific (APAC) region contributes to MES industry in India matures and they will contributed significantly to the MES market approximately 15 per cent of the total play a key role in facilitating MES penetration in 2009. The pharmaceutical industry market. The use of MES in North America in India. witnessed the first MES implementation by began in the early 1980s. However, in Astra Zeneca in its Indian facility. One of the TECHNOLOGY TRENDS recent years, the slow growth of the leading Indian pharmaceutical companies is Integration of MES with ERP and other economy and inclination of North American also in the process of implementing the applications, such as product lifecycle companies towards outsourcing system. The specialty chemicals and food & management (PLM) aiding collaborative manufacturing operations to low-cost beverages industries have seen instances of product design and manufacturing, seem regions in APAC has reduced the demand MES implementations, but the adoption has to be the key focus areas for MES vendors. for MES. In Europe, the mature industrial been sporadic. The capital expenditure on In developed economies, web-based MES markets of Germany and France have been the implementation of such a system varies products are gaining popularity as they at the forefront of MES adoption as significantly across each industry depending provide a real-time snapshot of equipment compared to countries in Scandinavia and upon the functionalities required by the and an interactive interface. Software as a Eastern Europe. MES software solutions end-user and the degree of integration with Service (SaaS) and Cloud Computinghave been sparingly deployed by plant controls. based MES solutions are yet to significantly manufacturers in APAC primarily due to COMPETITIVE SCENARIO impact the industry. Concerns over the lack of awareness and availability of Participants in the Indian MES market network and database security have low-cost labour. Japanese manufacturers have traditionally comprise of vendors and system delayed the widespread development and implemented customised in-house MES integrators. Market revenues can be split adoption of Cloud-based MES. The functionalities of an MES application solutions. Chinese companies have realised into licensing and software services are unique to each industry. Due to the the benefits of IT solutions in manufacturing revenues. Licensing revenues include complexity in developing a generic product and are making significant investments in payment made by end-users to vendors having functionalities, which could cater to that direction. As businesses in the APAC for buying software licences. Services numerous industries, vendors typically focus region expands to include outsourced and revenues include implementation, their products only on specific industries. contract manufacturing, home-grown IT consulting, maintenance and training D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 109 MANUFACTURING EXECUTION SYSTEM RESTRAINTS AND DRIVERS FOR FUTURE GROWTH IN INDIA and compete with global companies, they will encounter the need for an MES system to optimise their manufacturing process. Availability of low-cost labour has been one Several pharmaceutical products in the of the main restraints for US and Europe are going adoption of plant automation off-patent and would The MES market in India was over $30 million in 2009 and is systems in India. Data from become generic in the next equipment are recorded couple of years. Therefore, expected to grow at a compound annual growth rate (CAGR) manually and end-users are in order to cater to Food of over 18 per cent by 2016. India has gained substantially hesitant to invest in MES to and Drug Administration from enterprise solutions in business processes in the automate the data acquisition (FDA) and other regulatory telecom and financial services sectors. However, adoption of process. As the returns on requirements, a majority of MES investment are spread the export-driven IT in the manufacturing sector has been slow. over several years, difficulty pharmaceutical companies in accurately quantifying the are expected to implement benefits has also hindered the rate of this MES over the next five years. users want to be able to accurately capture The adoption of MES in the food & system's adoption. plant floor equipment data enabling them to beverages industry will also increase due to The implementation of MES in a plant track plant performance as well as compare the need to effectively track and manage may reduce some of the flexibility available data between multiple plants. IT initiatives product ingredients for regulatory and food in the processes due to the constant need to promote lean manufacturing are also safety compliance requirements. Steel, to capture plant data. In fact, the plant floor expected to drive the growth of the MES non-ferrous metals, specialty chemicals and staff of some conventional industries have industry. consumer-packaged goods are other resisted its implementation. Also, some of THE FUTURE SCOPE industries expected to deploy MES in the the plant equipment may not be compliant The Indian auto component industry is coming decade. to the online protocol connectivity (OPC) expected to reach $60 billion by 2020 standards. Moreover, additional interfacing Ashwin Haleyur, Research Analyst, Industrial accounting for about 5 per cent of the global equipment may be necessary for integration, Automation & Process Control, Frost & Sullivan sales. As these auto component and auto resulting in high MES implementation costs. (South Asia and Middle East). ancillary suppliers begin to export heavily Besides, end-users also occasionally choose a phased approach for implementation to spread the costs over several years. Need for real-time information is seen as the biggest driver for the industry. End- 110 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 CUTTING EDGE SOLUTIONS NEW DEVICE TO ENSURE ACCURATE MEASUREMENTS IN EXTREME ENVIRONMENTS Assuring accurate, reliable results in field applications amid extreme conditions, a new accessory SteadiQ launched recently helps in creating an ideal environment for better spectrometer performance. new accessory, SteadiQ, is different rates. The SteadiQ mitigates broadening the range of that by maintaining a stable applications of fieldtemperature." portable spectrometers. Highlighting the relevance of the This accessory, launched by Ocean device for Indian markets, Morris Optics recently, provides a says, "This is a useful tool that can be temperature controlled atmosphere used in extreme temperatures that helps to stabilise temperature anywhere in the world. For example, effects. It also eliminates temperature companies that make photovoltaic drift in inclement conditions or panels will test the panels in desert extreme temperatures from environments, where they face -20�C to 50�C. extreme temperature shifts. In this The rugged, portable device condition, the device can be of great assures more accurate, reliable results help. Apart from being a relatively The recently launched SteadiQ stabilises temperature effects for accurate in field applications including solar simple tool for use, it also enhances spectrometer performance irradiance, volcanic observation, the performance of spectrometers." greenhouse monitoring and industrial an accessory that enables the use of Available in both UV (200-1100 environments such as cold storage. spectrometer in environments where nm) and Vis-NIR (400-2500 nm) versions, According to Rob Morris, Director� greenhouse gases are measured." He the SteadiQ interfaces directly with Ocean Marketing, Ocean Optics, "The device can further adds, "In extreme hot or extreme Optics' USB2000+, USB4000, HR2000+, be used in spectroscopy to measure cold conditions, the unit operates HR4000, Maya2000, Maya2000 Pro, emissions. In doing so, one is required to independently from outside temperatures. QE65000, and NIRQuest spectrometers. make the measurement in the field and Spectrometers can drift with time and It connects easily to the spectrometer with keep the spectrometer stable, which is temperature, meaning the results will vary preconfigured plug-ins and communicates where the role of SteadiQ comes in � it is as the bench expands and contracts at via the spectrometer's USB port. A STAINLESS STEEL SENSORS WITH EXCELLENT RESISTANCE TO CORROSION wo new families of sensors that can withstand high pressure and high temperature wash downs have been launched recently by Rockwell Automation. These sensors offer excellent resistance to corrosion and damage caused by harsh cleansing agents. The 42CS photoelectric and 871TS inductive sensor families feature stainless steel construction, extended temperature ratings and IP69K enclosure ratings. This testing requires the sensors to withstand spray pressure up to 1,450 PSI and temperatures up to 80�C. In addition, both sensor families have been subjected to and certified to pass chemical compatibility testing by two independent labs, both of which are worldwide leaders in the development of cleaning and sanitising products. In testing, the sensors were subjected to some of the most commonly used caustic cleaning agents and disinfectants in the food & beverage industry. Paul Gieschen, Market Development Director, T Rockwell Automation, explains, "Harsh manufacturing environments require sensors capable of withstanding the frequent jet-spray wash downs, high temperatures and corrosive cleansing agents commonly used in these processes." He adds, "The highly durable sensors are specifically engineered to address these demands, while providing users with excellent sensor adjustment flexibility and a wide range of sensing modes." The PHOTOSWITCH 42CS sensor family features a choice of smooth or threaded 18 mm 316L stainless steel housing, with a hard plastic lens for enhanced reliability and long service life, as well as an operating temperature range of -25�C to 85�C. Smooth barrel models are designed to minimise the accumulation of undesired particles on the sensor's body and allow easier clean-up. An innovative ferromagnetic teach feature minimises the possibility of water ingress associated with the use of push button or potentiometer adjustment. This feature, offered on select sensing modes, allows users to easily adjust and optimise the sensing range to meet specific application demands. The 42CS sensor family offers polarised retro-reflective, diffuse, transmitted beam, clear object detection and background suppression sensing modes. A background suppression sensor is especially designed to detect shiny objects that often go undetected by other such sensors, if the object is approaching at a slight angle. A stainless steel bracket is offered for mounting of smooth-barrel sensors. The 871TS inductive proximity sensors feature a stainless steel 316L barrel and an FDA-certified polyphenylene sulfide plastic face that protects against chemicals and other corrosive agents. Sensors are offered in 12 mm and 18 mm diameter threaded cylindrical enclosures with operating temperature range of -40�C to 80�C. For added application flexibility, standard and extended range units are available. 112 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 CUTTING EDGE SOLUTIONS DESIGING FUTURE LAMPS THROUGH OLED TECHNOLOGY rganic light-emitting diodes structuring processes, while only a maximum layer structure: a flat electrode at the (OLEDs) are seen as the basis for of ten per cent of the luminous area may be bottom, several intermediate layers on top a new generation of lamps. covered by conductor paths. "The large as well as the actual luminescent layer However, illuminated glass is remainder including the chemical etchant consisting of organic molecules. The final expensive. Therefore, researchers have has to be recycled in a complicated process," layer is a second electrode made of a special been aiming at optimising the lamps of the explains Vedder. This is different in the new material called indium tin oxide (ITO). future and reducing the price through a new process. Instead of depositing a lot of material Together with the lower electrode, the ITO manufacturing process. by evaporation and removing most of it layer supplies current to the OLED The concept of pushing the light switch again, scientists only apply precisely the molecules causing them to light up. The gently, and the whole ceiling lighting up in a amount of metal required. Firstly, they lay a problem is, however, that the ITO electrode uniform and pleasant colour, has not mask foil on the surface of the ITO electrode. is not conductive enough to distribute the materialised as yet. However, researchers The mask has micrometre slits where later current uniformly across a larger surface. from all over the world are the conductive paths are supposed attempting to make it a reality. The Researchers have been aiming at optimising the to be. On this mask, the researchers technology behind this marvel is lamps of the future and reducing the price through a deposit a thin film of metal made of based on OLEDs. These diodes aluminium, copper or silver � the use special molecules to emit light new manufacturing process. The technology behind metal from which the conductor this marvel is based on OLEDs. as soon as current passes through path is supposed to be made of. them. Subsequently, a laser passes over Although the first OLEDs have only the conductor path pattern at a speed of Instead of a homogeneous fluorescent recently become available, they are small several metre per second. The metal melts pattern, the brightness visibly decreases at and expensive. A flat disk with a diameter of and evaporates while the vapour pressure the centre of the surface luminaire. "In eight centimetre costs around 250 euro. makes sure that the melt drops are pressed order to compensate, additional conductor Experts of the Fraunhofer Institute for Laser through the fine slits in the masks onto the paths are attached to the ITO layer," says Technology ILT in Aachen, Germany, are ITO electrode. The results are extremely Christian Vedder, Project Manager, working in collaboration with Philips to fine conductor paths. At up to 40 micrometre, Fraunhofer Institute for Laser Technology. develop a process for making these lamps they are distinctly narrower than the 100 He further adds, "These conductor paths distinctly bigger and cheaper, thus making micrometre conductor paths, which can be consist of metal and distribute the current them suitable for mass production. produced with conventional technology. uniformly across the surface, so that the The high cost of the new lamps is According to Vedder, researchers have lamp is lit homogenously." Normally, the conductor paths are primarily due to the expensive manufacturing already been able to demonstrate that the applied by energy-intensive evaporation and process. An OLED consists of a sandwich new method works in the laboratory. O EFFORTS ON FOR LEAD-FREE TECHNOLOGY echnical progress in the automobile industry is on the rise. However, the sector has still some hurdles to cross: `Lead-free materials' being one of the challenges. Till now, lead-zirconate-titanate (PZT) has been the material of choice when fast switchable piezoelectric applications in cars are concerned. To find alternatives without lead is not an easy task. However, in raw condition, all alternative materials still do not have the desired properties. A simulation approach that the researchers of Fraunhofer Institute for Mechanics of Materials IWM have developed gets the search going now. "We have to chemically and physically modify the potential candidates in such a way that in the end, the replacement materials behave similarly well as the PZT," says Professor Dr Christian Els�sser, Group Leader, IWM. T A potential candidate is potassiumsodium-niobate (KNN), which like PZT is a ferroelectric monocrystal. But as technical ceramics with uncontrolled atom vacancies and grain boundaries in the crystal lattice, KNN is initially useless as a material. "For this reason, we have to make a virtue of necessity and have to introduce the right doping, i.e. foreign atoms, in order to improve the properties of the ceramic KNN," says Els�sser. Where and how these doping atoms have to be introduced is figured out by the researchers by means of computer simulation: Different ferroelectric properties are obtained depending at which position of the crystal lattice the foreign atoms � such as copper � are placed. Els�sser explains, "At one position, the copper donates electrons, at another it prefers to accept them. Dipoles are formed or they are not formed depending on the lattice position." These solid-state physical parameters and a number of others shall be determined in advance. Researchers do this with the help of physics in a computer. This is by no means a trivial task because the quantum mechanical computations require complex atom model systems and big computer capacity. But on the other hand, a huge amount of time and money can be saved in the development of materials, because fewer synthesis and analysis experiments in the laboratory are required. Computer simulation also produces important thermodynamic parameters for the sintering process, such as pressure and temperature ranges at which the components have to be manufactured. In this way, all industries using leadcontaining materials can gain from this technology. 114 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 MANUFACTURING ENTERPRISE LANDSCAPE TRANSFORMATION `MELTING' BARRIERS, HARMONISING BUSINESS PROCESSES Business process management is at the heart of any transformation initiative of an organisation to gain a competitive edge in the market. Such an initiative calls for an integrated approach like Manufacturing Enterprise Landscape Transformation, which delivers a customercentric organisation built around industry best practices and standards. The approach `MELTS' traditional organisational boundaries and leverages technology-enabled digitised processes to deliver business results. he evangelists of business process management (BPM) have long believed that strategies built around strongly inter-linked processes are more sustainable than those built around independent activities & interventions. Moreover, integrated planning and management of change � people, processes and technology � are necessary for all process-centric initiatives to be sustainable in the long run. Subject matter experts or consultants from any organisation, working in the area of large process management interventions or large IT programs, invariably end up grappling a common set of questions or situations, pertaining to the following issues: Ownership of the intervention or the programme - whether it is the IT head or the process lead The roles played by business integrator, IT analyst, business analyst, process champion Area of convergence of multiple tracks � whether it is at management level; results level, or do they remain independent Building consensus � aligning the goals of these interventions Resistance to change and how to convince the business users that the intervention is for their benefit Aligning this project with the many other projects already going on in the organisation Analysing how many such interventions have really yielded their desired results, year after year, both in the context of the organisation and the industry in general. This set of issues has been even harder to address in the manufacturing industry, given the intensity of the `clicks vs. bricks' debate of the near past, and the relatively deep set of boundaries that have typified this industry over the years. Therefore, for driving a convergence of the numerous issues into one single framework, an integrated approach referred to as `MELT' T 116 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 Illustration By: Sanjay Dalvi MANUFACTURING ENTERPRISE LANDSCAPE TRANSFORMATION � Manufacturing Enterprise Landscape element is to align people towards the Though centralised IT brings tremendous Transformation, has been proposed. This organisational goal. Both hard elements � visibility and business value, on the approach signifies the enormous `change strategy, structure and system, as well as flip side it limits agility. Hence, for efforts' that go into transforming an soft elements such as skill, style, staff and organisations aspiring to get transformed organisation. The hypothesis in this shared values play a vital role in bringing the into agile global organisation, here is a approach, validated through multiple desired change. novel BPM concept of aligning business customer experiences, It is often seen that emphasises on the fact that employees resist change when Charting and managing a roadmap for transformation somebody else makes a choice every firm should align these factors right at the start, because of an organisation is the single most important element or decision for them. Instead, if every initiative of this type must of business process management & improvement, options are given that provide a ultimately add to the business sense of higher purpose, and change management holds the key to successful meaning, value. The alignment needs to challenging outcomes. An organisational internal `competency centre' work and the capacity to make happen at multiple levels: objectives of the interventions, a difference, will help the approach is proposed to drive such transformation. i.e. business goals, objectives of employees to not only make stakeholders and customers. the right choice, but also The best strategy lies in answering one and IT � customer-centric business, propogate it across the organisations, and common set of questions that include: business-centric processes and processthus change becomes smoother, quicker Who is benefited by the initiative � centric IT. and effective. customer, stakeholder or business The effective way to accomplish this is Where does it fit into the organisation CUSTOMER-CENTRIC to use an effective visual tool such as policy BUSINESS � PEOPLE goals/mission/values/policies objective matrix (PO Matrix). It not only ALIGNMENT How is it aligned with the customer helps to define transformational projects This concept involves defining strategyobjectives aligned to organisational goal, but also When and how does the alignment business policies & objectives and aligning cascades them to lower actionable tasks at need to happen people to the business goal. The most all levels across the organisation. Employees What are the conflicts and how can they important element in any business can easily visualise and appreciate their be resolved transformation initiative is to define the individual contributions towards achieving Why is this the only way to meet these vision and goal. And then follow a strategy organisational goal. objectives? Are there alternatives? to achieve this goal. Policies and objectives BUSINESS-CENTRIC PROCESS As a lean purist recently said, one should become the foundation for organisations to � PROCESS ALIGNMENT not undertake any of these initiatives, if it implement such a strategy. As a study This involves identifying and defining core does not add any value to the customer; or indicates, most successful organisations processes that deliver high business value. if there is no underlying intent of adding started off with a customer � centric vision. This also includes identifying key performance value to the customer or differentiating Hence, it is extremely important to be indicators (KPIs) and process performance one's competitive position from the customer-focussed while defining their indicators (PPIs) linking to business objectives customer's perspective. vision. � a true process alignment. Organisations The next important but most challenging MELT AND BPM BPM has led to the evolution of a comprehensive approach to enterprise transformation (ET) around BPM, which is referred to as MELT. The approach seeks to develop a customer-centric organisation, around industry best practices/standards, delivered through optimised business processes aligned with strategic initiatives of the organisation. Technology can bring wonders to life. However, in this fast changing world, the same technology could also become a bottleneck for change. The trend in the last decade indicates conglomeration of industries into large global enterprises. The true business value is delivered through global operations. The preference for such operations is to deliver IT through centralised enterprise system. ENGAGE the Business through Socialisation (Workshops, Training) � Induce Process Orientation � Facilitate Technology Change Awareness � 'Go To' Environment Simulation for hands on experience � Experience sharing � Detailed Communication Program LEVERAGE TCS Transformational Tools & Methods � 6-Sigma Based Value Chain Analysis � Due Diligence Framework � Value Stream Mapping � Policy-Objective Matrix Business Process Modeling II. Engage III. Leverage V. IT Outcomes � ROI � Global Footprints � Process Quality � Best Practices � Delivery on SLA V. Business Outcomes � Sourcing Spend � NPI Time � NPD Costs � Inventory � Lead Times � Cycle Times � Cost of Quality I. Model MODEL the Value Chain - Align with SCOR/MESA / Industry Standards � Product Design & Development - New Product Introduction � Manufacturing - Operational Excellence � Post Manufacturing - Customer Experience Processes IV. Transform TRANSFORM the Processes � Customer Centric � Process Driven � Technology Aligned Figure 1: The Transformation Framework D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 117 MANUFACTURING ENTERPRISE LANDSCAPE TRANSFORMATION Define Customer Centric Business Measure Analyze Design/ Improve Verify / Control Business Centric Processes Process Centric IT � Define Vision and Objectives consistent with customer demand and business Strategy � Cascade vision across the organization and align people towards the objective � Identify/Design Core processes independent of technology � Assign Process Owners � Standardize and align with industry standards � Define performance indicators and set targets � Simulate changes and work towards achieving acceptable result � Choose best fit technology � Harmonize processes involving diverse user base � Implement and test thoroughly � Train users and make them responsible Figure 2: Bringing 6 Sigma rigor into alignment typically have several processes interlinked to achieve the business objectives. The key to achieve exceptional performance is to identify a set of core processes that brings the maximum business value and directly link them to organisational performance. It is also important to benchmark them against best-in-class and monitor them continuously. The effort on the remaining non-core processes should be minimised as much as possible. The ability to distinguish between core and non-core processes and apportioning resources accordingly will provide organisations distinct competitive advantage. The best way to start off this exercise is through value stream mapping (VSM). For this, one needs to identify high business value product lines and draw a VSM. It is essential to apply lean principles to achieve the best business performance keeping the customer in focus. In this extremely competitive world, organisations constantly feel the need for frequent changes. Today's core process could shortly become non-core processes; hence, it brings the importance of organising and managing processes for business agility. It is best to maintain robust but flexible business process layer separate from technology layer. This provides ability to simulate policy changes and to observe its effect on the process performance before making key business decisions. Typically, process maps up to level 4 (activity) are recommended. Level 1 includes process type, level 2 is configuration, level 3 comprise process element, and level 4 is activity or implementation level. Each one of this process is driven by a set of business rules that in turn is derived from organisation policies and objectives. At this time, it is also recommended to assign process & activity owners depending upon the need and the complexity. Once the drill down process maps are available, the next step is to identify KPIs that are linked to business objectives and derive PPIs. PPIs express process performance along cost, time and quality (CTQ) dimensions in addition to volume and efficiency indicators. These performance indicators provide information at all three levels � strategic, operational and tactical. This information could also be classified into global or regional levels. Organisations are normally loaded with too many KPIs and PPIs. Following are some of the recommended best practices while defining performance indicators. Identify vital few who drive the key management decisions Definitions, measurement mechanism and control parameters should be made The first rule of any technology used in business is that automation applied to an efficient operation will magnify the efficiency. The second is that automation applied to an inefficient operation will magnify the inefficiency. BILL GATES, Chairman, Microsoft Corporation Establish objectives for the current period including implementation measures (What) (How) Establish priority improvement policies for the current period and the following 2 to 3 years Identify principal parties, leaders, and supporting parties (Who) Set due dates and milestones (When) Functional Objectives (Where) Performance Targets II I IV III Set targets for objectives (How much) Strategic Policies clear to the stakeholders across the organisation Ability to aggregate and dissaggregate Ability to change, simulate, analyse and control Define baseline and set improvement targets. (What) (How) PROCESS-CENTRIC IT � TECHNOLOGY ALIGNMENT This component involves identifying the technology that best fits the process requirement, stable yet brings the maximum flexibility for change. Governance and sustenance mechanism is one of the critical factors for successful business transformation. Paradigm shift is required at all levels to see IT as internal business process owners that not only own Results Estimate overall effects � Dollar contribution to business plans � Contribution to management indicators � Contribution to intrinsic technology � Contribution to management technology IV V Figure 3: Dr. Fakuda's PO Matrix 118 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 MANUFACTURING ENTERPRISE LANDSCAPE TRANSFORMATION IT but also closely collaborate with in the beginning and slowly reduce business, thereby providing towards the normalcy depending Technology (Applications) invaluable supporting services. In upon the length of the programme. Performance Indicators traditional world, IT is centered on In the absence of well-established Business Processes architecture, applications and governance mechanism, conditions Business Rules infrastructure and nothing more. tend to revert back to preOne can perceive a wall between transformation state. Policies and Objectives business and IT. Hence, it is extremely important Figure 4: Performance Indicators as a systemic output When process-centric IT is to institute a well-designed envisioned, it actually means: governance mechanism in the Business Strategy/Process standards Process forms the fundamental beginning of any transformational Industry Standard Reference model: Standard Process Set: piece to the business. Everything programmes. Lastly, organisations � Common business process language � Enterprise Policies � Industry Best Practices � Best Practices else is built or derived from this must realise what they completed � KPIs for continuous improvement Strategic Alignment � Dash board metrics (PPIs/KPIs) Need to provide/enable end-toas a transformational journey is not end process visibility, internal the end but just the beginning. Local BU 1 Local BU 2 Local BU 3 and external dependencies and Keeping their egos in check, leaders information flow of such transformational Figure 5: Aligning with Industry Standards Ability to make and simulate organisations must avoid policy changes other important aspect that needs to be Scalability with expansion and contraction watched during application fitment is the of business ability to map KPIs and PPIs and the ease at Avoiding redundancy. which information can be extracted. Even if the target seems so high as to Once the process catalogue is ready at Often, harmonisation process brings be unachievable at first glance, if you level 4, business process master list (BPML) changes to process catalogue, especially for explain the necessity to all the people the functional requirements � can be non- critical but essential business processes. extracted. This information should be used The best practice is to document them as involved and insist upon it, everyone to evaluate the technology or application scenarios against the chosen technology. will become enthusiastic in the spirit landscape. Despite these efforts, it is However, altering level 4 process due to of challenge, will work together, and extremely difficult to find a perfect fit. technology fitment is not recommended. achieve it. It is important to carry out process Once appropriate technology/application harmonisation, keeping out of the box is chosen, one can generate level 5 process (OOTB) functionality fit on one axis and maps that are technology-specific workflow, ICHIRO SUZUKI, business compliance on the other. The goal from which it is possible to come up with Chief Engineer of the first Lexus is to fit maximum processes (including all level 6 work instructions. the strategic/core processes) to the OOTB SUSTENANCE MECHANISM: product functionality. Thumb rule is to find defensiveness and resulting blindness. GOVERNANCE STRUCTURE 80 per cent of the processes fit to OOTB Instituting continuous learning and Bringing transformation is painfully slow functionality. Depending on the individual improvement mechanism along with honest process. In well-undertaken programmes, business cases, further evaluation should be & collective feedback and communication organisations show enthusiasm and rigour done to fit the remaining processes. The mechanism at all levels in the organisation is profitable. After all, a competency centrebased approach helps in becoming a nodal Application of point for all interventions. special control Standard Feature Process A Process E Process F Org Structure Process G Master Data Process C 80% of the processes Application functionality compliance workaround Process B >5% of the 15% of the processes processes Process D Process H Application of best practices Sreenivasa Chakravarti, Head-Automotive Center of Excellence, TCS; and Ramesh Narayan, Supply Chain Consultant, Manufacturing ISU, TCS E-mail: email@example.com and firstname.lastname@example.org SMART STRATEGIES: Design And Manufacturing Integration 3rd party Solution Exceptions Business compliance Fully Compliant Annihilating Production Scrap on pg. Figure 6: Application Specific Alignment 136 120 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 ELECTRIC ROD-STYLE ACTUATORS ACTUATING OPTIMAL With rising demand for controlling costs while achieving high speed & precision in factory automation, it has become more important than ever to fully analyse a linear actuator application and precisely determine a project's parameters. This is especially true with electric rod-style actuators due to their higher initial cost, complex design and more predictable performance compared to fluid power cylinders, both pneumatic and hydraulic. Here are 10 tips to ensure efficiency and optimal performance. n the hurry to get factory automation applications up and running, there is always the impulse to make educated guesses or take shortcuts. However, to ensure precision in factory automation and reduce costs, various factors need to be taken into consideration. One among them is the actuator application, mainly the electric rod-style actuators. Additional engineering and analysis at the front-end of an electric actuator application will reduce overall costs and result in automation systems with higher reliability, better performance, lower energy expenditures and less maintenance. Following are the top ten tips for optimal performance, reliability and efficiency of electric rod-style actuator application. dynamic loads of the application and matching them to the peak and continuous load capabilities of the actuator, the application will be both cost-effective and reliable. manufacturers make this task easier and more accurate than in the past. PERF RMANCE CALCULATE FOR ELECTRIC, NON-FLUID POWER (PNEUMATIC OR HYDRAULIC) I 2 3 FACTOR IN DUTY CYCLE Duty cycle is defined as a ratio of operating time to resting time of an electric actuator expressed as a percentage. An actuator that is moving for two seconds and stopped for two seconds has a duty cycle of 50 per cent. % Duty Cycle = On Time (On Time + Off Time) The ability of an electric rod-style actuator to perform its intended task with accuracy, speed and durability is dependent on matching the electric motor, the lead screw and the bearings to the anticipated loads. By knowing the precise static and 1 CALCULATE LOADS PRECISELY It is essential to avoid oversizing by properly matching the actuator to an application. With fluid power cylinders, the additional cost of a slightly larger actuator than necessary was minor compared to the extra engineering time that might be involved in sizing it correctly. It was common for engineers to build in a 2:1 safety factor on fluid power applications for a variety of reasons. These included erring on the conservative side to compensate for imprecise knowledge of the loads, fluctuations in available air pressure and oversizing in anticipation of higher loads in the future due to production growth or application changes. Electric actuators can cost significantly more upfront, so oversizing is a costly mistake. Sizing programs, graphs and formulas available from actuator Underestimating the impact of duty cycle on an actuator can lead to overheating, faster wear and premature component failure. Overestimating the impact of duty cycle can lead to higher initial costs due to oversizing. Typical conservative duty cycle estimates often stem from an incomplete understanding of the application. Electric rod-style actuators offer enhanced performance, control and efficiency over their fluid power (pneumatic and hydraulic) counterparts. However, because of the higher initial cost of electric actuators and their unique characteristics vs. a fluid power cylinder, it is essential to fully understand the application requirements. More productive and reliable automation systems will result from a careful determination and analysis of the loads, forces, application footprint and environment. SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 When considered together, force and velocity requirements dictate the capabilities of motors, screws and nuts in electric rod-style actuators. A common error is specifying a stepper motor to save money when a servomotor may be more appropriate for velocity and force requirements. As the speed of a stepper motor increases, its available force drops off precipitously. However, servomotors are able to maintain their force even as speed increases. Similarly, force and velocity 4 KNOW REQUIRED FORCE AND VELOCITY 122 FAC T FACT ELECTRIC ROD-STYLE ACTUATORS requirements will dictate the type and pitch of the lead screw � whether it is an acme screw with either composite or bronze nut, or a ball screw or roller screw. By knowing the precise speed and velocity requirements of the application, it is possible to specify an actuator with the proper components needed for high performance and long service life. Efficiency Ensuring Tips Match motor, lead screw and bearing to loads for best actuator performance. Avoid oversizing by properly matching the actuator to the application. Duty cycle is defined as a ratio of operating time to resting time of an electric actuator expressed as a percentage. Force and velocity requirements will dictate the type and pitch of the lead screw. A rod-style actuator is vulnerable to damage and wear, if the extended rod is subjected to side loads. In rod-style actuators, lead screw critical speed becomes an upper limit. Peak thrust needed for the application cannot exceed the peak thrust that can be delivered by the actuator. IP-ratings only address static conditions. Dynamic conditions (vibration, heat, cold, movement) also have to be considered. Overall stroke length and actual working stroke length of an actuator will be different due to the `dead length' needed to accommodate internal components. In some cases it is better to alter the application than compromise on drive system performance. 5 EMPLOY PROPER GUIDES AND AVOID SIDE LOADING A rod-style actuator is vulnerable to damage and wear, if the extended rod is subjected to even moderate side loads. Side loads on the rod usually occur when the actuator is out of alignment with the main load, causing severe wear to the front bearing and damage to the lead nut. The mounting of the actuator can also be a factor. For example, an actuator rod will have a tendency to run out of alignment at maximum stroke when it is mounted with a clevis type rod end, creating significant side loads on the rod and support bearing. To avoid side loading, be sure the actuator rod has an appropriate mounting and is either guided or precisely aligned with the load. 6 SET CRITICAL SPEED LIMITS Higher operating speeds can often improve manufacturing throughput, but in a rod-style actuator, lead screw critical speed becomes an upper limit. Critical speed refers to the rotational speed that excites the screw's natural frequency. When a screw reaches critical speed it begins to oscillate or `whip'. The critical speed limit is dependent on the screw length and diameter. As the stroke length increases, the distance between the support bearings increases, causing screw oscillation over a certain speed. This oscillation prematurely wears the support bearings and can result in vibration, noise and even catastrophic failure. peak and continuous thrust capability. For most of the duty cycle, the thrust stays under the continuous thrust curve. Make sure that the actuator's peak and continuous thrust capabilities are properly matched to the motor; some motors can provide more peak thrust than the actuator can withstand, causing stresses that will lead to premature failure. It is equally important to perform necessary column strength calculations and verify that the actuator is capable of providing the required peak thrust without screw or rod buckling. of the actuator and motor when the rod is fully extended. Failure to consider the total envelope may limit the size of motor that can be used or require an alteration in the layout of the application. Be aware that the overall stroke length and actual working stroke length of an actuator will be different due to the `dead length' needed to accommodate internal features such as lead nut, bumpers and limiters. 8 FACTOR IN ENVIRONMENT 10 DRIVE SYSTEM IS MORE THAN A FOOTPRINT The peak thrust needed for the application cannot exceed the peak thrust that can be delivered by the actuator. First determine what the peak thrust requirement is for the application and then compare that to the thrust curve for the selected actuator. Thrust curves from actuator manufacturers show a combined 7 MATCH PEAK THRUST TO ACTUATOR The environment in which the actuator will be operating can have a profound effect on performance, durability and maintenance. High temperatures can affect seals, lubrication, bearings and motor life. Extremely low temperatures can also affect performance, lubrication and wear. Contamination with oil, water or abrasive grit can destroy seals unless the actuator has an appropriate IP rating. Since IP-ratings only address static conditions, dynamic conditions (vibration, heat, cold, movement) also have to be considered. It is important to consider the overall actuator `envelope' � the length and width 9 TOTAL ENVELOPE MATTERS The actuator may be specified with an inline or reverse-parallel (RP) motor mount/drive system. While a RP system offers a more compact envelope, the RP is simply not as efficient due to the addition of belts or gears. RP motor mounts do offer gear/belt ratios for a mechanical advantage and inertia matching, plus an additional mechanical mounting option of a rear clevis. Inline motor mounting offers the most efficient drive system and the highest dynamic performance. In some cases it is better to alter the application to make room for an inline motor drive than to specify a reverse-parallel drive where its performance characteristics may not be the best match. Aaron Dietrich, Tolomatic, Inc. Electric Product Manager, D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 125 AUTOMATION EQUIPMENT Keeping MISTAKES At BAY Automation is the next step beyond mechanisation, wherein machines perform processes, but require human intervention to make them work. However, when choosing an automation system and equipment manufacturer, there are many aspects that should not be ignored, as the returns on investment will depend on the right selection. Here are 10 most common equipment buying mistakes, which are easily avoidable. uying an automation equipment can be quite a long and tedious process. However, the process can be made easier. Given below is a list of 10 mistakes most commonly made when purchasing such equipment. B Failure to define one's company's expectations with regard to performance, aesthetics and hardware preferences will eventually lead to confusion and misunderstanding. A detailed equipment specification will force the project engineer to examine all aspects of the project. Besides, while allowing the vendor to be creative in solving the automation problem, one also needs to be absolutely clear about the expectations. A simple equipment 1 NO EQUIPMENT SPECIFICATION specification could include the following: Project Objective Performance expectations that include cycle time, yield, machine or system uptime, quality expectations or other critical performance objectives Preferred hardware list, which includes details about PLC, valves, and robots. If one prefers component suppliers, it is important to let the automation/ integration partner know that as early as possible Design requirements that involve guarding, wiring and plumbing, ergonomics, as well as any in-plant obstacles or floor space constraints Product information on prints, current processes or any other critical characteristics of the end-product Acceptance criteria that take into account expectations before the delivery of the machine or system. 2 FAILURE TO MAKE TIMELY VISIT TO AUTOMATION HOUSES Often, requests for quotations are sent out to automation houses having little prior knowledge about the company. A visit to one or more appropriate suppliers early in the process will ensure that one is looking at viable solutions from capable partners. Such visits would also help clients interpret the quotation much more clearly. Besides, it would also provide a much clearer understanding of the scope of work that will be performed to develop a solution. As a result, the price quoted for the equipment will have more meaning and enable a better comparison. 3 INCORRECTLY ESTIMATING THE PROJECT COST There are many cases wherein a manager 126 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 AUTOMATION EQUIPMENT presents his supervisor a proposal for an automation project, sells the idea, and grossly underestimates the cost of the project. Now to save the stituation, the manager and his/her subordinates spend their time looking for the right price rather than the right solution. Without fail, this approach will force someone to shortchange the actual objectives and compromise where ideally one should not. The better alternative in such a situation would be to get a quote before floating the idea before the concerned team. Most automation houses would prefer to be involved at the earliest possible level. A good consultative problem-solving session with a potential automation supplier (or suppliers) will help all parties involved to work through the best approach; it may even lead to several different options. As long as someone is reasonably serious about pursuing a project, it should not be difficult to get a quick cost estimate before going to the concerned authority. In fact, careful planning, even if the initial quote seems more expensive, will invariably save money later. One should not allow the automation vendor to ship the machine before it is ready. Allowing this to happen usually prolongs the automation machine from performing as desired and puts the vendorcompany relationship at stake. improvements and lean manufacturing projects, factory personnel offer a great source of creative ideas. And since they are the closest to the process, they can save hours of wasted time by identifying problems early. By taking a lean approach, one might also discover that there is no need for as much automation as one originally thought. Or it would be just enough to repurpose or reconfigure existing equipment as part of a lean concept. installation are the biggest source of cost overruns with any project. If this happens, one will end up paying not only for the onsite fix, but also for any lost revenue from the product one was hoping to introduce. 8 FAILURE TO SUPPLY THE VENDOR WITH UP-TO-DATE DETAILS Maintaining proper and up-to-date documentation is an ongoing challenge for most companies. Failure to supply the vendor with sufficiently up-to-date drawings of the project will cause expensive delays. Even the best automation houses will not always detect non-conformance from the parts to the prints until it is too late, making rework inevitable. Supplying parts that are within specification is also important. 6 NO CONSTRUCTIVE COMMUNICATION WITH THE VENDOR Often, companies purchase a piece of automation without considering the technical expertise required to maintain the equipment on a daily basis. Therefore, it is essential to consider all the costs associated with new and unfamiliar technology. It has been observed that quite a few companies decide to save the cost of system integration upfront, only to have to hire them later, after the project has already suffered unacceptable delays. If one is spending hundreds of thousands of dollars on new automation, getting it up and running fast helps in recouping investments faster. This way, one can ensure that he/she does not put the market launch of a critical new product in jeopardy. 4 LACK OF TECHNICAL CAPABILITY IN-HOUSE 5 FAILURE TO INVOLVE THE PRODUCTION PEOPLE Even after a detailed equipment specification has been submitted to the vendor, constant constructive communication must be maintained. The word `constructive' holds great significance here. Simply documenting all conversations and responding to written correspondence for the sake of maintaining good records is not enough. A company and its chosen vendor must form a team. It is important to review the progress of the project in detail with the vendor at certain points in the project and notify them of any perceived problems as soon as possible. Besides, one should take advantage of modern technology, too. With the availability of the outstanding 3D solid modelling software, net meetings and videoconferencing, it is possible to meet frequently and get a good look at what the automation vendor is designing. It is also possible to spot errors early and ensure a superior final result. Some products are not designed to be manufactured or assembled automatically. Some process components cannot be fed automatically, and depending on how frequently the product mix changes, it might not be feasible to economically produce the part automatically. When automation is difficult, perhaps a semiautomatic or even manual solution would be more feasible. 9 FAILURE TO DESIGN FOR AUTOMATION 10 USING THE WRONG TECHNOLOGY FOR APPLICATION The people responsible for ultimately operating a piece of automation can impact the functioning of the machine. Hence, it is necessary to allow the production people to get involved in the project at an early stage, let them play an active role and give them a chance to take ownership. In today's manufacturing environment, where many people have been involved in process 7 ONLY SHIP COMPLETE AUTOMATION EQUIPMENT One should not allow the automation vendor to ship the machine before it is ready. Allowing this to happen usually prolongs the automation machine from performing as desired and puts the vendorcompany relationship at stake. Re-engineering and troubleshooting after The failure of a project engineer to do his/ her homework may result in the least efficient use of equipment, especially if it is not purchased as part of a long-term strategy. It is important to contemplate on certain questions such as can the anticipated system accommodate future change without having to start from scratch each time; is there an `off-the-shelf' piece of equipment available for the given application; should one employ flexible automation or hard automation? Some other areas of concern include whether one should opt for lean manufacturing or manual production or go for automation, etc. These questions should be answered before building a machine or investing in automation. By adopting a careful approach, one can be sure to have a successful experience when he/she finally starts producing parts with the new equipment. Courtesy: Bosch Rexroth 128 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 DESIGN & BUSINESS *Business wants to love design, but it's often an awkward romance. tough love The debate between the worlds of business-as-usual and business-by-design continues as each world tries to outdo the other to prove that its contributions have added real value to products. Corporates believe they can prove the future by applying inductive and deductive reasoning to the present. Designers, however, on the other hand, not only use inductive and deductive reasoning, but also rely on abductive reasoning to the present. The trick lies in building a cohesive bond with business & design to speed past competitors. orty years ago, Thomas for a few mavericks such as IBM, Kodak, and services that delight customers. Design, Watson Jr, Chairman & and Xerox, it would take years for design to in short, is becoming an important engine of Chief Executive, IBM, move in from the fringes of business. corporate profit. It's no longer enough to during its most explosive Today, companies are creating products outperform competitors; to thrive in a period of world of ceaseless and rapid growth, had Many business people have long regarded designers as change, businesspeople have to proclaimed, `Good design is mere stylists. More than a few designers see business out imagine competition as well. good business'. Corporate They must begin to think more people as Neanderthals willing to forfeit quality for the like designers. America, however, barely sake of profit. looked up from its work. Except As design gets its due, some F 130 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 DESIGN & BUSINESS business types wish the clock could be must be). For example, Costco might study nobody could prove that whole foods turned back to a time before all those the current cost structure of all of its outlets market would succeed at all, let alone designers were running around urging in order to set, inductively, future cost become the most profitable food retailer (in people to let their creative juices flow. They targets for the whole chain. Or Clorox terms of profit per sq ft) in the US. But resent that even as design is forced upon might use a core operating principle -- Mackey did it. As the computer scientist them or insinuated into their work, the `build market share and profits will follow' Alan Kay put it, "The best way to predict the designers are often not held -- to deduce whether to launch accountable for meeting firm a new kind of sanitising spray. Managing the yin and yang of business-as-usual and Corporate folks typically believe revenue and profit targets -- business-by-design means striking a balance between they can `prove' the future by the primary form of business discipline. any number of countervailing impulses: give people the applying rigorous inductive and This tension between deductive logic to the present. freedom to follow their nose, but hold them accountable business-as-usual and businessDesigners use inductive and for their performance. by-design is not new. Many deductive reasoning as well, but business people have long they also rely on a third type: regarded designers as mere stylists. More abductive reasoning, the logic of what might future is to invent it". And that is what than a few designers see business people as be. AG Lafley, former Chairman of the design-centric organisations do: They peer Neanderthals willing to forfeit quality for the Board, Procter & Gamble, understands the into the needs and desires of their sake of profit. Their mutual conflict springs need to braid all three forms of creative customers, identify patterns of behaviour, from a fundamental difference in the way thinking. Lafley also pores over anecdotal refine ideas that tap into those behaviours each side thinks about creating value -- research and allows customer comments to and then, push into the unknown -- or at corporate types, by and large, seek to fuel influence him even if they are not rigorously least the uncertain. growth by building from bulletproof, collected or statistically significant. He relied If an organisation wants to reap the reproducible systems; designers generally on anecdotal evidence when he championed benefits of design, it must do more than just attempt to do so by imagining something the conversion from big-box to compact hire `hot' designers or declare itself `designnew, different, better. That difference can detergents -- one of P&G's most important oriented'. be seen as a trust in reliability on the one decisions over the past 20 years, and one The challenge is to manage the chronic hand and in validity on the other. that flew in the face of the available hard push and pull between a value system A reliable process -- which tends to data. That decision opened a multibillionpremised on what's valid and one based on attract folks in finance, engineering, and dollar market for P&G and demonstrated what's reliable. As management theorist operations -- produces a predictable result that simply regressing the past isn't enough James March argued, by focussing on the time and again. This is business as algorithm to bust a daunting challenge. As Bernard intuitive and experiential, organisations -- quantifiable, measurable, and provable. Arnault, Chairman & CEO, LVMH, a French explore new sources of competitive It hews to that old management adage, luxury-products group, once put it, "It is not advantage. By looking to the provable and `What doesn't get measured doesn't get enough to have a talented designer; the replicable, organisations better exploit the done'. Wal-Mart, Dell, McDonald's -- each management must be inspired too". innovations they have brought to market. started out with a novel idea, yet each went To prosper in the long run, a company on to standardise every aspect of its needs to succeed at both. It must mesh the World of work: Permanent operation and blow it out across the US classical workings of a traditional organisation tasks or temporary and then the world, creating billions of with the prototypical features of a design projects? dollars of wealth along the way. shop, especially in three key areas -- Different sorts of logic are also reflected in A valid process, on the other hand, flows reckoning the future, organising work, and how work is typically organised in the from the designers' deep understanding of establishing status & rewards. business and design communities. Daily both user and context, and leads them to THREE KEYS TO MAKING work at a tradition-bound firm consists of a ideas they believe in, but can't prove. They DESIGN WORK series of permanent, ongoing tasks -- make work in a world of variables: the the 30 day forecast, upgrade the core unpredictable, the visual, and the product, and manage the next sales initiative. experimental. Great designers worry less Reckoning the future: Each person's role is clearly staked out, and about replicating a successful process than compensation is closely tied to the position's about producing a spectacular solution. Prove it or invent it? responsibilities, which vary little over time. Design leaders such as Panasonic, The glaring difference between the worlds In a design shop, however, everyone `lives Timberland, and Bombardier have grown of business-as-usual and business-by-design in the projects' as Tom Peters, a businessexponentially since their inception, yet each is the way each side actually thinks. In management strategist, once said. All work continues to put a premium on judgment, traditional organisations, the dominant is temporary and project-based, and people experience, and gut instinct. forms of logic are inductive (demonstrating are judged by their ability to add value to it. Valid thinking demands an inspired leap through observation that something actually Both approaches to work are necessary, of faith. For example, before John Mackey works) and deductive (reasoning from a set but insufficient. In the hurly-burly of day-tolaunched one of the country's first of existing principles to prove that something day business, work is a combination of supermarket-style natural-food stores, 2 1 132 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 DESIGN & BUSINESS ongoing activities and discrete, timenew Head, Filippo Passerini, moved bound projects. The trick is to pick to a business-by-design model when the style of work that best fits the he essentially challenged his problem. After all, company-defining information-technology group to products such as the iPod, the Razr, become problem-solvers. Having and the Mini did not emerge from a outsourced the bulk of P&G's fixed, standardised process. They mundane, day-to-day IT operations were born in the projects. to HP and IBM, Passerini freed half of And so, as a rough rule of thumb, his 2,300 staffers to become high-end when your challenge is to create value matchmakers. As he told CIO or seize an emerging opportunity, the magazine, `They match what is solution is to perform like a design needed in the business with what is team -- work iteratively, build a possible with technology'. Today, his prototype, elicit feedback, refine it, supergeeks are experimenting with and repeat. Give yourself a chance to virtual-reality technology and coding uncover problems and fix them in real new applications to improve time, as the process unfolds. customer-relationship management On the other hand, functions systems. including running a supply chain, By creating a problem-solving The biggest challenge for all building a forecasting model and culture, Passerini has transformed a designers and businesspeople alike is compiling the financials, are best left workforce of back-office drones into to become equally adept at to people who work in fixed roles a tribe of `intrapreneurs' who are quantifying the now and intuiting what is next. There is no other way to win. with permanent tasks, people more creating tremendous value for P&G. adept at describing `my responsibilities' His IT managers had even won than `our responsibilities'. bonuses when the global business why most executives prefer the known to If that sounds like a schizophrenic unit met an unprecedented challenge the unknown. It's a lot easier and safer to way to run an organisation -- where one following P&G's acquisition of Gillette -- run a billion-dollar business than to invent half functions like an accounting firm and the integrate 95 per cent of Gillette's systems one. other collaborates like a design shop -- capabilities into P&G in 15 months. Among designers, however, the tinder well, perhaps it is. But that's the way Google Marta Foster, a VP who oversees the IT that fuels the creative fire comes from does it. Eric Schmidt, CEO, Google, has team's business-solutions work, says the solving wicked problems. The best designers said that the part of Google that looks like a project, which required a workforce of 600 are not necessarily known for the revenues normal company (sales, marketing, coders and engineers, was `incredibly they have generated, but for the challenges operations) is run like a normal company, energising. It's far more meaningful when they have cracked. In the business world, but the part that defines what the customer our work is tightly aligned with the sees and experiences (software company's strategy. Our people coding and engineering) feels To prosper in the long run, a company must mesh the talk about their projects like they more like a design shop free are running their own classical workings of a traditional organisation with the businesses'. from top-down control. Call it prototypical features of a design shop, especially in three schizophrenic, but the challenge Managing the yin and yang of for CEOs like Schmidt is to key areas -- reckoning the future, organising work, and business-as-usual and businessmanage the paradox of by-design means striking a establishing status and rewards. freewheeling innovation and balance between any number buttoned-down operational of countervailing impulses: give for instance, Hartmut Esslinger is recognised discipline. people the freedom to follow their nose, as the founder & CEO of frog design, an but hold them accountable for their international creative consultancy that counts performance. Set a high bar, but recognise Source of Status: A large Hewlett-Packard, Disney, and Nextel among that failure is an unavoidable consequence its clients. But in the designer's universe, of pushing into new territory. Do everything staff or an outsize success? Esslinger will always be famous for conceiving possible not just to thrill your customers, In traditional firms, status -- the protein that the look and feel of the Apple IIc, now in the but also to wring costs and efficiencies out nourishes the ambitious as they claw their Whitney Museum of Art. of vendors and suppliers. The biggest Companies such as P&G have figured way up the corporate organisational chart challenge for all designers and businesspeople out that rank and title alone are less-than-- is conferred on those who run brawny alike is to become equally adept at stellar motivators. So, to keep its people organisations with big-time budgets. The quantifying the now and intuiting what is priming the growth engine, P&G imported relationship between size and status is next. There is no other way to win. the designer's ethos to `do meaningful straightforward -- the larger the revenue Roger Martin, Dean, Rotman Business School work'. When the company created its and the bigger the staff, the higher one's (Republished from FA&R Company Magazine). Global Business Services unit in 1999, its station and the greater the reward. That is 3 134 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 DESIGN AND MANUFACTURING INTEGRATION ANNIHILATING PRODUCTION SCRAP Defining all product information digitally can put a company on the right road to reducing scrap, which comes as a by-product of manufacturing. Often scrap results in rework and wastage of money and time. Hence, every manufacturer aims at reducing or eliminating it completely and now this is possible in four simple ways: full-digital product representation; virtual prototyping and functional simulation; tolerance analysis and dimensional testing and an information-dissemination workflow. uring manufacturing, production scrap gets generated from just about anywhere. It can be in the form of parts ordered from a subassembly supplier that do not fit into the finished assembly, or it can be a physical prototype that is used and discarded. Occasionally, scrap is a finished, delivered product that customers simply do not like, or in a worst D case scenario, it can be a defective product that triggers a costly and embarrassing recall. In each case, the scrap � and the required rework to fix the problem � costs money or time, or both. And with raw materials and labour being the two largest cost centres for most manufacturers, all scrap produced will cause a negative impact on both areas, according to industry analysts. CREATION OF PRODUCTION SCRAP Wrong materials, incorrect tolerances, faulty ergonomics � there are many ways in which scrap gets generated. Here are some of the more serious ones: Wasted prototypes: Physical prototyping is a necessary part of product development, but the fewer prototypes required, the better. One manufacturer of racing engines was able to cut weeks 136 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 DESIGN AND MANUFACTURING INTEGRATION of development time by by redundant data. Moreover, all changes lowering the number of and updates to the central file are managed physical prototypes used for by lockout and recovery mechanisms. testing. Parts that do not fit: With VIRTUAL PROTOTYPING AND product design teams now FUNCTIONAL SIMULATION dispersed across the globe, Today's products and assemblies, which are those inevitable last-minute designed with many moving parts, demand changes in design or Tolerance Analysis Extension (TAX) - powered by CETOL Technology: strenuous testing for fit and movement. To manufacturing have become Sophisticated statistical tolerance analysis results ensure quality and performance, physical even riskier: one subcontractor prototypes are essential, yet may not receive the most recent file or latest email, Production scrap and design rework are two inefficiencies they can also be wasteful, since the prototype, once used, and may end up producing that can quickly put a company at a competitive becomes scrap. Reducing or parts that would not work. disadvantage if efforts are not taken to continuously eliminating prototypes is every Changes in materials: When a subcontractor is unable to manufacturer's ultimate goal. reduce them. deliver the requested stock, Full-digital product means that all the digital data entered and/ they will often suggest an alternative. representation enables to replace some or generated over a product's lifecycle stays Too often, the new information gets lost physical prototypes with virtual prototypes. with the product throughout each stage of somewhere between a company's Full-digital also means � depending on 3D development � from initial concepts to final procurement office and the CAD software � one can `shrink wrap' a 3D product retirement. That way, the same manufacturing group. model to a smaller, more manageable size, data used for the CAD model can be used The impact of these errors, and countless and email it to remote members of the for simulation and analysis, as well as for others, can be devastating for a small or design or manufacturing team, thus saving manufacturing, and for storage in the PLM medium-sized business. A look at the significant time and cost. Shrink wrapping vault. website of the US Consumer Product Safety cuts out non-essential data from the model, Full-digital representation makes it Commission gives an idea of the extent of so only that data is shared, which is pertinent possible to achieve end-to-end integration, product recalls in the US alone. to a specific role or function within the so each step in the product development development enterprise. For instance, a THE SOLUTION � IN FOUR process is informed by the actions of other manufacturer of automobile seats would STEPS steps. For instance, in an all-digital want to use the body of a car as virtual Because it touches on all facets of design environment, any and all changes in the prototype, but might not care about the and manufacturing, the effort to reduce CAD software automatically update the engine or drive-train components. With scrap and rework must be defined and CAM file, and any change in a CAD or CAM shrink wrapping, one can send only the data designed as a company-wide initiative. It application updates the data in the PLM data they need (while also protecting valuable should begin with a commitment to fullvault. With an intelligent PLM solution, this intellectual property � i.e., the engine design digital product representation, and then interaction does not cause undue stress to � that one would prefer not to share with evolve to encompass virtual prototyping the PLM architecture because, although the auto body manufacturer). and functional simulation; tolerance analysis these functions give the appearance that DIMENSIONAL AND and dimensional testing; and an informationmultiple copies of each file exist, the reality TOLERANCE dissemination workflow that runs is that just a single, central file is being ANALYSIS throughout the business. created, updated, shared and stored at all Dimensional variation is always a key To a small or medium-sized business times. The multiple views seen by different parameter in product design. Variation (SMB), this goal may sound lofty � and users are the result of repository pointers among parts can come from any number of expensive. But that does not have to be the � or non-associative replications � and not case, thanks to advances in design and manufacturing integration, as well as today's out-of-the-box product lifecycle management (PLM) systems for small and mid-sized businesses. Here are the steps that many SMBs are using today to reduce scrap and rework in their organisations. STEP 2: STEP 3: STEP 1: Full-digital FULL-DIGITAL PRODUCT REPRESENTATION product representation Tolerance analysis evaluates the impact of tolerances and dimensioning schemes on the feasibility and manufacturability of product designs 138 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 DESIGN AND MANUFACTURING INTEGRATION circumstances. For instance, in manufacturing, CNC drill bits may be sharper at eight in the morning than at noon, or the purity of cooling fluids may change from shift to shift. Also, in the enduser's environment, temperature extremes may trigger shrinking or expansion. Setting tolerances is challenging because of the need to be cost-competitive. Tight tolerances may be good for the quality or the `feel' of the product. But too-tight tolerancing may prove too costly in terms of the time and the extra machining it requires. Ideal tolerancing is a matter of finding the best compromise between product quality and economics, and it is a critical consideration in terms of minimising production scrap and rework. Accurate tolerance analysis is essential, and it is important that the tolerance values assigned to the model by the designer remain with that model as the product moves through the entire development process. customers and design partners � should be able to share information on product development, where appropriate, and add more value. Information sharing is best accomplished with an information workflow that automates the movement of requests, queries, approvals and other actions among the people, who are most closely associated with product development process. The workflow should contain alerts, alarms and escalation levers to ensure that reviews or other requests do not go unnoticed. And the workflow should be tied-in with relevant product development processes, such as product validation and change management, that will contribute valuable information to the store of product development knowledge. FROM MANUAL TO AUTOMATIC Not long ago, these issues � virtual prototypes, wide-ranging information dissemination, production scrap, and rework � were less than supercritical for businesses. Only a short decade ago, products were simpler, and product development processes were somewhat slower, such that workers had more time to iron out design flaws or END-TO-END INFORMATION DISSEMINATION STEP 4: manufacturing errors. Today, business is working within a tightly compressed, 24X7 world. In consumer and business-tobusiness markets, demand can change instantly and new competition can emerge, with new and innovative products overnight. Time-to-market is now measured in weeks rather than months or years, and any design flaws, manufacturing errors or productdevelopment inefficiencies are exposed quickly. Production scrap and design rework are two such inefficiencies, and they can quickly put a company at a competitive disadvantage if efforts are not taken to continuously reduce them. Years ago, businesses could trust their product development information and processes to seasoned individuals � the designers who kept the drawings and the engineers who knew which Engineering change orders (ECOS) applied to which parts. Yet for small and medium-sized businesses, to keep up with today's pace and competition, that trust must now be placed in the hands of digital product development � from `manual to automatic' � and the sooner, the better. Rafiq Somani, Area VP PTC India , Engineering, manufacturing, procurement, service, sales and marketing � plus suppliers, 140 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 3D CAD Affordable best-of-breed digital design software solutions and state-of-the-art workstations have made it possible for small and mediumsized companies to transform their ideas into high-quality products with exceptional speed. This will help manufacturers increase their profitability and, at the same time, help them meet product design and production challenges head-on. NNOVATION partners to their large, multinational manufacturing customers, who are increasingly looking at their partners to bolster their product development supply chain. ACCELERATING ood product design is not about large-scale mass production, it is about quality. Today, with the best-of-breed digital design software solutions and state-of-the-art workstations and PCs, small and medium-sized companies can have the best of both the aspects. In short, ideas can now be transformed into high-quality products with exceptional speed. This also means that small and medium-sized businesses can be even more effective G WHAT MAKES THIS POSSIBLE? � Advancements in software tools: The most recent software in 3D CAD integrates critical tasks to make idea generation, model testing and visualisation easier. It reduces the need for physical prototypes and accelerates innovation through the use of iterative model creation and testing. These features were previously available only to those using large-scale supercomputers. � Advancements in hardware tools: Precision workstations will enable engineers to iterate their idea's design and analysis & virtually create the finished product. This will help reduce product development time and investments associated with physical prototypes and testing. D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 143 3D CAD Product Data Management � Conceptual Design Design Validation Design Review/ Approval Rapid Prototyping/ Testing � Product Delivery/ Shipment to Customers Creation of Marketing Materials/ Product Documentation Automated Manufacturing/ Production � � Advancements in workflows: Advancements in both software and hardware has made it possible for knowledge workers to migrate to parallel workflows and learn to design simultaneously while modelling, simulating or rendering. They can modify one design and, at the same time, simulate another. Knowledge workers now have a powerful new ally -- the 3D CAD software -- to help them transform their innovative ideas into products faster than ever. With effective 3D CAD software, integrated engineering and manufacturing tools, and advanced, high performance workstations, manufacturers can: � Compress design cycles while avoiding development delays � Reduce or eliminate physical prototyping and testing, thereby greatly minimising scrap/rework � Improve customer/partner communications and enhance customer/ vendor interactions � Promote innovation and deliver highquality products quickly, consistently and cost-effectively. Thus, 3D product development platforms can help small and medium-sized manufacturers increase profitability by helping them meet product design and production challenges head-on. The training process provided by the 3D CAD company to consumers ensures that they get the design experience necessary for environments, which need fast and predictable innovation from their designers. In fact, some mobile workstations, along with offering consumers the added benefits of a mobile system, have delivered better performance than some desktops. � � component and assembly performance using allied simulation software Facilitate design reviews, secure customer approvals and obtain production quotes using eDrawings files Create models, prototypes and castings with rapid prototyping solutions Automate tool-path generation directly from the 3D CAD models using integrated computer-aided manufacturing (CAM) partner applications Automate the creation of product visuals, marketing materials, packaging and documentation using photorealistic rendering, drawing and animation tools Manage the 3D data created using the product data management (PDM) software during the product development cycle. 3D CAD DEVELOPMENT SOFTWARE The integrated 3D product development solution is not a single CAD programme. It is a fully integrated software suite with a common-interface application specifically designed to provide solutions at each stage of product development. These tools enable small and medium-sized manufacturers to access the same features that were earlier accessible only on highend systems used by large multinational corporations, but at a fraction of the cost. It delivers true integration that leverages 3D CAD files across the entire product design chain, right from conceptual design, simulation, validation and testing to computeraided machining, mould production, assembly, documentation and training. Using a single data format and a fully integrated application, companies can eliminate delays related to file conversions and translations. Integration can help improve the quality of the product by minimising the potential for human error, reducing costs related to scrap and rework, and maximising the impact of training efforts. The 3D CAD programme provides a comprehensive solution that is powerful, reliable and manageable. At each phase of the product development cycle -- from conceptual design to production, packaging and product introduction -- manufacturers can use this programme to: � Create geometry for parts, assemblies and tooling � Analyse, simulate and validate BENEFITS OF 3D CAD SOFTWARE An industry benchmarking 3D CAD software and running on best-of-breed precision workstations delivers a robust set of modelling tools to meet geometry creation needs. Whether companies are designing large assemblies involving thousands of components, single parts involving simple geometries, tooling for injection moulding, or complex surfaces and organic shapes for consumer products, the 3D CAD programme provides the power to enable product development teams to work efficiently. The breadth of the software's capabilities could range from the specialised to the routine. 3D CAD software makers can help companies check for interferences within assemblies and sub-assemblies, fold sheet metal into intricate forms and shapes, develop moulds and castings, generate complex surfaces and patterns, and much more. Whatever the product development needs, 3D CAD software can provide the tools for generating innovative, conceptual designs to reduce the steps involved in geometry creation. With in-built configuration management capabilities, companies can create multiple design variations -- different capacities, lengths, weights, etc. -- from a single design. If an organisation needs to make a modification, it only needs to change the base design because the 3D CAD software programme will automatically update all the configurations. Leading 3D CAD programmes also allow organisations to leverage legacy 2D INTEGRATED PRODUCT DEVELOPMENT A comprehensive 3D CAD software programme and compatible workstations can help deliver a productive, efficient and dependable solution for designing, validating and manufacturing products in 3D. By installing 3D CAD software on the latest precision workstations, product development professionals can quickly solve complex problems, process large 3D data sets efficiently, and meet big engineering challenges head-on; all that, without having to compromise on their budgets. 144 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 3D CAD design data, maintain compatibility with other CAD system data formats, instantly create bills of materials (BOMs), automatically generate engineering drawings and download online component models directly into a 3D design. SOFTWARE HELPS MANAGE TIME Users of power precision workstations have discovered new ways to reduce the time lag between an idea and a product. In the past, manufacturers used repetitive prototyping and testing to validate designs. But today, users have a new tool to reduce the need for costly and timely physical prototypes and accelerate innovation -- the virtual workbench. Directly integrated in the 3D CAD software, the simulation software supplies complete and detailed performance information that a company can use to reduce the need for expensive physical prototypes, improve product quality and shorten time-to-market. Companies can eliminate costly product development delays, unfruitful detours and field failures by using simulation to help them validate parts and assemblies early in the product development process. information and manage diverse types of product design data. Unlike static 2D files, 3D files contain references, associations and interrelationships that link them to other files, such as parts, drawings, BOMs, multiple configurations and assemblies. PDM helps manufacturers manage, preserve and safeguard these relationships to make sure they remain intact. The software also enables revision control and prevents overwriting of CAD files and other data management-related errors. RAPID PROTOTYPING Many manufacturers are looking at new virtual workbenches as a tool to produce rapid prototypes for a variety of purposes, ranging from form and fit to testing. These virtual products can be routed quickly to the customer to gather immediate feedback so that changes could be rapidly incorporated. In addition to virtual prototypes, users employ rapid prototyping systems to support fast, cost-effective production of 3D concept models and physical prototypes directly from 3D CAD data. Organisations can access a full range of compatible rapid prototyping technologies to produce 3D models for prototype testing and design communications functions. materials is easy with 3D CAD, as the product development process uses a single data file. This allows product development teams to start production of marketing materials and user manual documentation well in advance. Companies can use photorealistic rendering tools along with the 3D CAD model to create images that can be used on the web as well as on brochures, product sheets and catalogs. With 3D CAD, companies will not have to wait for an initial manufacturing run to create product marketing and documentation materials. 3D CAD provides users with a range of flexible tools for creating product graphics and images in a variety of file formats. In addition to generating marketing images, users can produce exploded views for use in assembly instructions and product user manuals. INNOVATION WITH VIRTUAL WORKBENCHES Utilising powerful computing technologies, the 3D CAD software helps you accelerate your innovation with virtual workbenches. In addition to available 64-bit operating systems, some workstations can sport up to 8 computational cores, and can provide disk and memory capacity to meet even your largest assembly (eg 1M components), analytical and rendering requirements. These innovative virtual workbenches are also scalable to meet your ongoing needs. DESIGN REVIEWS & APPROVALS USING EDRAWINGS To facilitate sharing of design concepts, manufacturers can use the allied eDrawings software. With innovative eDrawings files, product design teams can supply accurate, easy-to-understand representations of 3D models to anyone, anywhere, via email. With an eDrawings file, the recipient can rotate, zoom and pan the model as well as use the mark up function to add notations and comments. Users can even animate an eDrawings file. With eDrawings capabilities, users can facilitate design reviews, secure customer approvals and communicate effectively with manufacturing specialists. With improved communications, companies can minimise or eliminate costly surprises, delays and rework. MANUFACTURING PRODUCTION Manufacturers can save more time and eliminate other potentials for error by using an integrated CAM package for generating tool paths and controlling the manufacturing processes. Integrated CAM software enables companies to utilise 3D CAD data to drive an important stage in the product development process. Instead of relying on manufacturing vendors or specialists to generate the correct tool paths, companies can manufacture accurately by using the actual solid model. With CAM applications, organisations can automate the manufacture of finished parts, prototypes and tooling directly from 3D CAD data. Compatible CAM applications support the complete spectrum of design data formats and production techniques. Solutions are available for 2-5 axis-milling machines, 2-22 axis lathes, multi-sided milling machines, multi-function lathes and mill-turn machines, and CNC punch, laser, plasma and flame machines. JOURNEY FROM INVENTION TO INNOVATION With the robust combination of 3D solutions and precision workstations, small and medium-sized companies can now achieve both speed and high quality. Knowledge workers can employ powerful new virtual workbenches to accelerate their imagination and iterate three-dimensional ideas. They can quickly test for form, fit and function and eliminate bad ideas. They can validate design integrity and identify & quickly remove designs that are not up to the mark. They can easily document and collaborate with partners and customers, curb miscommunications and help accelerate approvals. This software will certainly offer designers a powerful 3D virtual workbench to accelerate innovation. Manoj Mehta, Country Manager, India and SAARC Operations, Dassault Syst�mes SolidWorks Corporation PRODUCT DATA MANAGEMENT Some of the best 3D CAD software includes the product data management (PDM) system, a powerful tool that engineering workgroups can utilise to control design revisions, safeguard valuable product DOCUMENTATION CREATION Creating marketing and documentation 146 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 PRESIDENT, KASSIA KARNATAKA GOVERNMENT'S POLICY FRAMEWORK IS A BOON FOR INDUSTRIAL DEVELOPMENT "The prospects for industrial growth in Karnataka can be rated `A+' with the existing framework of collaborative functioning of large, medium, small and micro industries coupled with a vast reservoir of industrial talent," says SS Biradar, President, Karnataka Small Scale Industries Association (KASSIA), during an interaction with Shivani Mody. Excerpts... discipline, by and large, in micro & small enterprises (MSE) sector is a positive aspect of self-regulation and entrepreneurial competence. FUTURE GROWTH PROSPECTS The prospects for industrial growth in Karnataka can be rated `A+' under the existing framework of collaborative functioning of large, medium, small and micro industries coupled with a vast reservoir of industrial talent. The recently held global investors meet has been very promising. Even if 50 per cent of the probable Rs 4 lakh crore investments materialise in combination with the growth momentum at present, the state can expect a dramatic transformation of the industrial anatomy in the broad spectrum of infrastructure, manufacturing, tourism and mining. INDUSTRIAL GROWTH The manufacturing sector in Karnataka has witnessed considerable growth in the recent years. A conducive ecosystem, industrial environment, institutional framework and policy support have been the drivers of all-round industrial growth in the state. However, while considering development in the state, it is important to focus on rural development as well. Karnataka's urban areas are deficient in social, commercial and technical infrastructure, while in the rural areas information and guidance support, together with climate for cluster development and physical infrastructure are not adequate to satisfy growing needs. The manufacturing sector faces certain challenges and opportunities as well. Some of the major challenges faced are on the account of competitive environment, fastchanging designs and technology. However, steeply increasing demand, talents and skills together with specialised market needs are some of the factors, which help the sector thrive in this age. To enhance growth, the government has to play a major role in assisting companies in processing local information of institutional assistance, unutilised resources, wide range of skills and professional support. ADVANTAGE FROM OTHER FRONTIERS The development of IT, biotechnology and pharma, among other sectors has been supporting the growth of the manufacturing sector. Additionally, the contribution of knowledge-based industries towards increasing productivity and resources has emerged as a special ingredient in ensuring robust industrial growth. This phenomenon will continue in the coming years. ROLE OF GOVERNMENT The government's policy framework is a boon for industrial development. However, for effective results, the implementation issue has to match the policy stipulations. There is a need for strategic planning to identify urban suburbs, rural potential tracts, institution linkage with development, coastal and Malnad area resources. A focus on North Karnataka region is also required to compile opportunity scanning and development treatise, with professional expertise. LABOUR REGULATIONS Labour regulations in micro and small industries do not form a major bottleneck except in instances where there is inadequacy and deficiency of skills � multiple skills and advanced technology � in certain product and process domains. Industrial 148 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 ENGINEERING EXPO AHMEDABAD 2010 AHMEDABAD 10-13 DEC '10 Gujarat University Exhibition Hall SETTING INSPIRATIONAL BENCHMARKS By virtue of sheer resilience, inherent wisdom, and the spirit to experiment & innovate, Gujarat has seen a remarkable progress in industrialisation in the last decade. Being a part of such a promising growth haven has been a long cherished dream of investors and manufacturing companies. To make this dream a reality, Engineering Expo Ahmedabad 2010 is all set to provide a window of opportunities to companies wanting to spread their base in & around the state. Having proved its mettle since last eight years, the 9th edition of Ahmedabad Expo is scheduled from December 10-13, 2010, which is sure to be a game changer for the Indian engineering and manufacturing industry. A preview... PRERNA SHARMA he land of immense opportunities, Gujarat, is synonymous with vibrant business prospects, enviable deals and i n s p i r a t i o n a l entrepreneurial spirit. With huge inflows of foreign direct investments into the state, the state has become a region to reckon with. The need for a networking platform has become all the more significant with a robust industrial climate. The critical importance of trade fairs can be gauged from the fact that it offers a networking platform to both exhibitors and visitors for sharing their expertise and ideas to fructify business tie-ups under one roof. Carrying forward the legacy of supporting the industrial growth of India Inc, the Engineering Expo Ahmedabad is all set to infuse fresh vigour in its 9th edition starting from December 10-13, 2010. Covering a vast expanse of industry portfolio, the Expo has time and again proved to be a major trade facilitator. Being a veteran of the show, it has been providing a perfect platform to profit for exhibitors & visitors since its inception. Highlighting the role of the Expo in facilitating business, Sandeep Khosla, CEO�Publishing, Infomedia18, says, "With Gujarat setting the legacy in attracting foreign & domestic investors and facilitating business with the help of inherited entrepreneurial spirit and a dynamic industrial policy, Engineering Expo Ahmedabad is ready to provide the right platform to grow and harness trade ties. T Acting as a catalyst for robust, sustainable and inclusive growth, it will work in tandem with the holistic growth policy of the Government of Gujarat and open the doors for joint ventures, collaborations and foreign investments in the country." LAND OF INNOVATIONS The vivacity of Gujarat's economy is acknowledged today, supported by a strong entrepreneurial culture of its people and infrastructure focus of its policy makers. All these factors provide the state with an ideal platform to leapfrog to a much higher growth tip, which makes its performance comparable to global benchmarks. This is also important for Gujarat to achieve the vision of a much improved economic performance. The reasons are aplenty to invest in Gujarat and be a part of this growth bandwagon. While talking of promising industrial landscape of the state, the mere mention of Ahmedabad presents ample prospects to fructify enviable business deals. Ahmedabad is acclaimed as one of the most investor-friendly cities in the state as well as in the country. Housing major multinationals such as Adani Group, Nirma Group of Industries, Arvind Mills, Shell, Bosch and many more, the city has occupied the most prominent position in the industrial landscape. According to Industry Commissionerate, Government of Gujarat, "Ahmedabad district accounts for 21.5 per cent of factories and employs 18 per cent of workers in the state. Of the total industrial productivity of the state, nearly 60 per cent is contributed by the district alone." This speaks of the might that the city possesses. Further substantiating the fact, RM Sankar, Principal Scientific Officer, ATIRA, says, "Entrepreneurship, ease of organisation of production & availability of factors required for production, marketing and distribution network, family ties and the rich culture make the operations of the industry profitable." A PREFERRED INDUSTRIAL BASE A right mix of all the success ingredients � educational facilities, industrial infrastructure, proactiveness of government and foresight of companies has made Ahmedabad a preferred investment hub. This is not all... the spurt of major overseas investment into the city has also substantiated the fact that it is on the global investment radar. Supported by excellent road network, railway connectivity & port proximity, and of course, the most proactive government, the opportunities that Ahmedabad provides for companies to set up their base are aplenty. The city of Ahmedabad, which in itself is a successful industrial hub, has also helped trade and industry to flourish in neighbouring cities like 9th Edition 250+ Exhibitors 23,000+ Business visitors 150 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 ENGINEERING EXPO AHMEDABAD 2010 December 10-13, 2010 Gujarat University Exhibition Hall, Ahmedabad Pre-registration & on-spot registration 12 km from airport and 6 km from Ahmedabad railway station Online Registration : www.engg-expo.com Timings : 10 am to 7 pm Gandhinagar, Rajkot, Surat among others. Agreeing on the same, Anil Kumar Roy, Associate Professor, Centre for Environmental Planning & Technology (CEPT), observes, "The corporate culture and regular exchange of ideas through conferences, seminars and workshops provide an opportunity for industrial houses to promote trade in the city." This clearly necessitates the need of a trade exhibition in the city. Date Venue Admission Exhibition Ground : : : : Promotional Act, BryAir (Asia), informs, "As far as exhibitors are concerned, we will get the required exposure to our target segment of people. As far as visitors are concerned, they get updated information about different products available, technology trends, products enhancements, etc. We are looking for good number of visitors to attend this exhibition, so that we get to know the different problems faced by our customers and how we can develop better products from them. In addition, since there is a constant change in demand, we can keep a tab on the changing customer preferences and understand what additional measures INSPIRING PAST Having generated close to 4,500+ business leads as well as estimated business worth `40 crore, last year's Ahmedabad edition more than lived up to visitors' & exhibitors' expectations. Delighted with the last year's turnout, Dinesh Chaudhary, Director, Energy Mission Engineers, states, "We are extremely pleased with the response gained for our products' promotion and brandbuilding at the event." Generating leads, companies were overwhelmed by the response exhibitors received during last year's edition. Ashok Bhavsar, Proprietor, Delta Packaging Industries, says, "We received around 100 enquiries and also 30-40 orders for the machines displayed at the Expo. We are exceedingly satisfied with the visitor turnout and dealership queries. The timing EXPO INVITES Engineering Expo has the track record of breaking its own milestones year after year, be it in terms of generating business leads or displaying latest innovations. Moreover, the veteran of the brand, Engineering Expo Ahmedabad edition has been a proven success time & again with the kind of support it has been able to gain from the industry at large. Exhibitors at this year's Ahmedabad edition are eyeing to tap this investment haven. With high expectations, the exhibitors are looking forward to meet their prospective buyers & sellers at the event. Rajendra Damakle, Manager�Sales, Wellprint Technologies, says, "We have high hopes from the Engineering Expo Ahmedabad. We are expecting a large number of people there, who will showcase their products. This will greatly benefit both, the visitors as well as the exhibitors, as it will generate good business. We see the Expo as a platform that will help our business to grow." Seconding his thoughts, Anil Kumar Rout, CEO, Technosys Instruments & Equipments, avers, "The Engineering Expo Ahmedabad will definitely benefit visitors as well as exhibitors. Ahmedabad is one of the fastest growing auto industry lines in the country. The exhibition will help in getting more business for companies as visitors will get to know more about them. I expect the Expo to target all the industry people, wherein there are real buyers, thereby benefiting business." Citing Engineering Expo as an ideal trade platform, Dharmendra Gupta, Manager - Overwhelming response at Engineering Expo Ahmedabad 2009 we need to take for meeting the emerging demands." Agreeing with this, CB Panchal, Technical Director, Modern Power Semiconductor, says, "Engineering Expo is more of a technical event, which will bring technicians and other professionals together. As knowledge sharing and product display are the prime objectives of the Expo, we get a tremendous chance to learn and explore new avenues. Thus, it is of mutual benefit for both exhibitors as well as visitors." Dhaval Patel, Manager, Griphold Engineering, informs, "We are participating in the Expo for the first time. We are based in Vadodara and we keep getting product enquiries from Ahmedabad on a regular basis. The Expo will help us reach potential customers in Ahmedabad, which is an important industrial and trade hub, and we as manufacturers would like to explore further business opportunities in this market." of the event was appropriate for our product." On the same lines, Vishal G Sanghvi, Partner, Janak Enterprises, avers, "This has been the maximum businessmaking event for us in the past three years of participating in exhibitions. The Expo had a fantastic turnover and it was an extremely satisfying experience for our company." THE COUNTDOWN BEGINS... Being backed by a handful of trade magazines such as SEARCH, Chemical World, Modern Machine Tools, Engineering Expo Ahmedabad 2010 edition is set to break its own records of attracting quality visitors as well as offering innovative products & services to the entire engineering & manufacturing fraternity. With its 9th successful inning this year, the event will set the ball rolling for sealing profitable business deals. Be there to witness the extravaganza that is about to begin on December 10, 2010... 152 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 IPVS 2010 ALL SET TO PUMP UP PROSPECTS Today, pumps and valves have become an indispensable part of the Indian economy. Meeting the large global and domestic demands, Indian pumps and valves industry is bound to grow even further. Slated to provide booming growth prospects to companies, IPVS is back with its 4th successful edition, scheduled from December 9-11, 2010 at Chennai Trade Centre. With SEARCH as its media partner, the event is sure to provide industry players enormous opportunities to showcase their innovative offerings. ndia is gradually getting integrated into the world of global pumps & valves supply chain. The world market for pumps is projected to reach $36 billion by 2010 from an estimated $33 billion in 2007. But for this to materialise, India has to play a significant role along with China and the US (together with Canada), which is the world's leader with a $7 billion worth pumps industry. Similarly, the valves industry is also flourishing rapidly with several national and international gas projects in the pipeline. In order to provide Indian pumps, valves and systems fraternity, the much needed boost for growth, Orbitz exhibitions is back with its successful 4th edition of Indian pumps, valves & systems (IPVS) expo. The event will showcase advanced technologies in these sectors from around the world at the Chennai Trade Centre from December 9-11, 2010. Since all these activities are largely scattered and unorganised, there is a pressing need for a solid common platform to showcase technological advances and explore new markets. IPVS will fill this niche," says Rupen Vikamsey, MD, Orbitz Exhibitions. The Indian economy is one of the fastest-growing economies in the world. Its all-round growth is catalysed in all vital sectors such as chemicals, oil & gas, power generation, water handling/sewage treatment, infrastructure development, pharmaceuticals, etc. However, pumps, valves and process plants are the key industries, which are integral to all these sectors. Therefore, its growth is largely dependent on them. "By and large, Indian pump manufacturers have traditionally catered to the needs of the domestic market. In fact, the domestic industry today is looking up for overseas opportunities and quite a few have also made a good impact in the international scenario. Indian pump exporters have managed to have a presence in the Middle East and African countries, where standards and conditions are similar to those prevailing in India," says Vikamsey. The event will offer manufacturers of pumps, valves, process systems, foundries, components of valves, forge shops, actuators, gaskets, packings and sealants, research institutes, etc, a platform to showcase their offerings and organisers are confident of roping in more overseas exhibitors. In fact, IPVS 2010 will provide a single-point contact for potential buyers not only in India, but also from the world over. In its third successive hosting, IPVS had clearly emerged as India's biggest event for industrial pumps, valves & systems and one of the biggest in Asia. After having been credited as the first-of-its-kind in India, it has since inception, provided the much needed boost for growth of the sectors it represents as it showcases advanced technologies in those categories. I ASSOCIATION TIE-UPS IPVS enjoys the support of many associations prime being Euro Pumps, Holland Pump and All India Association of Industry. The previous successful edition of IPVS had a comprehensive range of products displayed on a single platform. The number of exhibitors and visitors has been growing steadily. Apart from India, countries including Australia, China, Germany, Hong Kong, Iran, Japan, Korea, Malaysia, Russia, Singapore, Sri Lanka, Taiwan, Thailand, UAE, and USA have participated in the event. Around 3,000 visitors representing assorted sectors such as power, oil exploration, pharmaceuticals, energy resources, fertilisers, health & hygiene products, so on and so forth were witnessed last year. The concurrent conference series has also attracted prominent speakers. "Every year, we expect IPVS to set new benchmarks, as well as create a platform, for the great lift-off of the Indian pumps and valves industry," says Vikamsey. With these promising opportunities, IPVS is set to offer a lucrative platform to the visitors & exhibitors alike. A BACKGROUNDER India has been home to most leading technologies in the field of industrial pumps & valves around the world for decades. Many others have realised the importance of having a base in India and are streaming in. "Such a base is not only important for gaining a share of the growing Indian economy, but also for catering to their global market share from cost-effective, technically competent and congenially communicating market set-ups, manufacturing plants and R&D centres. 154 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 HANNOVER MILANO FAIRS INDIA 2010 STAGING THE BEST-IN-CLASS INDUSTRIAL INNOVATIONS Brimming with bright prospects, India has been a major destination for overseas companies to set up base in the continent. With many tie-ups in the pipeline, companies are looking for a platform that provides strong networking opportunities. Having established the culture of bringing ground-breaking offerings from Hannover � the land of innovation � its Indian subsidiary Hannover Milano Fairs India (HMFI) is ready to unveil dynamic business opportunities yet again at HMFI 2010, scheduled from December 15-18, 2010, with SEARCH as the media partner. A preview... PRERNA SHARMA iming to establish strong trade network across the globe, Indian companies are keen on inking deal with their overseas counterparts to encash the current enviable growth prospects. While `going global' is the mantra on the domestic front, foreign multinationals are also eyeing to tap this vast domestic expanse. Testifying this, Sudhir Patil, MD, Hannover Milano Fairs India, opines, "The manufacturing industry in India is going through a buoyant time; the growth forecast for the economy is that of 8.5 per cent, which is enviable if other countries are taken into account. Sectors like automotives, infrastructure, machinery building, energy and consumer durables are all on a steep growth path. All the indicators suggest that growth will continue in the coming year as well." He further says, "Clear signs of economy revival has encouraged various companies to announce new investment and expansion plans involving adoption of better techniques & equipment, which are cost-effective and latest in technology. Amidst this, specialised industrial trade fairs prove to be the most ideal platform to witness new technologies and exchange information on the same." Slated to provide a promising avenue to companies, Hannover Milano Fairs India (HMFI) is back in its 4th edition of specialised international industrial trade fairs in Mumbai. Based on the format of world-renowned Hannover Messe of Germany, this edition of HMFI will be bigger & better than ever. associations like Fluid Power Society of India, ARC Advisory Group, Indian Transformer Manufacturers Association, Field Bus Foundation, German Machinery Manufacturers Association (VDMA), Indo German Chamber of Commerce and many more. Strengthening trade prospects with other countries, the show will witness participation from major countries. Elaborating on overseas participation, Patil avers, This year, the fairs are further strengthened "Our trade fairs will feature over with a comprehensive conference programme 350 exhibitors of which 35 per on topics like automation, energy, etc. cent will come from 20 overseas countries. Interaction among Perfectly in tune with a high growth rate international companies and economy, the theme for this year's edition is domestic companies lead to the enhancement of international `speed up your business'. trade by way of import-export technology tie-ups, agency arrangements and cross-country SUDHIR PATIL, MD, Hannover Milano Fairs India investments. Trade fairs are probably the most effective medium for strengthening visitors will get an overview of new bilateral trade." technology trends in diverse industrial CONCURRENT SHOWS sectors. HMFI has been known for its innovative According to Patil, trade shows have offerings to companies on the domestic soil, registered a growth of 12 per cent this year be it in terms of engaging the best-of-breed over the previous year, which is a testimony under one roof or attracting major foreign to the fact how well the shows are received companies to seal the deal with their Indian by the industry. He further adds, "These counterparts. Maintaining its rich tradition of form a B2B platform for latest technologies introducing one show each year, HMFI has and knowledge sharing. Such events play been successful in setting record partnership the role of catalysts in the economy by from exhibitors and visitors alike. With a helping industries choose the right diverse range of displays under one roof, technologies for their enterprises" the show will offer immense networking ASSOCIATION TIE-UPS opportunities to various verticals as well as The shows have received official support horizontal segments of the industry. from several organisations and industry Covering five core sectors of the industry, Starting from December 15, 2010, HMFI will present 5 international trade fairs, which will act as unique B2B event international companies to reach out to diverse user industries in India through a single platform. With more than 300 exhibitors, of which one-third are from 19 overseas countries, A 156 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 HANNOVER MILANO FAIRS INDIA 2010 the fairs will complement each other and enhance business prospects for the participants in the respective shows. The concurrent trade fairs announced by HMFI for this year's edition are: Honeywell Automation, Invensys, Larsen & Toubro, Laxsons Automation, Pepperl+Fuchs, Rockwell Automation, Turck Automation, Waaree Instruments, Misumi, and several international companies. CeMAT INDIA The requirement for material handling, transportation and warehousing is growing at a robust pace and is driving the demand for integrated logistics solutions. IT is playing a crucial role in this sector by minimising manpower requirements. With logistics fast emerging as a major industry in the country, CeMAT INDIA is highly significant in providing a common ground for all the participants to come together for a dialogue. With booming retail and widespread supply chain networks, it has tremendous potential for growth in India. Suppliers of material handling equipment, logistics and warehousing services and the technology developers will find CeMAT INDIA an ideal platform for presenting their products and services. The leading exhibitors in CeMAT include Godrej, Voltas, Maini, Jost's Engineering Company, Neelkamal, Toyota, Brady, Exide, Chep, DMAG, Puma, Sick, Kardex, Hercules, Action, Curtis Instruments, Kaup, Giovenzana, Schaltbau, Bolzoni, HETRONIC, Anwood Logistics, and many more. MDA INDIA Motion, drive and automation technology is significant as it is all about running plant and machinery efficiently. Similarly, as far as the auto industry is concerned, the revival in domestic demand in the last few quarters is giving tremendous boost to automobile manufacturing as well as components suppliers. Applications and usage of hydraulics, pneumatics, bearings, sealing technology and lubrication, etc, is in diverse sectors. All the hi-tech innovations in production technology will be featured at MDA INDIA. This show will feature leading names like Eaton, Parker, Janatics Pneumatics, Nord, Lenze Dynamatics, Schaeffler, and many others. Kremlin, Rexson, Metal Finish Systems, Prism Surface Coating, Milman, and more. "To enhance our offering to the industry, this year we have added Surface INDIA to the group of fairs. Surface protection technology is important in every sphere of industry and combining this topic with the other existing shows is only a logical extension for us," says Patil. Environmental concern is prime factor in the surface treatment processes. Surface INDIA will focus on environment-friendly technologies through a seminar on green coating and modern surface modification techniques organised jointly with Society for Surface Protective Coatings India, he elaborates. All the topics under the five fairs are closely interrelated and complement each other. The exhibitors in the concurrent shows will find the surface technology solution needed in their own operations right next door. VISITORS' DELIGHT The key visitor target groups for the fairs include automotive industry & component suppliers, diverse manufacturing industries, construction machinery, printing machinery, materials handling, electrical, electronics & engineering, oil & gas, plastic and rubber machinery, infrastructure, chemical, petrochemicals & process industries, ports, warehousing, railways and airport authorities, food processing and packaging, textile, etc. Mumbai being well-accessible from all metros and other major cities, a good number of outstation visitors are expected in the fairs. "Visitor mobilisation activities are being carried out targeting diverse user industries. Exhibitors will have a chance to meet high potential customers during the four day event," avers Patil. ENERGY INDIA Energy has been universally recognised as one of the most important contributors for the economic growth and human development within a country. Energy efficiency is the topic of the day. Given the challenges in the energy sector globally, energy-efficiency is on the top of the agenda in all the industries. Energy INDIA will feature a special `Transformer Industry Pavilion' to project efficient technologies in this field. INDUSTRIAL AUTOMATION INDIA In this fast evolving age of technology developments, industrial automation is important for efficiency in handling repetitive tasks by computerised or robotic machines. As efficiency in production and quality depends on automation, it has emerged as the key for success in every industry. Industrial Automation INDIA will be a B2B show for automation technology providers to showcase their latest products and services to the decision-makers from diverse sectors attending the show. The leading exhibitors to feature in this show are Siemens, Rittal, Festo, Fieldbus members like ABB, Azbil India, Belden, Chemtrols, Dearborn, Dresser Valve, Emerson, Endress+Hauser, Fischer Sanmar, Flowserve, Forbes Marshall, SURFACE INDIA The application of a surface industry is multi-fold considering that it could play a crucial role for every product � from a pin to an aircraft. New technologies and materials for surface treatment are always in demand in all the industries. Surface INDIA is a platform for all the segments of the industrial surface treatment market � from pre-treatment and coating to final measuring and testing. It will also showcase products & systems that will help companies to adapt to the growing demands. The exhibitors who will feature in this show include Metallizing Equipment, OPPORTUNITIES BECKON... The joint presentation of five fairs holds unique advantage for exhibitors as well as visitors. The topics of the five shows are closely inter-related. Exhibitors can find their potential customers among the participants of other shows taking place under the same roof. On the other hand, visitors have an opportunity to see integrated technologies in a single visit. This synergy effect is a wellproven concept at Hannover Messe. Experience this unique exhibition, which is sure to offer you immense growth prospects and the chance to interact with your counterparts worldwide. 158 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 EA WATER EXPO 2011 MANAGEMENT TECHNIQUES With India ardently striving to meet the growing industry demands for water, whose finite resources are depleting rapidly, the industrial and domestic sectors have realised the need for wastewater recycling. Keeping this in mind, India's leading knowledge solutions provider in the water sector, EverythingAboutWater, is organising the 8th EverythingAboutWater Expo 2011, from January 6-8, 2011, in Mumbai with SEARCH as the media partner, the event is ready to provide sustainable water managment solutions for future . PURNA PARMAR he $15-billion Indian water industry stands at crossroads today. The demand for water from various sectors continues to rise despite depleting water resources. In this scenario, there is a huge scope for growth in water purification and recycling. Aiming to tap this opportunity, India's leading knowledge and marketing solutions provider, EverythingAboutWater (EA Water) will organise the 8th EverythingAboutWater International Exhibition 2011 on Water and Wastewater Management at Bombay Exhibition Centre, Mumbai, from January 6-8, 2011. This is the only show for companies and associations specialising in water treatment, wastewater management and related industries, to showcase their products and expertise under one roof. SHOWCASING WATER T have sprung up all over the country. EXPO OFFERINGS EverythingAboutWater exhibition and conference is South Asia's largest water event, with over 1,50,000 sq ft of exhibition space. Around 350 companies including the US, Canada, Germany, United Kingdom, Italy, Israel, Norway, Singapore, and Thailand, are expected to exhibit their products at the Expo. The show, which is expecting 18,000 trade visitors and 900 conference delegates, will provide an ideal platform for networking and interacting with leaders from the water sector. The exhibition will present a two-day international conference on latest developments in seawater desalination technologies, training workshop on water reuse & recycle. It will also host a conference on non-chemical disinfection technologies -- Ozone & UV Processes. in the market will find their answers at EverythingAboutWater Expo 2011. Global manufacturers in the water & wastewater sector will launch their new product ranges at the Product Launch Zone. Dr H2O Pavilion: This is a discussion area where visitors will interact with leading experts and independent consultants. EA Water Forum: Exhibitors will have to book time slots to make their presentations in the exhibition hall. This will give exhibitors an opportunity to make a lasting impression while addressing a focussed audience. Best Stall Awards: To acknowledge the efforts of exhibitors in stall designing and fabrication, EverythingAboutWater has instituted the Best Stall Awards at the show which will be evaluated on the basis of concept, appearance, space planning, branding, product display and theme. GO FOR IT! The EverythingAboutWater Expo 2011 will offer attendees the access point to global technological advancements in the fields of water harvesting, water & wastewater treatment, water conservation, irrigation, wastewater recycling, desalination, etc., that are crucial for sustained development of the industrial segment in India. The event will offer industry players as well as government officials a chance to analyse the market trends and, at the same time, obtain first hand information on the latest technologies launched in the market. MARKET FOR WATER TREATMENT The water treatment market in India is witnessing immense expansion. EverythingAboutWater has estimated that the total water and wastewater treatment market size at present is around $420 million. An annual 18 per cent growth has been recorded in segments with the industrial and drinking water segments experiencing much higher levels of growth. Also, hundreds of small systemintegrators addressing local requirements THE PERFECT LOCALE According to organisers, Mumbai is the perfect location for organising this conference as it is the traditional base for water and wastewater treatment in India. It is also home to Asia's largest water treatment plant. STAR ATTRACTIONS FOR EXHIBITORS & VISITORS Product Launch Zone: All those curious to know about new products being introduced D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 161 ENGINEERING EXPO INDORE 2011 INDORE 7-10 JAN '11 Maharaja Shivajirao School Ground, Chimanbaug UNVEILING PROMISING OPPORTUNITIES With Madhya Pradesh Government stressing on creating more business opportunities in the region, Indore, the state's commercial capital, has emerged as an industrial hub. In order to create a platform for engineering and manufacturing companies to leverage upon the upcoming prospects in the region, Engineering Expo-Indore is all set to roll out the red carpet from January 7-10, 2011. A prelude... SUMEDHA MAHOREY adhya Pradesh, the secondlargest state in the country, is an emerging industrial powerhouse. It is home to around 1,800 companies and 19 industrial growth centres that bear close proximity to major cities with around 71,000 small-scale industrial (SSI) units, which contribute significantly to the economy. Apart from being a major auto manufacturing base and the largest producer of radial tyres in India, Madhya Pradesh boasts of being the growing hub for soya processing, FMCG consumer electronics, pharmaceutical & herbal products, and textiles & apparels in India. Indore, the undisputed commercial capital of Madhya Pradesh, is one of the fastest-growing cities in the country. Some of the big names having presence here include Kinetic Honda (Mahindra & Mahindra), Onida Saka, Pratap Steel, Prestige Group, Force Motors, Bridgestone India, Chirag Ingots, Eicher Motors, Dhar Textiles, Hindustan Motors, Crompton Greaves, Pratibha Syntex, Kores India and many more. It is the single-largest business centre in the state, commanding most of the volumes in trade, industry and services among others. To encash upon lucrative opportunities that are opening up in the region, there is an emergent need to create a common platform that enables interaction between the different entities that form a common link in the complete manufacturing process. Here comes the importance of trade fairs that generate the opportunity to tap the potential of an emerging market. Trade fairs provide the right platform for both buyers and sellers to network and leverage upon opportunities that are market-driven. M 3rd Edition 270+ Exhibitors 20,000+ Business visitors Providing such a platform to harness the potential of the `37,000 crore flourishing industry, the much-awaited Engineering Expo-Indore Edition will be organised from January 7-10, 2011, in Indore. has made it the highest contributor of tax revenues in the state. With the setting up of multiple SEZs, the state is efficiently harnessing the growth potential in Indore. the city is also characterised by more conventional production and manufacturing industries. The textile industry is a major industry in Indore. Supporting the spurt in development activities here, major industrial areas have come up around the city. EVENT HIGHLIGHTS With highly impressive records set last year, the next edition of Engineering Expo-Indore is ready to take the legacy forward and expand its horizon to bring in niche industrial segments under its umbrella. With over 270 exhibitors and dedicated pavilions on process machinery & equipment, machine tools & accessories, hydraulics & pneumatics, automation & instrumentation, packaging & auxiliaries, general engineering, material handling equipment, testing & measuring equipment and banking & financing services, the Indore edition is expected to cross the `40-crore mark in business generation. With expectation of over 20,000 footfalls this year, the event is set to surpass its own records. Highlighting the role of such trade fairs in upcoming industrial regions like Indore, Sandeep Khosla, CEO�Publishing, Infomedia 18, says, "In order to survive in this competitive but conducive environment, it is of paramount importance to analyse upcoming trends and have regular interface with customers to understand market demands. This not only helps in business decision making but also ensures customer satisfaction. The core of Engineering Expo lies in facilitating dialogue between the buyers & sellers to forge trade ties. We are sure that WHY INDORE? With the Government of Madhya Pradesh focussing on auto components, textile, pharmaceutical, IT and food processing as the priority sectors for Indore, this city is the next emerging industrial hub of the state. The city is a boon to the industry with major corporate and business houses including foreign investors identifying its potential and investing heavily in concurrent projects being undertaken in and around the city. Apart from the industrial-friendly environment with state-of-the-art infrastructure, the city boasts of a continuous supply of skilled workforce, a peaceful industrial work atmosphere and natural resources that have resulted in phenomenal industrial growth in this region. Indore has also inherited a diverse industrial population that makes it a favoured region when it comes to products, which are tested as a fresh concept. Additionally, it is one of the fastest growing tier-II cities in India and is considered as a centre for commerce in the central parts of the country. As an upcoming IT hub, the city has the potential to leverage on the growing IT industry. The immense growth of Indore 162 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 ENGINEERING EXPO INDORE 2011 the Indore edition will be able to offer unique opportunities for exhibitors & visitors alike." Engineering Expo-Indore 2011 has elicited huge expectations from past exhibitors and the manufacturing industry alike. Anand Rajadhyaksha, Advertising Manager, Nilkamal, avers, "We had received a good response last year. This year too we are expecting huge order books as the economy is doing well. Apart from this, we will be displaying a bigger range of products based on our satisfactory past experience." MILEPOSTS 2009 The Engineering Expo Indore 2009 edition had quite a few reasons to boast about its success. For many, it paved the way to access the Madhya Pradesh market. Highlighting this, Rajesh Godse, Director, Reliable Terrestrials, explained, "The Expo has been an ideal platform for us to gain entry into Madhya Pradesh and leverage on the benefits that this market has to offer." The trade fair also provides a platform to companies for displaying their new products and concepts. Sulabh Mucchal, Marketing Head, A-One Electrical Agencies, observed, "The response has been beyond our expectations, as we received several enquiries for our new range of products launched at the event. We have been associated with all the editions of Engineering Expo, and I must emphasise on the fact that this trade fair has been instrumental in the brand building and successful promotion of our products." Last year's event had registered the presence of over 250+ exhibitors and 18,500+ business visitors. The estimated business that was generated last year was over `30 crore, apart from the 3,860+ serious business leads. "On the very first day of Engineering Expo-Indore, we booked `15 lakh worth machinery and generated 700+ business leads," avered a happy SK Jain, Director, Quality Machine Tools Corporation. The Expo proved to be a huge success with over 92 per cent exhibitors being highly satisfied with the quality of visitors. Neeraj Bajaj, Partner, Atlas Radios, says, "Indore has given our business a great mileage. It has provided us the perfect platform for networking. We were also successful in getting several dealership requests. Thus, the Expo has been a tremendous success for our products as well as our brand." Apart from 3600 marketing initiatives, the Expo also showcases the latest innovations and technologies, with the help of excellent infrastructure for exhibitors as well as visitors. Sharing his experience at last year's Expo at Indore, JS Patel, Chairman, Dowell's Elektro Werke, articulated, "Our objective in participating at the fair was to showcase our latest products and technology. And we are extremely pleased with the response. With great facilities available at the Expo, I look forward to the presence of more companies from in and around Indore during the upcoming edition." ROLLING OUT THE RED CARPET With remarkable records attained last year, the Engineering Expo Indore 2011 is expected to be bullish right from day one. Acting as the platform for displaying latest technologies and products, this event will act as the unifying platform for buyers as well as sellers to come together and explore the emerging opportunities in the region, and make the region an industrial hub of the state. It is time for manufacturing companies to identify the potential of this trade fair and transform the opportunities galore into serious leads as the red carpet rolls out on January 7, 2011. 164 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 INDIA ENERGY 2010 ENERGISING INDIA'S ECONOMIC GROWTH SANDEEP PAI 7-9 October, 2010 Bombay Exhibition Centre, Mumbai Energy generation has created a lot of interest among Indian and global manufacturers lately. This is evident from the unprecedented success of the India Energy and India Nuclear Energy Summit 2010. Organised by United Business Media India with SEARCH as the media partner, from October 7-9, 2010, the event had an electrifying impact and proved to be a leading platform for companies in the Indian's energy sector. he energy sector holds the key to accelerating economic growth in India. However, capital, technology, environment and security issues arising out of internal and external consequences have restrained the development of the Indian energy sector. To provide companies with lucrative prospects waiting to be tapped in the Indian energy sector, United Business Media India with SEARCH as the media partner organised India Energy & India Nuclear Energy 2010, from October 7-9, 2010 in Mumbai. The event was inaugurated by Sushil Kumar Shinde, Hon'ble Union Minister for Power, Government of India. T EVENT AT A GLANCE During the inaugural address, Shinde detailed a plan for adding 62,000 MW of capacity to the 11th Plan and 1,00,000 MW to the 12th plan. He also said that there is a plan to increase nuclear power generation to 60,000 MW from the present 4,500 MW over the next 20 years. The New Electricity Policy is committed to provide electricity to all households by 2012 with rapid increase in power generation. Delivering the keynote address, Dr Srikumar Banerjee, Chairman, Atomic Energy Commission, discussed the nuclear industry and its efforts towards producing a sustainable nuclear energy future. He also spoke about the production of 40,000 MW using light water reactors. Banerjee said that the progress of indigenous technology would continue to supplement capacity augmentation. However, it is important to evolve a closed fuel cycle to conserve resources for the future. The event was also endorsed by Dr RK Sinha, Director, Bhabha Atomic Research Center (BARC), who was the Guest of Honour. He said that DAE and BARC have a mandate to exploit atomic energy to enhance the quality of (L-R): Michael Duck, Sr VP, UBM Asia; Dr RK Sinha, Director, Bhabha Atomic Research life of fellow Indians. "It Centre; Sushil Kumar Shinde, Union Minister of Power, Government of India; Dr Srikumar is an opportunity for Banerjee, Chairman, Atomic Energy Commission; Sanjeev Khaira, MD, UBM India; SK Indian and global Malhotra, Head-Public Awareness Division, Department of Atomic Energy at the India industries to unite as Nuclear Energy Summit 2010 held on October 8, 2010 in Mumbai. partners and facilitate Rand, GMR Group, Nuvia India, Khaitan & the accelerated growth of the Indian nuclear Co., Sandvik Asia, Nuvia, Rolls Royce, power programme," he added. He also Premium Energy Transmission, and advocated the idea of energy independence Ratnamani, among others participated in the for India in the long run. "Energy security event. Manufacturers from France, Russia, means tying up arrangements to ensure that USA and Finland also participated in the in future energy resources and technology event. At least 3,500 industry professionals are available from domestic as well as global from the energy space had visited different resources to meet the requirements," he stalls over three days. said, adding that such events would benefit The holistic event covered the entire the industry in the long run. This international gamut of the energy sector. Leading exhibition and conference was co-partnered corporates and PSUs from the energy & and endorsed by Department of Atomic power sector participated in the summit Energy (DAE), Government of India. India that provided domestic & international Energy & India Nuclear Energy 2010 was companies an opportunity to avail the vast also supported by the Ministry of Power untapped potential that the nuclear industry and Ministry of New & Renewable Energy, has in India. Government of India. India Energy & India Nuclear Energy PROMISING PROSPECTS 2010 provided companies a platform to Leading companies including Alstom, DAE, display their products and services to one of Areva, Hindustan Construction, Power Grid the largest markets in the world. The threeCorporation of India, BHEL, NHPC, REC, day summit brought together users, buyers, Gammon India, Electronics Corporation of and international suppliers and manufacturers India, Schneider Electric, Wartsila, Ingersoll of the energy industry under one roof. 166 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 WEST BENGAL INDUSTRIAL DEVELOPMENT SNIPPING OFF THE SHACKLES Illustration By: Sanjay Dalvi There is a notion that West Bengal is a difficult place to invest because of scarcity of available land, militant trade union and infrastructural bottlenecks. However, the Marxist government in the state has taken some ideological and neo-liberal measures for making it a preferred investment destination. SANDEEP PAI arxism began essentially as a reaction to the industrial revolution. According to Karl Marx, industrialisation polarised society into the bourgeoisie (those who own the means of production, the factories and the land) and the much larger proletariat (the working class who actually perform the labour necessary to extract something valuable from the means of production). He saw the industrialisation process as the logical dialectical progression of feudal economic modes, necessary for the full development of capitalism, which in itself is a necessary precursor to the development of socialism and eventually communism. Knowingly or unknowingly, the Marxists in West Bengal are showing allegiance to their esteemed mentor. Marxists would be generally expected to agitate in favour of state monopoly, but West Bengal seems to be an exception. Paradoxically, they are going all out in advocating for private industries in the state. Ideologues attribute this change of guard to three reasons � ideological, country set-up and statecentric. Ideologically, comrades in West Bengal believe that the rise of capitalism is central for the eventual rise of communism. For them, this epoch will see unprecedented rise of capitalism, with the fall of it in the same way. This has made them to not only support private capital but also endorse it. Secondly, West Bengal being part of India cannot have a different form of economic system than that of the country. Bansa Gopal Chowdhury, Chairman, Asansol-Durgapur Development Authority & Lok Sabha MP from Asansol, says, "Our country's economy is mixed and as a state works closely with the Centre, it ought to have a mixed economy as well. Thus, we have to accept the system that is prevalent in the country and invite private capital. Otherwise, our state will lose out, which we cannot afford." M D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 169 WEST BENGAL INDUSTRIAL DEVELOPMENT The third reason is best explained by the nearly three times the population density of ratio, fragmented land holdings and politically Hon'ble Chief Minister Buddhadeb India as a whole. Moreover, nearly 63 per disastrous land acquisition strategies make Bhattacharjee himself. In his article `On cent of the state's population is engaged in this problem severe in this state. Hon'ble Industrialisation in West Bengal', he writes, agriculture. This is because ever since LF CM recognises this problem, and states, "In the economy of West Bengal, the share government came to power three decades "The fragmentation of land in the wake of of agriculture is 26 per cent, the land reforms among the West Bengal has a population density of over 904 persons successors of the original industry 24 per cent, and services 50 per cent. This is per square km, which is nearly three times the population owners have contributed to this better than the situation in other density of India as a whole. Moreover, nearly 63 per cent problem even more." These states. Look at the relative problems were quite evident of the state's population is engaged in agriculture. This during the Singur agitations, as it figures of the agricultural sector and the industrial sector. It is not is because ever since LF government came to power was difficult to convince correct to hold that this is the three decades ago, they distributed `patta' rights for everyone, especially when it end of the road and the end of came to contentious issues such 1.3 million acre of land � the bulk of the agricultural land, as land. history. We must bring about in fact, of this state. changes gradually, and I use the However, much to the word with deliberation. We delight of the industries, the ago, they distributed `patta' rights for must maintain food security but increase problem has been tackled cautiously by the 1.3 million acre of land � the bulk of the the share of the industrial sector, gradually State Government over the last few years. agricultural land, in fact, of this state. Alos, reducing that of agriculture. This is the Recently, the West Bengal's industrial around 83 per cent of the agricultural land is general trend of the economy. Marxists department called on various industrial in the possession of the poor and marginal hold that development is from agriculture bodies (FICCI, CII, etc) and gave a farmers. While distribution of land has given to industry." presentation on the investment scenario in tremendous boost to agriculture, industrial Apart from this, there is a strong pressure the state. Gaurav Swarup, Chairman, development has suffered at large. on the State Government for job creation. Eastern Regional Council-FICCI, & MD, Furthermore, it is noteworthy that four Because of such reasons the Left Front (LF) Paharpur Cooling Towers, who was present categories of land use � fallow, cultivable Government in West Bengal has made a in the meeting, informed, "The government waste land, permanent pasture & other transitional change in their attitude towards has taken some solid and efficient steps, grazing land, and barren & uncultivable private industries. Whatever be the reasons, which are welcoming for the industry at land � constitute 17.6 per cent of land investors can expect total support from large. They have developed three to four under different uses in India but only State Government. clusters, industrial parks, etc and have made one per cent of land under different uses in While the industry at large is happy with land available for the industries. The best West Bengal. this turnaround, they are several doubts part is that all this has been done quietly and Thus, the critical problem facing the which still exist in the investors' mind when is pleasant for the industry." He further future of industrialisation in West Bengal it comes to setting up their shops in the added, "While we have carried a certain seems to be the required amount of land state. These apprehensions have become impression, especially after Nandigram and needed to set up industrial business and even more apparent after Tata backed out Singur, the recent presentation has helped infrastructure support. A high man-land of Singur and the land agitation in us in gaining confidence in the government,". Nandigram. The State Government had introduced two Non-availability of land for industries, initiatives to ensure planned utilisation of infrastructural bottlenecks and militant trade land for industry � land mapping and the unions were, and in some cases, are still setting up of a land bank. The Land and There must be private negotiations considered as hindrance for industries Land Reforms Department is overseeing with limited or no government wanting to invest in the state. But are these both the efforts and the data for five districts concerns of the past relevant now? Has the � Paschim Medinipur, Purulia, Bankura, intervention. If fragmented landState Government been able to address Birbhum and Bardhaman � have been holding is a problem, co-operatives some of these issues for the industrial made available apart from other places. must be formed with land owners for development at large? In fact, 6,000 acre of land has already negotiating the deals. Compensation There is no direct answer to this. While been acquired in Purulia, Burdwan and should not be linked to jobs because the first concern is related to the industrial North 24 Parganas through voluntary policy and government's proactiveness, the submission of land for development industrial jobs require specialised last one is not as directly in its ambit. For purpose. This was conveyed by the Chief skills, whereas the state has a huge better understanding, it is imperative to Minister while addressing a number of uneducated low skilled manpower. analyse all the three issues separately and industrial leaders at Confederation of Indian then come out with a larger picture. Industry (CII) National Council meeting in Kolkata recently. Asserting confidence on DR SUGATA MARJIT, LAND FOR INDUSTRIES the government, Swarup says, "Though the Director, West Bengal has a population density of requirements are different for different Centre for Studies in Social Sciences over 904 persons per square km, which is industries, if a general industry needs land, 170 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 WEST BENGAL INDUSTRIAL DEVELOPMENT say 100 acre, the government can provide it in a week's time. This was something unimaginable a few years ago.". As the situation is improving with respect to land availability, experts have come forward in suggesting certain beneficial measures. Dr Sugata Marjit, Director, Centre for Studies in Social Sciences, makes several suggestions as to what should be done for the future. He points out, "There must be private negotiations with limited or no government intervention. If fragmented land-holding is a problem, co-operatives must be formed with land owners for negotiating the deals. Compensation should not be linked to jobs because industrial jobs require specialised skills, whereas the state has a huge uneducated low skilled manpower." He further adds that while the state should not interfere in the land accusation process, it must provide a base line survey for the industries. The survey can include: Expectations from the industry Social situation Public information survey. Nonetheless, government officials are seriously considering the implementation of these measures in the near future. The government has taken some solid and efficient steps, which are welcoming for the industry at large. They have developed three to four clusters, industrial parks, etc and have made land available for the industries. The best part is that all this has been done quietly and is pleasant for the industry. GAURAV SWARUP, Chairman, Eastern Regional Council-FICCI, & MD, Paharpur Cooling Towers INFRASTRUCTURE BOTTLENECKS If land availability is indispensable, good physical infrastructure is also an important prerequisite for industrial growth. West Bengal was known for having the worst industrial infrastructures among the various states in the country. This impression is still present among several quarters. But, ever since the State Government formulated the New Industrial Policy in 1994, it has been slowly working towards improving infrastructure facilities. Curiously, the State Government has been the first in India to formulate an act on special economic zones (SEZs), the Special Economic Zones Act, 2005. The first sector-specific SEZ in India, Manikanchan Gem and Jewellery Park, has already become operational. Moreover, West Bengal Industrial Development Corporation (WIDC) is developing sector-specific and multi-product industrial parks in the state, keeping in mind the Government of West Bengal's roadmap for rapid industrial growth. Also, apart from the two above-mentioned parks, the government has also sanctioned five more parks and will been initiated and/or developed. Further, the state is also planning to set up several Mega IT projects taking the SEZ route, which include centres such as Siliguri, Haldia, Durgapur and Kharagpur. Apart from industrial infrastructure, tremendous progress has been made for improving the physical infrastructure in the state as well. Confirming this, Swarup states, "Though the Government of West Bengal has taken a lot of measures for improving the infrastructure facilities, it's still far from what's the need of the hour." TRADE UNIONS Apart from uncertainty concerning availability of land and infrastructure, the trade unions in West Bengal are considered as disruptive in nature. Swarup says, "The militancy of trade unions, I can say is both a problem and not (it is and it is not). The problem in West Bengal with respect to trade unions is that they have a close relationship with political parties. Thus, if say CPI (M) led state government takes certain steps that are beneficial for the industry, then Centre of Indian Trade Unions (CITU) will be supportive in their venture. However, the opposition unions will be disruptive. Thus, the trade union is more of a political problem than anything else." "While the problem exists, today even the Opposition realises that without industrial development nothing is possible in the state," he adds. This is affirmed by the International Labour Organisation's (ILO's) report on `The Evolution of Industrial Relations in West Bengal'. It states that from 2000 onwards, the state government's reading of the industrial relations situation is that there is `stability' (Labour in West Bengal, 2006) or that there has been a `significant improvement' in labour management relations (Labour in West Bengal, 2003). This is based on the reduced number of strikes or the conclusion of `long-standing issues through bipartite and tripartite negotiations'. Interestingly, in spite of the large number of lockouts, the government claims that industrial relations in the state are largely `satisfactory' or `by and large peaceful'. In West Bengal, the traditional industries are intensely unionised, there being many unions among all categories of workers, reaching almost 100 per cent density. The public sector, including government employment, banking and insurance, too is highly unionised and except for a handful of casual or temporary staff, unions cover almost all workers. Hence, density would be over 90 per cent. In the large private sector, other than in traditional industries and MNCs, membership is confined mainly to permanent employees and factory workers. Office staff, and temporary, casual or contractual employees are generally not unionised and are discouraged by management from joining unions. Union density in these organisations would be above 50 per cent but probably less than 75 per cent. The IT industry and the new service sector units (insurance, foreign banks), which have emerged in the last decade, are not unionised at all. Thus, the newer industries are not under the clout of the unions. The ILO report revealed that most large and modern industries have gone on record to say that they have not had any problems related to industrial relations for the last 10 to 15 years. OVERCOMING THE ILLUSIONS There is no denying the fact that the most distinctive feature of modern civilisation is industrialisation, keeping its onward movement towards redressing the lot of the have-nots. Several myths exist with regard to investments in West Bengal, but the recent developments have helped in overcoming these. The State Government has taken serious steps for making land available for the industries and improving infrastructure facilities. Contrary to the views, even the trade unions have been working closely with the industries. Thus, West Bengal is witnessing a different type of industrial revolution, with Marxists advocating it. D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 171 OPPORTUNITIES UNLIMITED TO INVEST IN WEST BENGAL West Bengal, though predominantly an agrarian economy, boasts of a golden history of industrialisation. Since decades, industries here have suffered a downfall due to a variety of reasons. However, the state is actively engaging investors in industrial sectors in an effort to regain its position as a critical hub for multifarious industries, notably iron & steel, petroleum sector, agro-based industries, cutting-edge technology, and the services sector. PURNA PARMAR est Bengal, one of the most industrialised states, is endowed with abundant natural resources, including minerals, and suitable agroclimatic conditions. Apart from a traditional domestic market in eastern India, the state offers investors and traders easy access to the north-east, including the land-locked countries of Nepal and Bhutan. Below are some of its lucrative investment features: W 1 ECONOMIC GROWTH West Bengal boasts of a Gross State Domestic Product (GSDP) of $75.5 billion. The state, which is home to one of the largest consumer markets in India, is one of the leading exporters of finished leather goods, contributing to around 25 per cent of the total exports of the country. It accounts for almost four per cent and 13 per cent of India's petroleum products and polymer production. West Bengal has also emerged as a favourite destination for the steel industry. INFRASTRUCTURE DEVELOPMENTS West Bengal has a robust infrastructure network spread across the state. As of December 2 0 0 8 , investments worth over $54.3 billion were made to ramp up its infrastructure. The state 2 has made 23 per cent of investments in power generation and distribution. West Bengal's strategic geographical location near the coast of Bay of Bengal, its well-connected roads and railways is what gives the state easy access to all the major markets. Below are some of the factors that play a key role in its progress: Road network West Bengal has a total road length of over 92,023 km, with a road density of 1.04 km per sq km. There are 14 national highways running through the state and covering 2,578 km. The golden quadrilateral project undertaken by the National Highway Authority of India (NHAI) passes through major districts in North Bengal. A number of road development projects have been taken-up under public-private partnerships (PPP). Railways West Bengal also has a 4,500 km-long wellconnected r a i l w a y network, with Howrah, Asansol, Sealdah, Bandel, Bardhaman, Kharagpur and New Jalpaiguri being its main junctions. Indian Railways has an electric locomotive production unit -- Chittaranjan Locomotive Works (LCW) -- on the West Bengal-Jharkhand border, having a production capacity of 230 engines. Indian Railways has also proposed to set up an electric locomotive assembly and ancillary unit at Dankuni. Airports West Bengal has a domestic airport at Bagdogra in Siliguri and an international airport (Netaji Subhash Chandra Bose International Airport) at Dum Dum, 18 km from Kolkata. In 2008-09, the total commercial traffic at Kolkata airport included 7 million passengers and 88,040 tonne of freight. The Government of India has sanctioned $6,80,000 to set up a perishable cargo complex at the Bagdogra airport. The Kolkata airport is being modernised at a cost of $435 million. The project will be completed by August 2011. The upgrade will raise the airport's handling capacity to around 20 million passengers, annually, from the 5 million in 2009. Ports West Bengal has two modern ports at Kolkata and Haldia. In 2007-08, the combined volume of goods handled by both the ports was over 53.3 million tonne. The State Government plans to construct a $265-million container port at Kulpi and a small port at the mouth of the Hooghly river. Power As of March 2009, West Bengal had a total installed p o w e r generation 174 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 OPPORTUNITIES UNLIMITED capacity of 6,890.1 MW -- 5,808.7 MW under state utilities and 1,081.4 MW under the private sector. Also, West Bengal had 5,768.4 MW of thermal power, 1,022.0 MW of hydro power, and 99.7 MW of renewable energy sources as of March 2009. The State Government is encouraging the setting up of renewable energy-based power plants. 3 LITERACY RATE West Bengal has a literacy rate of 68.6 per cent -- the male literacy rate is 77 per cent, while the female literacy rate is 59.6 per cent. As of 2008-09, the state had 49,893 primary schools, 980 upper primary schools, 4,582 secondary schools and 9,659 high and higher secondary schools. West Bengal has 18 universities, 53 engineering colleges, 450 degree colleges, 43 polytechnics, 50 industrial training institutes, 29 management institutes, and nine medical colleges. important industries in the state include engineering products, electronics, electrical equipment, cables, steel, leather, textiles, jewellery, frigates, automobiles, railway coaches, and wagons. The natural resources, policy incentives and infrastructure in the state are favourable for investments in major sectors such as iron & steel, biotechnology, coal, leather, jute products, tea, IT, and gems & jewellery. Besides, West Bengal has climatic conditions that are suitable for the cultivation of tea and jute, which have made the state a major centre for these products and related industries. for medium-and large-scale industries in West Bengal. There are exclusive growth centres for electronics, software technology, export processing and export processing. The Nabadiganta Industrial Township was set up in January 2006, in Kolkata's Salt Lake Township, to encourage IT and related industries. West Bengal's major industrial areas are Haldia, Kolkata, Asansol-Durgapur region, and Kharagpur. About 23 per cent of the investments made in infrastructure have been in the area of power generation and distribution. 9 INVESTMENT CLIMATE The West B e n g a l Government has formed a liberal and investorfriendly policy to amend the industrial scenario in the state. It has welcomed appropriate/mutually advantageous foreign technology and investment. While the State Government considers the public sector as an important vehicle for ensuring social justice and balanced growth, it also recognises the importance of the private sector in providing accelerated growth. 6 EXPORTS TRENDS West Bengal is one of the country's l e a d i n g exporters of finished leather goods. In 2008-09, the state accounted for 15.7 per cent of the country's exports of leather & leather products. The state is also the country's leading exporter of flowers and has accounted for 70 per cent of India's dried flower exports in 2008. 4 SKILLED WORKFORCE West Bengal has a huge E n g l i s h speaking population, which works as one of the advantages of the workforce of West Bengal, especially in Kolkata. In addition, the state has a large base of knowledge-based and manufacturing sector. 7 INVESTMENTS AND FDI INFLOWS According to the Reserve Bank of India (RBI), foreign d i r e c t investment (FDI) inflows from April 2000 to October 2009 amounted to $1.3 billion. In December 2008, outstanding investment in the state was $142 billion. Manufacturing and electricity sectors accounted for 69 per cent of the state's total outstanding investments. 10 OPPORTUNITIES FOR SMEs The West B e n g a l Government has in place a number of investment a n d promotional policies to protect, support and promote Small & Medium Enterprises (SMEs). West Bengal has also framed marketing policies for SMEs that include price preference in purchases; exemption from payments of earnest money; distribution of products through the public distribution system; construction and development of industrial estates, plots, commercial and trade offices; extension of credit support through the West Bengal Financial Corporation, State Cooperative Banks and Commercial Banks; and eligibility to incentives as provided under the West Bengal Incentive Scheme. KEY INDUSTRIES IN WEST BENGAL The services s e c t o r contributes 51 per cent of the state domestic product, while agriculture and the industry sector contribute 27 per cent and 22 per cent respectively. Industrial growth in the state has picked up pace in recent times. Most major industries are based in Kolkata, while major steel plants are located in the colliery belt of Durgapur-Asansol. The other 5 INDUSTRIAL DEVELOPMENTS The West B e n g a l Industrial Development Corporation (WBIDC) has set up 12 growth centres 8 176 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 WEST BENGAL INVESTMENT PORTFOLIO HARNESSING GREEN ENERGY IMPROVEMENT AREAS POWER AND INFRASTRUCTURE STEEL � A STEADY REVENUE GENERATOR PROMISING PETROCHEMICAL SECTOR FORTIFYING DEVELOPMENT THROUGH PLANNED INITIATIVES largest share to the gross domestic product of the state, contributing 55.59 per cent of the state domestic product compared to 25.92 per cent from agriculture and 18.49 per cent from industry. The state has established itself as one of the fastest growing states in the field of IT in the country with biggest names from across the country and abroad pouring in investments. As part of its endeavour to facilitate convenient implementation of government programmes, the Hon'ble Chief Minister recently inaugurated the e-district project, which aims at percolating government benefits to the remotest corners of the state. With the government willing to extend all support to industries coupled with its geographical advantages, West Bengal seems to have emerged as an attractive destination for companies willing to park their funds with the state. ANWESH KOLEY he state of West Bengal has always generated interest from all industrial corners. While it is the third-largest economy in the country after Maharashtra and Uttar Pradesh, recent stirs across the state have had multiple effects on its image as a viable investment destination for prospective entrepreneurs. West Bengal had pioneered the concept of industrialisation during the pre-independence era, but a look at the current geographical spread of industries highlights that the industrial hub has shifted base to states like Gujarat and Maharashtra. However, the State Government has been taking proactive steps to ensure steady flow of FDI in the state and provide a conducive atmosphere for companies willing to invest. The service sector contributes the T YEAR-ON-YEAR IMPROVEMENT In 2008, the state witnessed a total of 187 projects with a total investment of `4,060.78 crore. The index of industrial production (Base 1993-94 =100) of West Bengal has been on a constant rise, going up from 132.8 in 2001-02 to 2008 in 2007-08. Notwithstanding economic recession, the industrial production index in West Bengal grew by 4 per cent in 2007-08 over previous year. Within the industrial sector, the growth rate of manufacturing sector has been quite impressive over the years. The salient features of the state policy on industrial promotion and economic development are to welcome foreign technology and investment, private sector investment in power generation, improvement and upgradation of industrial infrastructure. The thrust areas are petrochemicals and downstream industries, electronics & information technology, iron & steel, metallurgical & engineering, textile, leather & leather products, food processing, D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 179 WEST BENGAL INVESTMENT PORTFOLIO medicinal plants, edible oil, vegetable processing and aquaculture. Data for projects under implementation reveals that there are 97 major industrial projects currently under implementation at the state level involving an investment of `1,62,047 crore, which are likely to be completed in the coming years. The overall industrial growth as measured in terms of index of industrial production with new base year 1999-2000 grew by 5 per cent in April-November 2009-2010 as compared to 3.9 per cent in the corresponding period of 2008-09. While it is interesting to note that the government has been working in tandem with companies that have shown interest in the state, the development of infrastructure STEEL � A STEADY is a key factor for welcoming Financial support and incentives in the form of exemption players to invest in this region. REVENUE GENERATOR from payment of Excise Duty & Income Tax for a specific The electricity generating utilities The steel sector in the state has in the state sector include: West period similar to that of Uttaranchal, Himachal Pradesh, Bengal Power Development shown promises in the past and J&K and the North East will go a long way in attracting Corporation continues to be a steady (WBPDCL), revenue generator for the state. Durgapur Projects (DPL) for investment into the state's pharma sector. "The pipe and steel rollthermal power generation, manufacturing sector are doing well. While West Bengal State Electricity Distribution industrial entrepreneurs memorandum we are expecting big players like Arcelor Company (WBSEDCL), and Renewable (IEM) for setting up 1,200 MW power plant Mittal to invest in the state, existing Energy Development Agency (WBREDA) by Bharat Aluminium Company at Raniganj. companies like the Jindals already have their for non-conventional energy generation. Although the state has no linkage for plants in the state, which is a good sign," For the last five years, the annual rate of sourcing iron ore, many companies have said Dipankar Nandy, DGM, Gontermann growth has been nine per cent, which is decided to set up steel plants in the state Peipers. commendable. WBPDCL uses captive coal and source the raw materials from In recent years, the districts of Bankura, from its mining blocks for catering to its own neighbouring states like Jharkhand and Midnapur, Burdwan and Purulia have needs, and many of its commissioned Orissa, which are mineral rich. Apart from witnessed steady flow of investment. In projects have been either well ahead of these, the State Government has also been 2009, the highest amount of investment, time or have successfully met the taking efforts to locate Petroleum, Chemical `1,532.52 crore took place in chemical and deadlines. and Petrochemicals Investment Region petrochemical sector, followed by Besides, Damodar Valley Corporation (PCPIR) in the state, which has the potential `1,359.62 crore in iron and steel sector, (DVC) and National Thermal Power to draw huge investments. `705.13 crore in food processing sector, Corporation (NPTC) in the public sector, PROMISING PETROCHEMICAL `471.26 crore in engineering industry, CESC and Disergarh Power Supply SECTOR `328.51 crore in software and other Corporation in the private sector are the Petrochemical is one of the sectors, which services sector. While in 2009, the highest other power generating utilities in the state. appears promising in West Bengal. While amount of investment of `5,965.12 crore Total generation of power produced by the the region of Haldia has seen considerable took place in drugs, chemicals, state agencies was 16,270.1 MU in 2008development, the Central Government petrochemicals & allied industries, followed 09 (from April to October). The total had gone ahead and signed an agreement by engineering `625.25 crore, agro-based number of mouzas electrified up to October with West Bengal to develop a PCPIR at & food processing `579.33 crore, iron & 2008 is 37,416 and in 2008-09 (up to Haldia. The West Bengal Government has steel `474.49 crore, IT & ITES & other October 2008) the total number of pump envisaged an investment of `93,180 crore services `311.34 crore, electrical & sets energised was 1,15,357. in the proposed PCPIR, which will be electronics `72.58 crore, jute & textiles Major investments are taking place spread over 250 sq km. `37.87 crore, according to Quarterly across the state in mining, forging, pig iron, "West Bengal had been a pioneer in the Bulletin on Investment, Industry & Trade in etc. The easy availability of power, removal chemical industry. The growth of West Bengal. of freight equalisation, close proximity to petrochemicals started here. While there Several companies like JSW Bengal, areas with natural resources relevant to the have been minor glitches in the past, we are Bhushan Steel, Jai Balaji, Videocon Group industry, and a labour force, traditionally hopeful about the future of this industry in will set up integrated steel, cement and skilled in operating iron and steel units are the state," said SK Pal, General Manager � captive power plants in the state. Apart factors that have influenced the surge in Operations, West Bengal Chemical from JSW Bengal, some of the important investment in this sector. In recent years, Industries. approvals received in the sponge iron and investment in the chemical and cement Nayachar, a stretch of land covering steel sector during the period include 5 industry is also expected to pick up. million tonne per annum (tpa) steel plant of Jai Balaji group involving investment of `7,737 crore at Purulia. Another 1.1 million tpa steel plant of Adhunik Corporation involving an investment of `1,850 crore at Raghunathpur in Purulia, 0.6 million tpa steel plant at Kharagpur in Midnapur; and 1.1 million tpa steel plant of Shyam Group involving investment of `910 crore; 2 million tpa steel plant of Shyam Steel involving investment of `1,028 crore are expected in the state. Apart from the above mentioned power projects, the state received an important around 12,500 acre on the riverbed of Hooghly, was handed over to Prafulla Chandra Roy Chemical Complex (PCRCC). It is a joint venture company in which West Bengal Industrial Development Corporation (WBIDC) has 49 per cent stake and the New Kolkata International Development (NKID) has 51 per cent share. POWER AND INFRASTRUCTURE 180 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 WEST BENGAL INVESTMENT PORTFOLIO HARNESSING GREEN ENERGY The renewable energy sector in the state has shown remarkable improvement. Today, West Bengal is one of the leading states in the country with respect to utilisation of renewable sources of energy. Over one lakh families in West Bengal are now using electricity derived from sun, biomass and wind. As of now, the state has not seen any major renewable energy player, but with relaxation of government policies, big names are soon expected to enter this space. "Very few states in the country have potential for renewable energy development and West Bengal is one among them. While the share of renewable energy is not huge, we currently have around 1.25 MW of green power, which is grid connected. We trying to harness this energy through the local grid system in various parts of the state. Support from the government is essential and we have been fortunate to get it throughout our operations," said Joy Chakroborty, Divisional Engineer, West Bengal Renewable Energy Development Agency. Another form of sustainable power generation that is taking shape in the state is biomass. Though this form of energy is in its nascent stages, it has provided potential contribution to power generation. "We currently have 67 MW of installed capacity through biogas plants in West Bengal. Of this, 18 MW is through the grid and the rest is off-grid," says Chakroborty. IMPROVEMENT AREAS West Bengal has seen considerable improvement in its industrial performance over the years. However, there are areas that have potential and can bring in substantial revenues for the state. "There is a need to invite more pharmaceutical companies to the state. While there are players existing, it is one area, which can see more participation," feels Pal. Financial support and incentives in the form of exemption from payment of Excise Duty & Income Tax for a specific period similar to that of Uttaranchal, Himachal Pradesh, J&K and the North East will go a long way in attracting investment into the state's pharma sector. The government has recognised the importance of this industry, and developments like the setting up of chemical hub/ PCPIR and a branch of the National Institute of Pharmaceutical Education & Research (NIPER) in the state indicate positive enthusiasm on the government's behalf. These developments coupled with the present conducive environment are expected to provide a fillip to the growth of the pharma sector in the region. Tourism is another domain, which, while having vast scope, does not generate enough for the state. "West Bengal has much better potential in tourism than many other states, but it remains untapped to a large extent. Promotion of the state as a viable tourist destination needs to be done earnestly. The vast expanse of the state presents both natural and historical places of interest, which can be turned into exciting tourist destinations," says Chakroborty. THE STATE TO WATCH IN THE FUTURE The existing sectors in the state are showing improvement over the years and are expected to witness heightened activity in the years to come. The fact that better infrastructure leads to higher investments has propelled the State Government to lay great emphasis on strengthening existing and building new infrastructure to encourage more investments. D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 181 OPINIONS & MORE THE GOVERNMENT & NEED TO HAVE A SHARED VISION TO "West Bengal is blessed with a favourable strategic location, fertile farm land, access to ports, mineral wealth and a huge talent pool. industry and farm sector is what the state needs to reach commanding heights," avers Rajesh Nath, MD, German Engineering Federation The Government of West Bengal has initiated steps to modernise infrastructure facilities as well as create new clusters and growth centres. However, infrastructure creation requires considerable investments. Therefore, the State Government has welcomed private participation in this area. In fact, it has already made considerable progress in laying the groundwork for state-of-the-art industrial facilities to attract entrepreneurs. The State Government has encouraged the development of growth centres through the West Bengal Industrial Infrastructure Development Corporation (WBIIDC). The infrastructure facilities provided in these growth centres include developed land, industrial shed, water & power supply, street lighting and internal drainage & sewerage system. Facilities such as telephone, banks, post offices, fire stations, police outposts, and shopping & recreational centres are also being contemplated for the new growth centres. Till date, WBIIDC has established 12 growth centres in Kalyani (Phases I, II, III), Falta, Uluberia, Bishnupur, Raninagar, Coochbehar, Malda, Dadgram, Haldia, and Kharagpur. It is also in the process of setting up three more growth centres at Jalpaiguri, Bolpur and Malda (Phase II). The State Government has also put in place sector-specific infrastructure. West Bengal already has excellent road connectivity, which comes as a major advantage for the state. It is also in the process of modernising and upgrading it's Kolkata and Haldia ports to deal with the growth in cargo quantity. As of now, the two ports handle a combined cargo of over 46 MT annually -- the second highest in the country. A new 3,000-acre port-cum-special economic zone is being set up at Kulpi. I NFRASTRUCTURE DEVELOPMENT West Bengal has two airports and a dedicated freight corridor between Delhi and Kolkata is also being considered. The state also has a rail network of 3,681 km, of which 1,700 km is electrified. An additional 240-km railway line is being constructed. PROMISES AND PERILS Despite recording an impressive growth in recent years, enterprises have been facing several challenges, especially in the state's rural sector. Infrastructure in the rural sector needs to be developed so that small and medium enterprises (SMEs) and large industries could be set up there. Apart from transportation, electricity and communication, the rural sector needs to develop its manufacturing technology and technical skills so that quality products can be manufactured by the sector. However, the Government of West Bengal has already taken initiatives to substantially improve social infrastructure facilities such as development of satellite township, housing, health, education, water supply, hotels, so on and so forth. Apart from promoting schools and colleges of appropriate standards, a major thrust has also been given to technical education and training through Polytechnics and Industrial Training Institutes (ITIs). Expansion of hospital facilities in and around Kolkata and of the growth centres through private and joint sector efforts are being The SME sector that accounts for a majority of businesses and employment forms the backbone of West Bengal's GDP. They have mushroomed all over urban areas. However, the lack of infrastructure has prevented its establishment in rural areas. explored. In the field of industrial relations, the State Government has evolved a system of tripartite negotiations and understanding, both at the unit and industry level, over the years. Similar long-term agreements have been successfully implemented in various industries including engineering, jute, tea and textiles. INVESTOR-FRIENDLY INDUSTRIAL POLICIES The State Government has formed a liberal and investor-friendly policy to amend the industrial scenario in the state. Its proposals for an alternative economic policy call for a statement of policy on vital issues including industrial development, rehabilitation of sick units, generation of employment opportunities, and protection of labourers legitimate interests. OPPORTUNITIES FOR NEW ENTREPRENEURS West Bengal has rapidly progressed over the last decade. Today, the state has an industrial growth rate that is 1.1 per cent higher than the national average. Projects having a budget of more than `9,000 crore have been commissioned in the last four years. The state has also been promoting joint sector and assisted sector units in important industry segments together with developing business, trade and industrial links with domestic as well as foreign institutions and companies. Various sectorspecific industrial parks have also been developed. GROWTH OF SMEs The SME sector in West Bengal that accounts for a majority of businesses and employment, forms the backbone of West Bengal's GDP The SMEs sector has been . growing at a steady rate. They have mushroomed all over urban areas. 182 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 OPINIONS & MORE ADMINISTRATIVE MACHINERY FACILITATE GROWTH These factors drive industrial growth in the state. However, a shared vision and collective effort of the government, administration, (VDMA) during a conversation with Purna Parmar. Excerpts... However, the lack of infrastructure has prevented its establishment in rural areas. PROMOTING INDUSTRIAL GROWTH The government has taken steps to promote growth in the state's overall economy through industrial growth. The industries include petrochemicals, electronics and IT, iron & steel, metallurgical & engineering, textiles, leather & leather products, food processing, tea, manufacture of basic drugs, chemicals & pharmaceuticals, optimal utilisation of minerals, and development of mine-based industries. GLOBAL INVESTMENT DESTINATION West Bengal is diverse in nature with regard to its culture, geographical distribution, and weather. It is the fourth most populous state and has a huge expanse of area. A stable political climate, infrastructure, and labour relations are driving industrial development in the state. These factors have contributed to the growth in the state. Apart from these, efficient transportation networks and competitive market rates are also helping the cause of West Bengal. However, global investors are wary of investing in the state due to the negative perception and image it carries. Therefore, the state needs to change this negative perception by highlighting to investors the benefits of investing in the state. The State Government and the administrative machinery need to have a shared vision for facilitating economic growth in the state. The pro-investor attitude needs to be collective and should percolate to the lower bureaucracy as well. The government needs to initiate a sustained mass communication campaign to create a widespread buy-in for successful implementation of development initiatives. D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 183 WEST BENGAL AIR BLASTERS ega Industries manufactures and offers air blasters that remove and prevent blockages and build up of bulk material in hoppers, bins and chutes. A quantity of compressed air at 4-8 bar is released in a few milliseconds as a blast into the bin at the position of the blockage. The suddenly released energy frees the compacted material and the free flow of the material is restored. By firing air cannons in adjustable sequence by means of a sequential timer, blockages can be avoided and the full capacity of the hopper or bin utilised. The plant can run uninterruptedly (claims the company). As the quantity of air is very small in proportion to the storage bin or hopper, the energy of the blast is dissipated and absorbed by the material. There will be no damage whatsoever to the structure (claims the company). T machined out from monolith structure and thus very stable; easily transportable; and actuating lever with positive spring lock. Applications include: for handling of steel plates, blocks, rounds, press moulds & loading/unloading in machines; commonly used near flame cutting & during fabrication; can handle finished components without leaving behind any scratch marks, unlike binding and slinging; and can be used with spreader beam hanging multiple magnets to handle long plates/pipes/bars. East Coast Enterprisers Ltd, Kolkata 700 001. Tel: 033-2242 4617, Fax: 033-2242 6568 Email: email@example.com, Website: www.sardamagnets.com ANTI-VIBRATION MOUNTINGS E Tega Industries Ltd, Kolkata 700 053. Tel: 033-2478 3356, Fax: 033-2478 3649 Email: firstname.lastname@example.org, Website: www.tegaindustries.com FASTENER TOOLING SYSTEMS eratizit SA, Luxembourg offers fastener tooling systems (PowerDie-2000) for nail manufacturing. The tool holders can be used for a range of nail sizes. There is a considerable improvement in cost-effectiveness. Machines are used more effectively with shorter changeover times and less lost times. Holders and hard metal inserts without a ground groove are part of the standard programme. Ground grooves to customer requirements can be easily and quickly added. This guarantees short delivery and greatest flexibility for customers. The clamping insert provides double tool life, excellent process safety and automatic force compensation. Two-piece design provides unique breakage protection for clamping inserts, thus helping nail producers to prolong tool life up to double time. Short changeover times due to the patented Plansee Tizit clamping system play another important role in enhancing productivity. C sbi Hi-Flex manufactures and offers E & ET series of antivibration mountings that are indispensable where vibration from diesel generators, compressors, screens, blowers and a host of high and heavy weight equipment needs to be isolated. These mountings provide large deflection, high load capacity with extended service life. The mounting springs are loaded in shear and compression for optimum load/deflection characteristics and are protected from oil and physical damage by the robust metal casing in which they are housed. Additionally, the E & ET (special) incorporate friction pads, thus eliminating the need for bolting. EM type mountings are indispensable where machine tools, office machines, textile machinery, small workshop and sensitive laboratory equipment, pumps and compressors have to be vibration insulated. EM mounts are vibration insulating and solid-borne sound absorbent. ESBI U-shear mountings are most flexible and provide the best insulation when the load is in shear, ie, in the vertical and longitudinal directions. Esbi Hi-Flex Pvt Ltd, Kolkata 700 017. Tel: 033-2282 3520, Fax: 033-2282 9100 Email: email@example.com, Website: www.esbi.info SCREW THREAD INSERTS tainless steel screw thread inserts offered by Fastener Manufacturer are helically wound coils made out of diamondshaped high tensile 18-8 stainless steel wires. These inserts when installed inside a tapped hole, produce permanent precision internal threads, conforming to standard specifications; and in the process protect the parent thread from damage against shock, vibration, corrosion, stripping, etc. The inserts are specially suited for use in soft materials, like aluminium, cast iron and where often threads wear out fast. Other types of screw thread inserts, ie, screw-lock type, are self-locking type of inserts that provide locking feature by applying locking torque on the bolts, thus preventing from loosening due to vibration. The inserts in the form of coils, aligns with the parent threads, eliminating lead and angle error. The process of installation involves tapping with special taps, driving the insert with an inserting tool and breaking the tang from a V-notch provided at the bottom of the insert, using tang break-off tools. S Ceratizit India Pvt Ltd, Kolkata 700 008. Tel: 033-2494-5435, Fax: 033-2494 1472 Email: firstname.lastname@example.org, Website: www.ceratizit.com PERMANENT MAGNETIC LIFTERS E ast Coast Enterprisers offers permanent magnetic lifters that more effectively use available floor space by eliminating gauging and increasing stacking height. Large and heavy workpieces can be moved safely and easily by only one operator. These magnetic lifters are suitable for both flat and round components. Labour saving, time saving, can lift both round and flat components. Some of the features include: tested to 3 times the rated lifting capacity; state-of-the-art design; smaller & lighter than ever; made with high energy rare earth NdFeB magnets; SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 Fastener Manufacturer Pvt Ltd, Kolkata 700 019. Tel: 033-2440 5544, Fax: 033-2440 2092 Email: email@example.com 184 WEST BENGAL PVC HOSES F lexible Hose Industries offers PVC hoses that are available in sizes ranging from 38 mm to 1000 mm dia in 4 to 10 metres length. These hoses can withstand temperature of -20�C to +60�C. They have a smooth inside diameter as well as strength and durability. The PVC hoses are lightweight and designed for maximum airflow and can be used with a wide range of blowers, portable evacuators, fans, printing machines & dryer machines for both positive and negative pressure. Fire-resistant and antistatic quality hoses are also available. These are weather-resistant hoses. M1 specification of the PVC hoses are also manufactured and supplied based on customers' requests. The PVC hoses come in three different types, ie, PFFH, PSRH and UNPH. These PVC hoses find applications in removal of air, gas, fumes & dust and can also be used in washing machines & tumbler dryers. offered. Also available are hydraulic pressure testing machines, designed for testing steel, brass or steel cast shells with oil/water. Test pressure in these machines ranges from 20 to 1000 bar. The machines can be offered with pick-&-place manipulators and data acquisition system. Simpletec Automatics Pvt Ltd, Kolkata 700 108. Tel: 033-2577 6438, Fax: 033-2556 8905, Mob: 09903030366 Email: firstname.lastname@example.org Website: www.simpletecautomatics.com, www.simpletec.co.in RTU SYSTEMS M Flexible Hose Industries, Kolkata 700 071. Tel: 033-2227 1303, Fax: 033-2466 4751, Mob: 09831179093 Email: email@example.com, Website: www.ductsandhoses.com SURFACE ROUGHNESS GAUGES aserCheck portable surface roughness gauges offered by SBS Precision Systems (India) are rugged, portable Ra gauges capable of being carried from sample-to-sample for batch work, one-off or higher production runs. Readings are activated by pushbuttons and take less than 1 second. These gauges are equipped with LCD display and memory to store 10,000 Ra readings. Data can be downloaded and firmware upgraded, via optional software and RS232 interface. The surface roughness gauges are used for measuring type of surfaces, like ground, sanded, polished, honed, super-finished, fineturned, shot-blast, measurement range Ra 0.025 �m to 2.0 �m, measurement size 5 mm x 1 mm, etc. The detectors inside the measurement head measures distribution of specular and scattered laser light reflected from surface. Increased roughness creates less specular reflection and more scattered light reflection. Electronics and software digitise signals and calculate Ra (average) surface roughness. L otorola MOSCAD RTU systems from M B Control & Systems can be used for monitoring of unmanned sub-stations or remote control of power distribution systems. These RTU systems are in use worldwide for monitoring and control of water distribution, electrical distribution, gas pipelines, etc. They can also be used for remote control of RMU for control of distribution networks. Features include: remote control & monitoring; remote programming and diagnostics; seven layer communication protocol; availability of various types of I/ O modules, like digital, analogue, counter, etc; real time stamping with 1 milli second resolution; multiple redundant communication channels & ports; on-line change over to active communication channel; supports radio, GSM, GPRS, TCP/IP, etc; full ladder diagram programming; compatible with various SCADA programs; and availability of OPC server. M B Control & Systems Pvt Ltd, Kolkata 700 019. Tel: 033-2287 3791, Fax: 033-2287 0445, Mob: 09748899011 Email: firstname.lastname@example.org, Website: www.mbcontrol.com PROVING RINGS nstruments Internazionale offers proving rings that are most suitable for calibrating load testing machines and verifying the accuracy of applied load. Manufactured from high quality steel, these rings are available in the range of 10 KN to 500 KN. The integral loss design eliminates possible deflection error that might occur at high loads. All proving rings are calibrated in accordance with BS:1610 and certified by NPL, New Delhi. The proving rings have repeatability of 0.2 per cent and an accuracy of �1 per cent indicated load between 10 per cent to 90 per cent supplied complete in a carrying case. I SBS Precision Systems (India) Pvt Ltd, Kolkata 700 053. Tel: 033-3292 0078, Fax: 033-2400 3097, Mob: 09331140202 Email: email@example.com Instruments Internazionale, Kolkata 700 035. Tel: 033-554 6758, Mob: 098302 96170 Email: firstname.lastname@example.org HYDRAULIC PRESSURE TESTING MACHINES impletec Automatics offers 2000 bar hydraulic pressure testing machines that are designed for testing hydraulic cylinders, gun-barrels, shells, etc. Hydraulic oil or water can be used as the testing fluid. Some of the special features of these machines include: test pressure up to 2000 bar; hydraulic oil or water as test fluid; precision pressure transducers to measure test pressure; linear transducer to measure expansion/ displacement due to pressure; computerbased data acquisition system; low noise. Machines with lower working pressures are also TUBULAR LEVEL GAUGES K Instruments manufactures and offers tubular level gauges that are simplest form of level indication in the process industry. These level gauges are simple and reliable devices for direct reading in atmospheric or pressurised tank applications. They are mounted parallel, along side of the tank. As the process level fluctuates, the level in the transparent glass tube changes accordingly and gives local liquid indication. S D D K Instruments Pvt Ltd, Kolkata 700 031. Tel: 033-2405 0944, Fax: 033-2415 2311, Mob: 09433208550 Email: email@example.com, Website: www.dkinstruments.com 186 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 ROBOTICS WELDING AUTOMATION & ROBOTS LOADING & UNLOADING ROBOTS V Robotics & Automation India offers robots for loading and unloading materials. These robots pick up jobs from the conveyor and load them to the machines and unload finished jobs from the machines to the conveyors. The robots help load any type of job irrespective of the weight to be loaded onto the machines. They can be customised for online operation on the assembly lines. A TE WER A offers welding automation and robots for welding. Welding rotators are available from 5 MT to 300 MT, in conventional, self-centering, and self-aligning types. Column and boom for submerged arc welding are available from small to large sizes. Welding manipulators range from 500 kgs to 20 MT, as well as in standard to tilting types. Hard automation is available for users' welding requirements. Robotic automation is provided for welding requirements of users. S S V Robotics & Automation India Pvt Ltd, Pune 411 041. Tel: 020-2439 0444, Fax: 020-2439 0700 Email: firstname.lastname@example.org, Website: www.svispm.com ROBOTIC LIQUID GASKETING MACHINES win Engineers manufactures and offers a wide range of profile dispensing machines for dispensing fluids, like RTV silicone sealants, anaerobic liquid gasketing adhesives, etc. These machines are capable of processing high viscous material and facilitates to dispense the material in any desired profile; spots, lines or continuous path pattern. CNC robotic and magnetic X-Y controls are provided to achieve dispensing of sealants or adhesives in bead form. Important features include: provision of oil cup to prevent solidification of costlier sealant & adhesives; curtain sensors to stop the cycle if interrupted; job sensors to ensure dispensing does not take place; optical job sensors to ensure that right job is sensed; signal tower lamp indication; cartridge empty signal facility; drum empty signal facility; and interrupt programme run facility. Application areas include: automobile: form-in-place gasketing for crank case assemblies, oil pan/sump, differential housing, water pump assembly, auto luminaries, etc. T ATE WERA Pvt Ltd, Pune 411 018. Tel: 020-2747 4457, Fax: 020-6611 4196, Mob: 09850574575 Email: email@example.com, Website: www.ate-engg.com GANTRY CARTESIAN ROBOTS umitron Marketing offers gantry cartesian robots (model I&J6000) from I&J Fisnar Inc, USA. These robots have working areas up to 32" x 24" and high-speed movement up to 800 mm/ sec. These industrial robots are ideal for dispensing applications requiring an economical but high quality solution to automated manufacturing, including conveyor operations and work cells that require XYZ movement above the work. Examples are form-inplace gaskets, seals, bonding, encapsulation and potting applications. The Gantry Cartesian robots use stepping servomotors that provide control of the 3-axis, which fully interpolate all axes and provide continuous path or point-to-point dispensing. Programming is by an easy-tolearn teach pendant, using simple step-by-step instructions. S Twin Engineers Pvt Ltd, Pune 411 026. Tel: 020-2712 1626, Fax: 020-2712 1849 Email: firstname.lastname@example.org, Website: www.twinengineers.com Sumitron Marketing, New Delhi 110 028. Tel: 011-4141 0631, Fax: 011-4141 0494 Email: email@example.com, Website: www.sumitron.com GLUE DISPENSING ROBOTS LINEAR ROBOTS E P rasad Wemo Robot System, in joint venture with Wemo Automation (Sweden), offers linear robots that cover the need for injection moulding machines ranging from 25 tons to 1500 tons. These robots are designed for maximal stability and precision, high speed and trouble-free operation. One can choose among three different models. Model ES economy servo is a cost-efficient solution, which can handle most basic needs; model FS full servo is for more complex solutions where there is a demand for maximal flexibility; and model HS highspeed servo is for extremely short cycles. co-Tech Solutions & Systems manufacturer and offers CNC engraving machines, glue dispensing robots, CNC robotics, CNC trainer lathe machines, CNC trainer milling machines, etc. Besides these, the company also imports a gamut of products, like CNC controllers, axis drives & motors, etc. The products are designed with utmost precision and are a reflection of superlative technological innovation and sophistication, thereby making them perfect for industrial application. The products can be customised by incorporating the specifications provided by clients. These products are used on a large scale in the following areas: small dies & tools, jewellery designing, manufacturing automotive lamps, production of small components, in training institutes for training programmes, etc. Prasad Wemo Robot System Pvt Ltd, Ahmedabad 382 445. Tel: 079-2583 0112, Fax: 079-2583 0129, Mob: 09377737924 Email: firstname.lastname@example.org Website: www.prasadgroup.com Eco-Tech Solutions & Systems, New Delhi 110 015. Tel: 011-4142 0618, Fax: 011-4142 0618 Email: email@example.com Website: www.ecotechsolutions.in 188 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 ROBOTICS ARC WELDING ROBOTS U nisys Automation offers Motoman's (model EA1900N) arc welding robots that are specifically designed to maximise performance of arc welding. These highperformance 6-axis ExpertArc welding robots feature a patented internal cabling design that streamlines the robot profile and increases cable life by reducing wear and eliminating cable flip. Eliminating cable interference reduces programming time as well as cycle time by minimising the motion required for torch orientation. The robots feature a 1,904 mm horizontal reach and a 3,418 mm vertical reach. B-axis features an expanded range of motion, which improves circumferential welding on cylindrical workpieces. T-axis can rotate the torch �200 degrees without cable interference. Hollow upper arm maintains the optimum bend radius of the welding torch cable, maximising weld performance and extending cable life. Unisys Automation Pvt Ltd, Ghaziabad 201 001. Tel: 0120�6473442, Fax: 0120-6473442, Mob: 09873909306 Email: firstname.lastname@example.org Website: www.unisysautomation.com GANTRY ROBOTS P recision Automation & Robotics India offers gantry robots (GL, GR & AG series) that are high-speed Cartesian robots used for typical handling applications requiring top access and overhead transport, like machine tending, pick-&-place operation D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 189 ROBOTICS and palletising. Standard gantries are available in various series of configurations, each having a range of capacities and specifications. GL series line gantry robots have two standard axes for vertical and transfer motions, typically used for material handling applications. GR series rectilinear gantry robots have three standard axis, the cross movement axis (X), in addition to the vertical (Z) and transfer (Y) motions, typically used for material handling applications, where small cross travels are necessary. GA series area gantry robots have three standard axes, the cross movement axis (X), in addition to the vertical (Z) and transfer (Y) motions, typically used for material handling. Precision Automation & Robotics India Ltd, Pune 411 041. Tel: 020-6646 2000, Fax: 020-2439 2843 Email: email@example.com, Website: www.parirobotics.com ROBOTIC SHOT-PEENING MACHINES N ational Enterprises offers robotic shotpeening machines with 6-axis robot. These shot-peening machines have doormounted CNC turntable. They have shot classifiers and shape/spiral separators. Close loop media controller and close loop pressure controller are also provided. The robotic shot-peening machines have cartridge filters. National Enterprises, Faridabad 121 003. Tel: 029-4083366, Fax: 029-4083366, Mob: 09718383333 Email: firstname.lastname@example.org, Website: www.nationalenterprises.org OVERHEAD ROBOTS T he overhead robots (model roboFlex) manufactured by Gudel consist of a 5-axis robot arm, which is fitted in a suspended position on a linear travelling axis. Thanks to the overhead robot roboFlex it is possible to position workpiece grippers and operating heads in any axes direction and angle required. The small mass guarantees very high dynamics and maximum rigidity and accuracy. The modern robot control systems allow optimum movements to be carried out. With simplified on-screen operator guidance the partprocess is quickly achieved. Gudel India Pvt Ltd , Pune 411 038. Tel: 020-2545 9531, Fax: 020-2545 9530 Email: email@example.com, Website: www.gudel.com INDUSTRIAL ROBOTS rithvi Power Engineers offers industrial robots for various applications, such as: arc welding, palletising, coating, painting, dispensing, metal cutting, spot welding, bagging, narrow gap welding, etc. These robots are used in automobiles, fabrication, cement, rubber, steel (sheet), chemical plants, wire, etc; and in various industries like dairy & food, fabrication & structural, fertilizer, etc. P 190 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 SENSORS Prithvi Power Engineers, Noida 201 301. Tel: 0120-4256488, Mob: 09818899636 Email: firstname.lastname@example.org, Website: www.prithviengineers.com DIFFUSED BEAM SENSORS P roximon Controls offers diffused beam sensors that consist of a transmitter and a receiver together. These look alike inductive proximity sensors and hence also are known as infrared proximity sensors. The emitter emits infrared rays that are reflected on the receiver through the object to be registered. In the use of these sensors, it is important to bear in mind the colour of the object. Light colour corresponds to the maximum distance and vice-versa. Some of the advantages include: transmitter & receiver housed in the same housing; and as the self-reflection of an object is used for detection, dark & light marks can be distinguished. The diffused beam sensors are particularly used for position sensing and counting of non-metallic objects. These are also used for bottle sensing, level sensing, height sensing, plastic film sensing, edge detection of paper or sheet metal, etc. Proximon Controls Pvt Ltd, Thane 400 606. Tel: 022-2588 9244, Fax: 022-2588 9246, Mob: 09820059434 Email: email@example.com, Website: www.proximon.com MAGNETIC SENSORS S Electronics offers magnetic sensors that are two-piece devices having magnet on one end and electronic reed sensor on the other end. When both come close, the sensors activate and open the circuit and the contact. The applications are numerous. These sensors are available in different shapes and sizes, which suit different applications. Each and every design is available with different sensing gap/distance with various configurations. Applications include furnace flow switch, photocopiers, washing machines, security alarms, pneumatic cylinders, machine tool rotation sensing, elevators, conveyors, limit switches, rolling shutter metal doors, etc. Non-stand/specific types of magnetic sensors are available as per customer's requirements. R R S Electronics, Chennai 600 122. Tel: 044-2478 0314, Mob: 09444659962 Email: firstname.lastname@example.org CAPACITIVE SENSORS ajdeep Automation offers capacitive sensors (KAS series) that react to metals and non-metals, which exceed a specific capacitance on approaching the active surface. The sensing distance with respect to a specific material is greater the higher the dielectric constant. These sensors are used to detect objects, for counting functions and for all types of level monitoring applications in liquid materials (ie, water, oil, acids, glue) and bulk materials (ie, powder, granulate, pellets). Some of the technical specifications of these capacitive sensors include: housing ranging from � 8 mm to � 64 mm; operating voltage range of 10 V DC to 250 V AC; operating distance from 0 mm to 50 mm; housing material R D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 191 SENSORS of stainless steel/brass, PPO/PA/PVC, PTFE/PEEK/PVDF; and permitted ambient temperature ranging from -70�C to +250�C. Rajdeep Automation Pvt Ltd, Mumbai 400 011. Tel: 022-2300 2837, Fax: 022-2300 2389 Email: email@example.com, Website: www.rajdeep.in minimum/maximum temperature to be measured, and the type of sensors to be used. Chroma Electronics, Mumbai 400 077. Tel: 022-2501 1259, Fax: 022-2510 1096 Email: firstname.lastname@example.org Website: www.chromaelectronics.com FIELD PLATE SENSORS K atlax Enterprises offers field plate sensors that are non-contact proximity switches with two magneto resistors arranged in a magnetic bridge. A ferrous target influences the resistance values of the magneto resistors. The sensors are particularly effective for trouble-free measuring of rotating objects. For eg, using a gear with switching frequencies up to 20 kHz can be obtained. Applications in single channel only counting or rotational speed monitoring is required; and in two-channel the direction of rotation can be determined using external electronics. SENSORS echno Controls offers sensors with triclover connections that are widely used in pharmaceuticals and food industries. Normally threaded joints are avoided in these industries because of depositions of bacteria in sharp edges of thread, which can contaminate the products. High dimensional tolerances are required for such kind of sensors. Materials of construction are generally SS-316L. Head material of construction can be either SS-316 or die cast aluminum. T Katlax Enterprises Pvt Ltd, Dist Gandhinagar 382 721. Tel: 02764- 286784, Fax: 02764�286793 Email: email@example.com, Website: www.katlax.com Techno Controls, Ahmedabad 382 481. Tel: 02717-241312, Fax: 02717-241380 Email: firstname.lastname@example.org Website: www.techno-instruments.com TEMPERATURE SENSORS J upiter Electronics offers PCS non-contact temperature sensors that are compact low-cost infrared thermometers for measuring temperature ranging from -20�C to 350�C. Salient features of these sensors include: size: M12 x 1.87 mm long, stainless steel housing; rugged coated silicon optics; integrated electronics with LED alarm indication & smart electronic sighting support; usable up to 75�C ambient temperature without cooling; scalable analngue output: 0-10 V or 0-5 V; short-circuit & polarity reversal protection; adjustable signal processing; optional USB programming interface & software; and wide power range of 5-7 & 12-28 V DC. SENSORS T oshni-Tek International offers an extremely wide range of sensors that are available from Keyence Corporation, Japan, to suits almost any application. May be it is tough environmental condition or special sensing application; Keyence has an answer for them. These sensors find applications in general sensing of an object; confirmation of objects & process in an assembly; sensing precise distances; sensing colours of reflective as well as transparent objects; counting; confirmation of orientation; and double-fed metal plate detection. Jupiter Electronics, Mumbai 400 086. Tel: 022-2517 0795, Fax: 022-2517 0867 Email: email@example.com, Website: www.jupiterelectronics.com Toshni-Tek International, Chennai 600 010. Tel: 044-2644 4214, Fax: 044-2644 8847 Email: firstname.lastname@example.org, Website: www.toshnitek.com AREA SENSORS THERMOCOUPLE SENSORS hroma Electronics offers assembled thermocouple sensors to suit customers' specifications and in various shapes, such as needle, leaf, bow, spring loaded, mineral insulated, ceramic, washer type, gas probe, etc, in different sheathings, like SS304, SS310, SS316, inconel 600, ceramic 610, ceramic 710 as per temperature specifications. Thermocouple grade wire of Cr/ Al in size of 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 36 SWG and 3.20, 2.50, 2.3, 2, 1.6, 1.5, 1.2, .9, .7 mm, J-type in 24, 30, 36 SWG, etc. Also offered are extension grade element wires of Cr/Al, Fe/K, Cu/K, etc, in PVC or FFSS. User industries are chemical, textile, steel plant, plastic, glass, etc. Also manufactured are instruments as per customers' requirements, according to the required temperature range, C F lexible Automation Systems offers area sensors (also called as safety curtains) that are through beam type photoelectric sensors manufactured by Snux of Japan, a subsidiary of Matsushita Electric Works. These sensors are available in NA/NA2 series general purpose and slim body type with 40 mm beam pitch available at protective height variation from 120 mm to 920 mm and maximum range up to 5 m suitable for both NPN/PNP PLC applications. Clearly visible job indicators are present on the emitter and receiver both. Cross beam scanning area sensors are used to detect very thin objects like post cards and also to detect falling objects whose path is uncertain. The area sensors conform to the EMC directive and have UL recognition. Type-2 and Type-4 intelligent safety guards include the monitoring section CPU in emitter and receiver for perfect beam alignment. 192 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 SENSORS Flexible Automation Systems Pvt Ltd, Bengaluru 560 052. Tel: 080-2228 2427, Fax: 080-2225 7108 Email: email@example.com, Website: www.flexibleindia.com FLUID PROPERTY SENSORS M easurement Specialities Inc offers novel fluid property sensors (model FPS-2800B12C4) that directly and simultaneously measure the viscosity, density, dielectric constant and temperature of fluids. Relaying on patented tuning fork technology, these sensors monitor the direct and dynamic relationship between multiple physical properties to determine the quality, condition and contaminant loading of fluids, such as engine oil, fuel, transmission & break fluid, hydraulic & gear oils, refrigerants and solvents. The fluid property sensors provide inline monitoring of fluids for wide range of OEMs and after market installations including fluid reservoirs, process lines and pressurises high flow conduits for applications that include on- and off-road vehicles, HVAC&R, compressors, turbines, etc. The universal CAN J1939 compliant protocol provides easy to connect interface to host controller. A simple 4-pin connector allows for cost-effective mounting options. Measurement Specialties Inc, Bengaluru 560 095. Tel: 080-2563 3475, Fax: 080-2563 3475, Mob: 09448094263 Email: firstname.lastname@example.org, Website: www.meas-spec.com SENSORS B alluff offers IO-Link Master sensors that make machines and systems more productive. These sensors make complicated multiple cabling superfluous, reduce installation time and expense, and make startup faster and configuration simpler. The IO-Link Master stands for simpler processes, higher productivity and lower life cycle costs in systems and machine building. As the central element of the new communications technology, the IO-Link Master makes the intelligence integrated into sensors and actuators accessible to the controller level. Regardless of whether signals from measuring or binary sensors are sent to the machine controller or configuration parameters are uploaded to the actuators and sensors: with the IO-Link Master both are simple to implement, since IO-Link replaces complexity with standardisation and handles the entire data exchange over a single 3-conductor standard cable. With IO-Link diagnostic concepts are now possible all the way down to the sensor/actuator level. Balluff India, Mumbai 400 088. Tel: 022-67551646, Fax: 022- 6797 3257 Email: email@example.com, Website: www.balluff.co.in MOTION SENSORS hagwan Associates offers Honeywell's 5898 wireless Kband dualtec motion sensors that provide superior detection and reduce the risk of false alarms. The combination of PIR and K-band microwave technologies enable the sensors to distinguish between real intruders and other environmental conditions by confirming each other within a defined area of protection. The sleek, compact design makes it ideal for applications where aesthetics and discretion are critical. PIR sensitivity and temperature sensing can be enabled via local programming or from the central station. Installation is easy, with no B 194 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 SENSORS jumpers, switches or disassembly, fewer mounting restrictions and an automatic walk test mode that turns on the LED for ten minutes -- saving installers one trip up the ladder for each sensor. The 5898 blends perfectly with Honeywell's 5800 series family of sensors to create a seamless look in any residential or commercial environment. Bhagwan Associates, Mumbai 400 003. Tel: 022-2344 1379, Fax: 022-2342 3050, Mob: 09820043612 Email: firstname.lastname@example.org Website: www.bhagwanassociates.co.in UV FLAME SENSORS inear Systems offers UV flame sensors that use very sensitive electronic UV tubes. The specially tuned UV tube is designed to detect UV radiations emitted by the naked flame. These UV flame sensors are insensitive to normal light and refractory glow in furnace walls. They are ideally suited for detecting all types of flame, namely flames due to gas/coal/oil fired burners in boiler and furnaces. UV sensors (model UV-01-AJ) are specially designed for harsh industrial environment. These sensors provide for easy cleaning of the UV sensors and viewing of the flame. The UV flame sensors are housed in metal jackets to provide mechnacial protection and various mounting features. L Linear Systems, Mumbai 400 088. Tel: 022-2551 2534, Fax: 022-2557 6002, Mob: 09820707710 Email: email@example.com, Website: www.linearsystems.net D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 197 WELDING STORED ENERGY WELDERS P owersaver capacitor discharge stored energy welders offered by Artech Welders have large-scale reduction in kVA demand. Welding of similar and dissimilar metals is possible. No watercooling is required for electrodes. Installation and operating cost of the machine is less. The machines can run on gensets. Other features include: weld joint free of blackening & distortion; no effect of voltage fluctuation on weld quality; welding of heat sensitive parts is possible; and minimum heating of components during welding. All recommended electrode materials are suitable for these welders. Applications are in shock absorber components, projection nut/bolt welding, oil port to cylinder tube welding, oil filters, window regulators/seat adjusters, cap nuts, tie rod ends, stainless steel impellers, sheet metal fan covers, brake shoes, ball-to-rod welding, auto electrical components, switchgear components, stainless steel kitchenware, white goods components, relays, carbon brush assembly, aeroengine & aerospace components, sheet metal furniture parts, dissimilar metal parts, silver contact welding. fluctuations protected against overvoltage, under-voltage, single-phasing, over-heating with indications. They have in-built selectable pulsing of 1 to 10 Hz of output current. High OCV and controlled start current ensures reliable electrode ignition. Fast regulation speed and excellent dynamic properties ensures spatter-free welding performance even with difficult electrodes. Applications are in chemical plants equipment, dairy equipment, food processing machinery, pharmaceutical machinery, ornamental metal, furniture, brewery plants, kitchen & hotel equipment, hospital equipment, pipeline welding structural fabrication, etc. Arcraft Plasma Equipments (I) Pvt Ltd, Mumbai 400 068. Tel: 022-2896 5745, Fax: 022-2896 6418, Mob: 09321327001 Email: firstname.lastname@example.org, Website: www.arcraftplasma.com WELDING CONTROLLERS M Artech Welders Pvt Ltd, Pune 411 018. Tel: 020-2746 2771, Fax: 020-2746 1348 Email: email@example.com, Website: www.artechengg.com WELDING ROTATORS A nvin Engineers manufactures and offers high quality welding rotators that are used with various processes, such as SAW/ TIG/MIG/ARC, etc, with capacities up to 2000 tons. Steel rollers or polyurethane lined rollers are provided as per application. For higher capacity rotators forged rollers are provided. Standard rotators consist of drive unit and idler unit. The frame and rollers brackets our fabricated rollers heavy section, stress relieved and precision machined. Steplessely variable surface speed ranges from 75 to 1500 mm/m or higher ratio and are controlled through AC variable frequency drives. For precision movement encoder feedbacks are provided on case-to-case basis. Self-aligning, self-centering, manual adjusting type (coupling shaft) with single motor and special custombased rotators along with other classifications suiting to different requirements that covers the entire range up to 2000 tons capacity. Applications are in welding of pipes, API pipes, boilers, heat exchangers, pressure vessels, mounted vessels, LPG bullets, barrels, tanks, etc. icroprocessor-based welding controllers offered by Asiatic Welders, are compact and user-friendly. Three consecutive programmable weld timings, viz, preheat, weld and anneal are provided with intermediate cool timings in one weld schedule to achieve high quality splash-free welding. Timings are set in terms of half cycles of mains supply frequency to get better resolution. Relay contact output is provided to actuate pneumatics of the welding equipment. Other features include: non-volatile memory to store up to 15 weld schedules; individual operations within weld schedules indicated by LEDs; built-in compensation against fluctuations in the mains supply voltage; single weld & repeat cycle mode selectable by toggle switches; and weld/no weld switches on front panels. The welding controllers are provided with separate firing pulse output for high rating water-cooled thyristors up to any capacity for use in higher rated resistance welding machines, like seam, spot, projection, butt welders, etc. Asiatic Welders, Mumbai 400 093. Tel: 022-2824 2899, Fax: 022-2821 8315 Email: firstname.lastname@example.org, Website: www.asiaticwelders.com WELDING HOLDERS tul Arc manufactures and offers welding electrode holders that are available with fully-insulated brass body lightweight with fibre body. Some of the features of these welding holders include: for high conductivity of current (copper/bass) body; heat-resistant insulators for longer life; heavy-duty manual arc welding; current rating up to 600 A; suitable for electrode dia up to 5 mm; open mouth jaw type; for better cable connection 2 Allen screws provided with grip plate in fully insulated; and for better cable connection 3 bolts provided with grip plate in semi-insulated. A Anvin Engineers Pvt Ltd, Pune 411 018. Tel: 020-3078 0541, Fax: 020-3078 0542, Mob: 09370780556 Email: email@example.com, Website: www.anvinindia.com WELDING INVERTERS A rcraft Plasma Equipments manufactures and offers welding inverters (models Power-160 & Power-160-Power-140 with built-in HF and pulse facility). These welding inverters are lightweight & compact 80 per cent less weight compared to conventional machines (claims the company). No-load input of 0.2 A results in substantial savings in power cost. Onload power consumption is 50 per cent lesser than conventional machine. The welding inverters are designed to work under wide voltage SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 Atul Arc, New Delhi 110 005. Tel: 011-2573 6102, Fax: 011-2705 3622, Mob: 9810273058 Email: firstname.lastname@example.org, Website: www.atularc.com/www.atularc.net 198 WELDING ARC WELDING MACHINES M anual metal arc welding machines (ATE-IN series) offered by ATE Welding Equipment, Robotics & Automation (WERA) are designed for extreme efficiency. These arc welding machines consume so much lesser power to deliver the same weld as their predecessor machines. All these MMA welding machines come with built-in filters designed for robustness. Be it fluctuation of input supply voltage or the shaking of the welder's hand. The machines deliver a performance and delight users with the quality of weld they deliver. The MMA welding machines have built-in arc force to weld on those rusted or galvanised plates and a mere tuning of the potentiometer penetrates through the top layer and begin a weld, just the way users want. ATE Welding Equipment, Robotics & Automation (WERA) Pvt Ltd, Pune 411 018. Tel: 020-2747 4457, Fax: 020-6611 4196, Mob: 09850574575 Email: email@example.com, Website: www.ate-engg.com SPOT WELDING MACHINES V ulcan pedal-operated rocker arm type spot welding machines manufactured by Canary Electricals are available in 6, 8, 10 and 15 kV A models each with three standard throat depths to cover practically all applications. All machines are made of steel fabricated rigid structures to eliminate the minutest spot deflections. Some of the salient features include: low leakage (high linkage) design, proper cooling and insulation including winding D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 199 WELDING varnishing by vacuum pressurised impregnating system to enhance reliability and service life; current settings from minimum to maximum can be done by a 6-position, off-load tap switch; and solid-state electronic timer to control weld time from 5 to 50 cycles & 1 to 10 seconds to achieve accurate & repeatable spots. Adjustable maximum pressure levels are derived from a heavy-duty compression spring mounted on a pressure rod with calibrated nut. Canary Electricals Ltd, Morbi 363 641 . Tel: 02822-250431, Fax: 02822-250433 Email: firstname.lastname@example.org, Website: www.vulcanwelding.com PLASMA WELDING TORCHES A biplasWeld plasma welding torches offered by Abicor Binzel Production India, are the generation for top economical efficiency. Thanks to their extremely compact design, these torches improve accessibility even with difficult component geometries. The very stable process makes spatter-free welding and brazing possible with high-quality joint characteristics. Complicated reworking is no longer necessary. The plasma welding torches are suitable for both manual and automated applications. Abicor Binzel Production India Pvt Ltd, Dist Pune 411 001. Tel: 020-6674 0732, Fax: 020-2292 9242 Email: email@example.com, Website: www.binzel-abicor.com DIESEL ENGINE DRIVEN WELDERS olton Industries manufactures and offers diesel engine driven welders (models Force-400 & D-Force-700) that give users the best of two worlds (claims the company). One has a high quality welding unit whenever and wherever needed. No place is too remote, no job too tough. Low sound levels make them suitable for densely populated areas too. The diesel engine driven welders are ideal for pipelines, petrochemical plants, offshore jobs. They give enough power to run machinery for grinding, cutting, etc. C Colton Industries, Bengaluru 560 015. Tel: 080-2838 3643, Fax: 080-2846 6311 Email: firstname.lastname@example.org, Website: www.coltonweld.com WELDING RECTIFIERS D elta Engineering Works manufactures and offers welding rectifiers (model DRD-400) that come with rugged features and high performance. These welding rectifiers are suitable for site jobs due to their rugged construction with class-H insulation in the coil windings. They have long life even in hazardous conditions. Salient features include: excellent reliability with high 200 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 WELDING performance, suitable for outdoors, on-site use, even with long leads and cellulosic electrodes; less power consumption; ideal for TIG welding with suitable accessories; remote control facility; ideal for project site jobs; rugged construction with heavy-duty under carriage & rubber wheel; and class-H insulation. Delta Engineering Works, Pune 411 026. Tel: 022-3068 6296/97, Fax: 022-3266 3358 Email: email@example.com WELDING RECTIFIERS G lobal Medi Weld offers DC welding rectifiers. Pro-Weld model series is a magnetic amplifier type welding rectifier with an efficient electrical design. These welding rectifiers are designed for round-the-clock welding application. The use of three-phase dull wave silicon rectifiers along with a welldesigned magnetic amplifier gives a smooth and steady arc with minimum spatter and excellent welding characteristics. Pro-weld welding rectifiers are ideally suitable DC power source for manual metal arc welding and TIG welding. Salient features include: efficient electrical design; two ranges of current selection; transformer with H-class insulation; compact & sturdy with an aesthetic exterior; and easily maneuverable with negligible maintenance. Global Medi Weld, Hooghly 712 235. Tel: 033-6453 9830, Fax: 033-6453 9830, Mob: 09230507639 Email: firstname.lastname@example.org, Website: www.globalmediweld.com D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 201 NEW LAUNCHES DIGITAL INSULATION TESTERS K usam-Meco has introduced the new digital high-voltage insulation testers (model KM-6213BIN) with polarisation index and dielectric absorption ratio having output voltage range from 500 V~10 kV, and with rechargeable battery. These insulation testers have new added features with a low consumption highperformance processor. They display results much faster and have more advanced features. The instruments have automatic polarisation index & dielectric absorption ratio calculations. Their convenient mounting angle makes them more readable for most users, in diverse working conditions. The digital insulation testers have large LCD display with timer. They can also stop the test automatically and switch off automatically. The instruments are portable, tough & rugged and can sustain industrial environment handling, as well as test at voltage from as low as 500 V up to as high as 10000 V, adjustable with a 500V step. The insulation testers are lightweight, robust and compact in size. phones, LCD interfaces, and video connections. These new 300-um packages are less than half the thickness of a credit card, or 60 per cent shorter than the nearest competitor. Texas Instruments India Pvt Ltd, Bengaluru 560 093. Tel: 080-4138 1665, Fax: 080-2504 8308 Email: email@example.com, Website: www.ti.com CABLE TRAY FIXING TIES N Kusam Electrical Industries Ltd, Mumbai 400 015. Tel: 022-2412 4540, Fax: 022-2414 9659, Mob: 09867000456 Email: firstname.lastname@example.org, Website: www.kusamelectrical.com SMPS SYSTEMS mron Automation offers the new economical (model S8JCZ) SMPS systems that are suitable for all general application needs. These ultra-compact SMPS systems are offered in power ratings of 15, 35, 50, 100, 150, 350 W and output voltage of 5, 12 (15 & 35 W), and 24 V DC for all other wattages. Outputs are protected against short circuits, overvoltage and overload conditions thus suitable to be used in a wide range of applications. Both DIN track-mounting and bottom-mounting models are available for easy installation. Whether one is building or maintaining control panels for equipment used in food and beverage, automotive, electronic assembly, security, pharmaceutical or other automation equipment, most of today's machine controls require DC voltage. O ovoflex Marketing has introduced cable tray fixing ties that are specially designed to provide a convenient method of fixing cables to perforated cable trays. Supplied as a one-piece tie, the two sections can easily be pulled apart and fixed on either side of the trays, thus eliminating the need to access the rear of the tray. These have a tensile strength of minimum 55 kg. The ties can withstand temperatures ranging from -25�C to +85�C. They are available in standard colours of natural white & black. Also offered is a wide variety of products, such as, cable identification systems, cable binding & fixing systems, cable protecting accessories, circuit board accessories, electronic component parts & electrical installation products. These products are primarily designed to make assembly more efficient and cost-effective by reducing labour and promoting easy interchangeability for maintenance & repair. Novoflex Marketing Pvt Ltd, Kolkata 700 016. Tel: 099031 63634, Fax: 033-2229 7814 Email: email@example.com, Website: www.novoflexgroup.com SCARA ROBOTS E Omron Automation Pvt Ltd, Bengaluru 560 042. Tel: 080-4072 6400, Fax: 080-4146 6403, Mob: 09980943045 Email: firstname.lastname@example.org Website: www.omron-ap.co.in EMI FILTERS exas Instruments Inc, USA, has introduced 6- and 4-channel electromagnetic interference (EMI) filters for LCD display applications, the TPD6F202 and TPD4F202. Electrostatic discharge (ESD) ratings exceed the IEC 61000-4-2 specification by at least three times for contact discharge. Both are 67 per cent better than the specification for air-gap discharge. This allows the signal to be transmitted through the device while it filters out the higher frequency RF and electromagnetic interferences (RF/EMI) that can appear as lines on a screen, especially LCD displays. The devices' compact size allows designers to optimise previously wasted space under connectors. Targeted applications include LCD display interfaces and anything that needs RF/EMI filtering on data lines, such as portable applications, cell T pson Robots has announced the launch of model RS4 long reach scara robots. The new unique design of the RS series robots clearly put them ahead of other robots in their class with superior cycle times and larger work envelope access thus opening up new application possibilities. The new Epson RS4 is the long reach, zero footprint robot, featuring all the benefits of a typical Scara plus more. Unique to the Epson RS4 arm is the new workspace design, which maximises work envelope usage. The unique arm structure of the RS series robots utilises the entire workspace underneath the arm, defeating the old Scara design limitations so there is no dead space in the center of the work envelope. A pallet size this large would normally require a 1,200 mm Scara arm in a 2.4 m enclosure which is double the size. Epson Robots, USA Tel: +1-562-2905910, Fax: +1-562-2905999 Email: email@example.com, Website: www.robots.epson.com VIBRATORY BOWL FEEDERS E lscint Automation has developed special vibratory bowl feeders for feeding of flat drippers used in drip irrigation. These are made of plastic. The drippers have a highly critical orientation the convex side has to face up. Due to this orientation and the flat parts, the speed, which can be achieved, is limited. However, in 202 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 NEW LAUNCHES the special bowl developed, Elscint could achieve a speed of 200 parts per minute in the correct orientation with no jamming and stoppages and not even a single wrongly oriented component coming out. Additionally, the company provides a stand for mounting the bowl feeder and an elevator feeder for extra loading capacity. Model 400 is used with a cast aluminium bowl for this application. The bowl is coated with Elscinthane polyurethane coating and the tooling is made of stainless steel. Elscint Automation, Pune 411 026. Tel: 020-2712 2059, Fax: 020-2712 2994 Email: firstname.lastname@example.org, Website: www.elscintautomation.com PUMP VANE MEASURING EQUIPMENT M ayura Automation & Robotics Systems has developed indigenously a high-speed dimensional measurement and segregation system for a precise polished and ground component (pump vane) with deliverable measurement accuracy of 0.5 microns. These machines measure both thickness and length in onego using four numbers of LVDTs and also segregate the approved components into three distinct D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 203 NEW LAUNCHES maximise the performance. Various design features, like dual diaphragm, orifice seat assembly are also introduced to ensure long lifetime and reliability. The new range of thermostatic expansion valves covers all applications and is built up of four valve sizes covering the capacity range combined with the orifice program. Danfoss Industries Pvt Ltd, Chennai 600 119. Tel: 044-5550 1555, Fax: 044-5500 1444 Email: email@example.com, Website: www.danfoss.com FLOOR CLEANING MACHINES oma Specialities has introduced the latest model of flameproof floor cleaning machine (CYCLON FP-240) fitted with a 3-phase 1 HP flameproof motor. All electrical fittings are also compliant to the requirements of flameproof area. The brush speed of 240 RPM is just ideal for all kinds of floor cleaning and maintenance operations, such as scrubbing, stripping, waxing, buffing, spray buffing, scouring, scarifying, etc. With use of proper chemicals and accessories, these machines make it extremely easy to maintain all types of floor in a very clean and hygienic condition. The machines are equally effective for all types of floors, like marble, granite, mosaic, kotha stone, vinyl, epoxy, ceramic, cement floors, etc. They are ideal for floor cleaning applications in any industry in flameproof areas, such as in paint industries and paint shops, chemical industries, pharmaceutical plants, oil refineries, etc. S groups on a band of 5 microns each. The vane measures 3 mm �6 microns thick and 9.9 mm length �15 microns. The machines are capable of measuring and segregating 12000 components per shift. They have eliminated a band of inspectors and also the errors of judgment that goes with manual inspections. The machines use a servomotor for the positioning, NI motion card for controlling and NI digital I/O card for activating the pneumatics. PC interface presents statistical process control (SPC) reports, trending graphs, alarms & events logging, diagnostics & maintenance options and database logging. Mayura Automation & Robotic Systems Pvt Ltd, Chennai 600 030. Tel: 044-2626 0346, Fax: 044-26281181, Mob: 09940314575 Email: firstname.lastname@example.org, Website: www.mayuras.com Soma Specialities Pvt Ltd, Mumbai 400 083. Tel: 022-2578 6895, Fax: 022-2579 3034 Email: email@example.com, Website: www.somaspecialities.com OPTIMISED DISTRIBUTOR SOLUTIONS H EXPANSION VALVES D anfoss Industries has announced the launch of their new range of thermostatic expansion valves (TE). This easy mounting range of expansion valves comes with a special mix & match feature, which helps provide optimal flexibility as with only a few parts, one can design their valve based on refrigerant, capacity and connection. The new range delivers higher efficiency and reliability with the help of the mix & match parts program. This program makes it possible to select the exact valve for different refrigerant, capacity, connection size and support design for engineers to optimise the system and SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 ensel has developed standardised system solutions, which are fine tuned to the specific requirements of the PV installation. A PV system consists of various components, which must be electrically interconnected to the interfaces. The main components are PV modules and inverters. Several PV modules are interconnected to form PV strings. Such strings then form a DC power supply unit, a so-called PV generator. Each PV generator supplies DC voltages of up to 1,000 V. The PV generators are connected via PV generator junction boxes to the inverters, which convert the direct current into alternating current. Several inverters are again interconnected via inverter collectors. From there it is linked to the grid connection or the supply to the consumer. For all these interfaces, specially developed distribution solutions are available, which are finetuned to the respective requirements. The requirements for various components are thereby very different. Hensel Electric India Pvt Ltd 631 604 . Tel: 044-3727 0202, Fax: 044-3727 0200 Email: firstname.lastname@example.org, Website: www.hensel.in 204 GENERAL PRODUCTS NEW LAUNCHES FLANGE FILTERS learPoint flange filters from Beko Compressed Air Technologies offer many benefits for the end users. The filter housing has a equal levelled air in- and outlet, which makes installation in existing air mains systems possible without causing too many problems. Besides the common hanging of the filter one can choose for the option where the filter is positioned on the floor. For replacing the elements users do not need any lift installation. One can simply remove the top cover to get access to the elements. A remaining bolt can work as a hinge, and the blind flange can be moved away. Smaller sized flange filters have blind flanges, which can be lifted off, easily. Larger sized filters have grips welded on the blind flanges (for manual or automatic lifting). C Beko Compressed Air Technologies Pvt Ltd, Hyderabad 500 037. Tel: 040-2308 0275, Fax: 040-2308 0274, Mob: 09393002464 Email: email@example.com, Website: www.beko.de HMI/SCADA SOFTWARE he industrial automation group of Advantech has introduced a new version of HMI/SCADA software (WebAccess 7.0) which is a browser-based software package for HMI and SCADA applications, and has already been successfully utilised in many industrial applications and vertical industries around the world, including environmental control & monitoring systems, facility control & monitoring system, intelligent building automation, factory process & manufacturing integration systems, the chemical industry, machine automation, transportation, and power & energy. The WebAccess consists of three parts: project node, SCADA node and client node. Project node is the development platform for WebAccess, SCADA node is the data acquisition and supervisory control node, which is connected with field hardware and users in client node can remotely view data and live pictures on the site. Engineers can create, configure and manage projects with the ability to view and control real time data through Ethernet or Internet. T Advantech India, Bengaluru 560 055. Tel: 080-2337 4567, Fax: 080-2337 5898 Email: firstname.lastname@example.org, Website: www.advantech.in ALUMINA ADHESIVES C otronics Corporation has introduced Resbond 989F pre-nano, ultra fine, fast setting, 3000�F, alumina adhesives. There are no limits to applications requiring a 3000�F ultra fine alumina adhesives, with the ability to bond super fine electric components, bundles of fibre optics filaments, cable end seals, components with tight tolerances, etc. These adhesives have excellent adhesion to metals, ceramics, graphite or glass and cure to provide high bond strength and excellent electrical, moisture, chemical and solvent resistance. The alumina adhesives are ideal for any applications requiring a 3000�F, ultra fine, alumina adhesives with the ability to bond super fine electric components, etc. Cotronics Corporation, USA Tel: +1-718-7885533, Fax: +1-718-7885538 Email: email@example.com , Website: www.cotronics.com D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 205 GENERAL PRODUCTS DIGITAL VIBRATION METERS ndia Tools & Instruments Co offers digital vibration meters with full graphic LCD and spectrum analysis. Some of the technical specifications include: acceleration range from 0.1 to 392 m/s�; velocity range from 0.01 cm/s to 80 cm/s; displacement range from 0.001 to 10 mm; acceleration frequency range from 10 to 200 Hz, 10 to 500 Hz, 10 Hz to 1 kHz, 10 Hz to 10 kHz; velocity range from 10 Hz to 1 kHz; displacement range from 10 to 500 Hz; frequency resolution at 0.25 Hz; and accuracy of �5 per cent. AIRLESS SHOT BLASTING MACHINES I M India Tools & Instruments Co, Mumbai 400 003. Tel: 022-2342 8862, Fax: 022-2341 2578, Mob: 09819345050 Email: firstname.lastname@example.org, Website: www.indaitools.net TUBE STRAIGHTENING MACHINES TL Industries manufactures and offers a wide range of tube straightening machines with various features available in manual & automatic models. These machines are fully stress-relived, and come with fabricated frame. Work rolls are made up of from HcHcR steel, hardened for longer life. Rolls are mounted in anti-friction spherical roller bearing and the entire roller mechanism is independent for all other components. Easyto-read dial-type indicators with simple initial machine setting are few of the unique features of these machines. Other features include: accuracies of 1 in 1000 and 1 in 2000 & 1 in 3000 respectively for 6, 10 & 14 rolls; available with a wide range, starting from tube dia 6 mm to 220 mm; available in single speed, dual speed and with stepless speed variation; high-speed of 120 m per minute is easily achievable; and straightening done without any marking on inside & outside of the tube. I ec Shot Blasting Equipments offers a wide range of tunneltype flat bar airless shot blasting machines to suit the job size and required number of blast wheels according to production output required. Major assemblies of the machine are blast wheels for giving high production output, roller conveyor for job conveying and media recovery consists of bucket elevator, screw conveyors, air wash separator, abrasive storage hopper & pleated bag dust collector for dust collection. The numbers of flat bars are to be placed in the guides of rotating rollers of in feed conveyor pass through entry vestibule tunnel and then enter into the blasting chamber for blast clean process. Blast wheel stations are arranged strategically around and located on the top of cabinet propels abrasives on the rolling flat bars. The blower arrangement continuously blow-off abrasive accumulated on the top side of the workpieces. MEC Shot Blasting Equipments Pvt Ltd, Jodhpur 342 005. Tel: 0291-2740609, Fax: 0291-2742409 Email: email@example.com, Website: www.mecshot.com SLIDING & SWING GATES G ITL Industries Ltd, Indore 452 015. Tel: 0731-3044400, Fax: 0731-2721110 Email: firstname.lastname@example.org, Website: www.itl.co.in MECHANICAL SEALS echnomech Engineering manufactures and offers mechanical seals for chemical and process pumps, compressors, vacuum pumps, dewatering pumps, agitators, reactors, mixers, dryers and process equipment with rotating shafts. These seals are supplied to leading OEMs as well as end users in chemicals, petrochemicals, oil & gas, fertilizers, cement, thermal power generation, ore processing, metallurgy, pharma, food, beverage, cosmetics, breweries and allied industries. The mechanical seals are available in various designs, including multi-spring, single spring, Teflon bellow, metal bellow, double mechanical and cartridge type. They are also available in a wide range of materials, including carbon steel, stainless steel, hastealloy, monel, tungsten carbide, stellite, ceramic, glass filled PTFE, resin impregnated carbon, etc. T andhi Automations offers the latest technology in automatic entrance systems from Ditec SpA, Italy. The remote controlled sliding and swing gates are the ultimate in luxury with the controls at users' fingertips. These come with built-in electronic control unit that has a number of features, like operating time adjustment, partial opening, automatic closing, step-by-step control, stop safety, reverse safety etc. The motors have highly compact dimensions, silent operations and have provision for manual operation in case of power failure. ODS obstacle detection causes the gate movement to stop if an obstacle is detected. The sliding gate motors have MPS startup at maximum power allowing the motor to overcome any initial friction caused by ice, dust, etc. Swing gates with large pillars are provided with models with articulated arms. For prestigious swing gates the concealed underground operators gives users the freedom to automate without compromising on the looks. Gandhi Automations Pvt Ltd, Mumbai 400 064. Tel: 022-6672 0200, Fax: 022-6672 0201 Email: email@example.com, Website: www.geapl.co.in ULTRASONIC PROCESSORS C Technomech Engineering, Mumbai Tel: 022-2678 9468, Fax: 022-2678 9468, Mob: 0986709809 Email: firstname.lastname@example.org ole-Parmer offers high-intensity ultrasonic processors that are extremely versatile and can safely process a variety of organic and inorganic materials in a range of volumes. Typical applications include sample preparation, cell lysing, disaggregation, homogenisation, particle size reduction, soil testing, and acceleration of chemical reactions. The ultrasonic processors are capable of delivering 500 or 750 W at 20 kHz. Designed with the smallest footprint in their class, these compact units fit on any laboratory's existing bench space. Timer controls processing from 1 second up to 10 hours and monitors both the elapsed time and duration of processing. The sealed converter protects the unit from humidity, dust, dirt, and fumes. These units monitor both power (watts) 206 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 GENERAL PRODUCTS and energy (joules), and feature 100 per cent automatic tuning. The ultrasonic processors with temperature controller prevent harmful sample overheating by terminating the ultrasonics when the sample temperature reaches a predetermined limit. Cole-Parmer India, Mumbai 400 022. Tel: 022-6716 2222, Fax: 022-6716 2211 Email: email@example.com, Website: www.coleparmer.in SANDWICH BALL VALVES A ira Euro Automation offers ISO:5211 pneumatic rotary actuator operated investment casting WCB/CF8/CF8M sandwich ball valves. These ball valves are engineered for multiple on/ off operation in the down steam. Technical specifications are: (for actuators): rack & pinion type, double-acting/single-acting (spring return), Namur standard pneumatic connections; and (for ball valves): body & ball of CF8/CF8M/ WCB, PTFE seat, standard connector, PTFE gland packing, gland bush of SS-304/316, and PTFE gland washer. Accessories include: on/off indicator; Namur standard solenoid valve in all standard coil voltage (flameproof solenoid coil, on request); I/P transducer (converter); pneumatic valve positioner; electro-pneumatic valve positioner; declutchable manual over-ride; limit switches for on/off indication at panel board; filter+regulator combination with pressure gauge; and air lock valve. Aira Euro Automation Pvt Ltd, Ahmedabad 382 405. Tel: 079-4024 7003, Fax: 079-4024 7012 Email: firstname.lastname@example.org, Website: www.airaindia.com D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 207 India Inc. Spearheading Ecological Balance Participate in the Siemens Ecovatives Awards 2010 TM In Association with Process Advisors Corporate India has been making its mark in the global market. Now, it aims to make another, very positive one, on the environment. Maintaining ecological balance is high on its agenda and India Inc. is willing to walk that extra mile to achieve it. If you believe that your company has deployed innovative processes to ensure a positive impact on the environment, please nominate for the Siemens EcovativesTM Awards 2010. Visit http://ibnlive.in.com/siemensecovatives/ to participate and let the world know of the change that you managed to bring. Your effort will go a long way in inspiring others. Last Date for Nomination 25th October 2010. GENERAL PRODUCTS FIBREGLASS CABLE TRAYS umip Composites offers fibreglass cable trays that are better in loading as compared to conventional material trays with good corrosion resistivity and faster installation (claims the company). Some of the important features of these cable trays include: strength & durability, fire-redundant, lightweight and UV stabilities. All fittings are pre-fabricated and have same specification as that of straight trays. Two standard composite resin systems are also available. Applications are in power plants, fertilizer plants, paper mills, refineries, offshore platforms, laboratories, etc. S Sumip Composites Pvt Ltd, Ahmedabad 380 051. Tel: 079-2693 3456, Fax: 079-2693 2424, Mob: 09825074921 Email: email@example.com, Website: www.sumip.com CENTRIFUGAL FINISHING MACHINES M Systems offers Super-Fin removable barrel-type centrifugal finishing machines. In this type centrifugal finishing machines barrels are of detachable type. Barrels are removed from the machine for loading/unloading of parts & media. By keeping one set of spare barrels, the idle time of machine during unloading/loading can minimised and therefore the output from the machine can be maximised. The barrel rotation S D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 209 GENERAL PRODUCTS axis can be straight or skew as per requirements of the process. Turret & barrel rotation speed (RPM) can be made variable by incorporating variable speed drive. The machines are provided with manual sorting table for part media separation. S M Systems Pvt Ltd, Thane 400 604. Tel: 022-2583 8176, Fax: 022-2583 8179 Email: firstname.lastname@example.org, Website: www.smsystemsindia.com PRECISION BALLSCREWS H VERTICAL MACHINING CENTRES A ce Manufacturing Systems offers Spark vertical machining centres (VMCs) that are smallest machines under the BT-30 series. The table size of these VMCs is 500 mm x 330 mm. These VMCs have 6 tools disc type tool changer. The machines are targeted mainly for educational institutions and small entrepreneurs those who are making a shift from conventional machines to CNC machines. Key specifications include: stroke (X/ Y/Z axes) at 300/250/250 mm respectively; spindle nose face to table top 220 mm to 470 mm; spindle power 5.5/3.7 kW; rapid traverse (X/ Y/Z axes) at 20/20/15 m/min respectively; LM guideways; chip-to-chip time 5.8 sec; basic machine weight at 2200 kgf; and power supply (basic machine) at 8 kVA. MT Machine Tools offers a wide range of precision ballscrews that are used in CNC machine tools and other various engineering applications where conversion of rotary motion into linear movements and vice-versa are required. These ballscrews have high mechanical efficiency, and superior positioning accuracy coupled with low wear & long life. The range covers ballscrews in sizes from dia 16 mm to dia 80 mm with leads 3, 4, 5, 5.08, 6, 6.35, 8, 10, 12.7, 16, 19 and 20 mm. Number of turns in nuts is 2, 3, 4, 5, 6, and 8, depending on the size. Maximum length of up to 3500 mm is offered depending up on the size. The ballscrews find wide applications in machine tools as mechanical feed elements, industrial robots, material handling equipment, nuclear reactors, rail-road equipment, medical equipment, printing and paper machinery. HMT Machine Tools Ltd, Bengaluru 560 032. Tel: 080-2333 0333, Fax: 080-2333 7800 Email: email@example.com BALL BEARING MOUNTED UNITS Ace Manufacturing Systems Ltd, Bengaluru 560 058. Tel: 080-2836 0508, Fax: 080-2836 2791, Mob: 09880493879 Email: firstname.lastname@example.org, Website: www.amslindia.net U ltra-Class high-performance ball bearing mounted units offered by East India Bearing are used in many industrial applications, since they are versatile, easy to mount and simple in design. These units carry radial, axial and combination loads. They are slip fit with shafts and complete with housing ready for 210 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 GENERAL PRODUCTS mounting. The units are suitable for chain drives, belt drives, fans and blowers, conveyors, baggage handlers, power transmissions, mail handling equipment, food processing equipment, textile equipment, mining equipment, etc. The ball bearing units use high carbon through hardened steel purified using a vacuum degassing process with stringent quality control to achieve optimum hardness and microstructure. They are consistently manufactured to tight tolerances for concentricity and roundness. When combined with the cage design, cage quality and overall cleanliness, these bearings provide greater accuracy of shaft rotation, quiet operation, longer bearing life and contribute to higher speed capability. East India Bearing Co Pvt Ltd, Mumbai 400 003. Tel: 022-5633 6420, Fax: 022-2341 2478, Mob: 09820123655 Email: email@example.com MOTION CONTROLLERS trategi Automation Solutions offers state-of-the-art multi-axis motion controllers manufactured by Galil Motion Control, USA, for precise and complex applications. The cards are available for 18 axis of control. These cards can be used for point-to-point, jogging, linear & circular interpolation, helical & tangential moves, contouring with teach & playback, electronic gearing & electronic cam profiling. The motion controllers have a 32-bit microprocessor with on board memory to store application programs and variables. Programs can be downloaded to the controller and executed without intervention of the host PC, and that improves system reliability. Programming the controller is achieved through simple English like commands. The multi-axis motion controllers support C DLLs for programming in C & C++. An Active X toolkit is available for programming from a visual environment, like VB, VC++, Delphi, Lab View, Wonder ware, etc. S Strategi Automation Solutions Pvt Ltd, Mumbai 400 072. Tel: 022-2847 3114/15, Fax: 022-2847 3114 Email: firstname.lastname@example.org Website: www.strategiautomation.com STEP LAP LAMINATIONS K RYFS Power Components manufactures, designs and assembles step lap lamination cores of various size and various types, like horizontal step lap, staggering vertical step lap and variable vertical step lap, that are manufactured on Georg and CNC lines. Step lap laminations are offered in complete core design as per customers' technical specifications up to 1000 MVA, 1200 KV class in step lap. Advantages of lamination in step lap design are: reduction in no load losses (up to 8 per cent), lower noise level, and time saving in assembly. KRYFS Power Components Ltd, Mumbai 400 050. Tel: 022-6785 9999, Fax: 022-2643 4462, Mob: 09619492806 Email: email@example.com Website: www.kryfs.com 212 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 Adsar Hydraulics | Amcats Pvt Ltd | Atlas Copco | Atlas Radios | Autotech Machine Tools | Aventura Components | Berlin Machine Corporation | Boge Compressed Air System | CTR Manufacturing Industries Ltd | Dewas Techno Products Pvt Ltd | Durr Ecoclean | Dynaflex Pvt Ltd | East India Bearing Co (P) Ltd | Economy Refrigeration Ltd | Emtex Marketing Pvt Ltd | Energy Mission Engineers | Engineering Hindustan | Esskay Lathe & Machine Tools | Gandhi Automations Pvt Ltd | Hi Tech Thermal Insulations | Hi-Tech Robotic Systemz Ltd | Igus India | Jamnagar Machine Tools | Janak Enterprises | Jay Equipment & Systems | LMT | Mactrol Automation Misumi India (P)Ltd | | Neutron Power Tools Pilot Pneumatics Pvt.Ltd | Power Tech Marine | | S&T Engineers | | Rexello Castors Pvt Ltd | Shalin Material Handling K Engg Products | | Mahavir Engimach | Nilkamal Ltd | | Omron Automation | PFERD-Swit | RD Weld Products (P)Ltd Are You There? Samson Extrusion India | Quick Heal Technologies | Sreelakshmi Traders | Shamam Engineering Industries | Shuter Enterprises India | Technosys Instruments & Equipments | Welding Technologies India | Masibus Automation And Instrumentation | Modern Power Semiconductor | Moselle Developpment Council | Production Aids & Consultant | and many more... YOUR COMPETITION IS LEVERAGING THEIR BUSINESS POTENTIAL Hurry! Limited Stalls Left PUNE Oct' 2011 AHMEDABAD Dec 10 -13, 2010 INDORE Jan 7-10, 2011 CHENNAI Mar 11-13, 2011 For Stall Booking: Contact Nitin +91 9920401226 T 91-22-30034649 / 51 E firstname.lastname@example.org W www.engg-expo.com SMS EXPO to 51818 GENERAL PRODUCTS BRAKES/CLUTCHES & COMBINATIONS mco Dynatorq manufactures and offers brakes, clutches and combinations for a wide range of application in rotating equipment, viz, conveyors, mixers and blenders and for electric/geared motors, packaging machines, centrifuges, etc. AC/DC flameproof failsafe and nonflameproof electromagnetic brakes, clutches and combination and brake motors are also available. Brakes of torque up to 1200 Nm, flameproof failsafe brakes of torque up to 400 Nm and weatherproof brakes conforming to IP66 standard of torque up to 600 Nm are also manufactured. Flameproof failsafe brakes are designed for high toxic and hazardous environment in industries where non-flameproof equipments are not recommended for safety reasons. They are approved and certified by Central Mining Research Institute (CMRI) for gas groupI and gas group-IIA and IIB for zone 1 and 2 areas. Marine duty IP66 protection brakes are approved and certified by Electrical Research & Development Association (ERDA). E Emco Dynatorq Pvt Ltd, Thane (W) 400 602. Tel: 022-2540 5488, Fax: 022-2545 2233 Email: email@example.com, Website: www.emco-dynatorq.in NON-RETURN VALVES C aliber Valves offers a wide range of non-return valves for practically all process fluids. These valves are of lift check- D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 217 GENERAL PRODUCTS type with bolted bonnet construction. They have flanged end connection for easy fitment and maintenance. The valves are designed as per BSI:1868 for a rating of ND 40 and tested as per BS:5160/API:598. They are available in sizes ranging from 15 mm to 200 mm and can also be offered with IBR certificate in form III. The body and cover plate are ASTM A 216 Gr WCB and the seat and disc are CS hard faced with 13 per cent chrome steel for wear resistance. These non-return valves are essentially used for the safety of the equipment and the people handling them particularly in parallel operations. The valves make sure that there is no unintentional bypassing of the process media through the equipments and pipelines when not required. Caliber Valves Pvt Ltd, Chennai 600 102. Tel: 044-4350 0192, Fax: 044-4350 0143, Mob: 09381005709 Email: firstname.lastname@example.org, Website: www.calibervalves.com Rane Rao Reshamia Laboratories Pvt Ltd, Navi Mumbai 400 705. Tel: 022-2768 3175, Fax: 022-2783 4814 Email: email@example.com, Website: www.rrrlabs.com ELECTRIC WIRE ROPE HOISTS ddycranes Engineers offers electric wire rope hoists from 0.5 tons to 50 tons capacity and maximum height of lift of 200 metres in accordance with class I, II, III, IV heavy-duty specification as per IS:3938-1983. These wire rope hoists are manufactured offering foolproof electro-mechanical brakes operating on conical rotor motor principles. Brakes are far superior to electrohydraulic thrustor brakes offered by most other manufacturers. All hoists have high torque, crane duty, 40 per cent CDF, classF insulated conical motors suitable for 150 starts/hour. Brakes are provided in hoisting as well as cross traversing motion. The hoists are available n four basic arrangements, viz, fixed mounted type, push-pull trolley type, hand-operated trolley type and motor-driven trolley type. The hoists are also manufactured to suit special applications, eg, outdoor location, hoist with driver's cabin, twin hoist for exceptionally high height or lift or high hoisting speeds, etc. E CYLINDRICAL TAPER & GROOVED PINS K Engineering Company offers cylindrical, taper and grooved pins. Cylindrical (dowell) pins are used for retaining parts in a fixed position or for preserving their alignment. Cylindrical hardened pins are manufactured as per IS:6689, unhardened pins as per IS:2393 and taper pins as per IS:6698 standards. These are suitable for parts that have to be taken apart frequently, in which case cylindrical pins would tend to wear the holes. Grooved pins have parallel equidistant longitudinal grooves impressed on their exterior surface and are manufactured to IS:7368 standards. Also manufactured are non-standard pins. R Eddycranes Engineers Pvt Ltd, Mumbai 400 034. Tel: 022-2352 1798/2710, Fax: 022-2352 1886 Email: firstname.lastname@example.org, Website: www.eddycranes.com ABRASIVE FEEDING SYSTEMS peedfam India offers abrasive feeding systems that keep the abrasive and vehicle mixture in homogeneous condition all the time to ensure optimum usage of abrasive particle in cutting process. This helps in imparting an efficient and uniform stock removal over a period of time. This also helps to reduce consumable cost & cycle time and hence more output as compared to nonrecirculation type system. Stirrer in the system provides continuously stirring during and in between two cycles. The tank is equipped with casters for easy movement of system for disposal. S R K Engineering Company, Mumbai 400 023. Tel: 022-2267 1141, Fax: 022-2265 5255 Email: email@example.com TRIVALENT CHROMIUM PASSIVATION PROCESS ane Rao Reshamia Laboratories offers RoHS-compliant trivalent chromium passivation process on aluminium and its alloys. The new, trivalent-chromium (Cr3+) based process (TCP process) does not use any toxic chemicals and its performance matches or exceeds that of well-established, Cr6+-based passivation processes for aluminum and its alloys. Besides, the TCP process offers excellent corrosion protection and serves as an excellent base-coat for organic coatings such as painting and lacquering. This roomtemperature passivation process gives bare corrosion resistance, low electrical contact resistance and excellent adhesion of topcoats. The process is effective on a variety of materials based on plain and anodised aluminium and its alloys and finds application in electrical and electronic, automotive, aerospace, construction, architecture, bicycle, packaging, engineering and marine industries. Its range of applications is continuously growing. The process is very simple to use, maintain and operate. Effluent treatment costs are negligible. R Speedfam India Pvt Ltd, Navi Mumbai 400 701. Tel: 022-2769 2621, Fax: 022-2769 2869 Email: firstname.lastname@example.org, Website: www.speedfam.co.in ELECTROCHLORINATORS i Anode Fabricators manufactures and offers electrochlorinators the best solution for disinfection of water through electrochlorination. Sodium hypochlorite, a strong oxidizing agent, is produced by the process of electrolysis of salt water. Electrochlorinators are used as an alternatives to chlorine gas for disinfection of Domestic water supply, cooling towers, swimming pools, power stations for control of bio-fouling, disinfection of ballast water in ships, fire water wystem, fountain water, etc. Sodium hHypochlorite will be generated onsite with the help of synthetic brine or seawater is very efficient in protecting the equipment from the growth of micro organic fouling and control of algae and crustaceans. Portable model electrochlorinators are T 218 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 GENERAL PRODUCTS ideal for disinfection of water during disasters, like earthquakes, floods or epidemics. Electrochlorinators are designed for rural and village point-of-use disinfection of drinking water. Ti Anode Fabricators Pvt Ltd, Chennai 600 073. Tel: 044-2278 1148, Fax: 044-2278 1362 Email: email@example.com, Website: www.tianode.com LINEAR ACTUATORS una Bearings offers Hiwin Mikrosystem linear actuators and accessories, like controllers from 1-axis to 6-axis and overcurrent protection boxes. These actuators are available in various models, such as LAM, LAS, LAN, LAC, LAK, etc. All the models are available in different stroke lengths with various speeds and with additional features, like safety nuts. Salient features of the linear actuators include: lightweight & compact structure, user-friendly, simple installation, low noise, high rigidity, competitive price, etc. Applications of the linear actuators are in automation equipment, automatic windows & doors, automatic cupboard, automatic satellite antennas, automatic wheel chairs, automatic hospital beds, entertainment facilities, household appliances, automatic drawing tables, patient lifters, massage chairs, hospitals & rehabilitation centers, nursing homes, dental chairs, etc. L Luna Bearings, Mumbai 400 003. Tel: 022-2342 7671, Fax: 022-2342 7773 Email: firstname.lastname@example.org, Website: www.lunabearings.com D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 221 GENERAL PRODUCTS ONLINE WATER FLOWMETERS S K Technologies offers digital battery-operated online water flow rate indicators-cum-totalisers that show continuous flow of water when they pass through the water line and simultaneously also show totalisation that can be resetted if required at any point of time by password. Built in battery of 3.6 V lithium can be replaced if in case required. The life of these instruments at sleep mode is 7 years and 1 year 6 months @ 25�C as tested. Horizontal or vertical mounting is possible. Also offered is a wide range of pocket, portable, panel, online types of testing & measuring instruments for different applications like water, pH, TDS, conductivity, environment, weather stations, process, flow, instrumentation, pressure, temperature, humidity, lux, sound, data loggers, scanners, dosing pumps, speed, engineering parameters, etc. INDUSTRIAL PLUGS & SOCKETS onnectwell Industries manufactures and offers industrial plugs and sockets that provide a versatile and robust connection system for industrial field and factory connection applications. These are designed and manufactured as per IEC 60309-1 and IEC 603092 standards. The housings of the plugs and sockets are made of halogen-free, V0 grade polyamide 6 materials and hence are non-flammable with a very high impact resistance. Contacts are made from electroplated copper alloy offering high corrosion resistance and very low contact resistance. By virtue of their design these industrial plugs and sockets enable low insertion and extraction forces while maintaining excellent electrical contact. A wide range is available in 16, 32 and 63 A versions with a choice of IP44 or IP67 protection class and in 3-, 4- and 5-pin configurations to suit various applications. The industrial plugs & sockets are extremely safe and reliable for the field & factory connections. B C B S K Technologies, Secunderabad 500 003 . Tel: 040-3912 4339, Fax: 040-3912 6177, Mob: 09391036177 Email: email@example.com, Website: www.bsktechnologies.com CENTRALISED LUBRICATION SYSTEMS enlub Systems manufactures and offers centralised lubrication systems. Special package solutions are available for OEMs to reduce the installation time. These systems address the total cost of ownership issue over a period of time by ensuring technological solutions to the problem. The lubrication units distinguish them from the look alike in more than one way. In model ELU-2700, the container body is made of polycarbonate making it resistant to any mechanical or thermal force. Monitoring accessories like pressure switch and float switch plays no less role ensuring correct parameters for lubrication. Metering cartridges used to supply the required quantity of lubricant to the lube point undergoes a rigorous testing procedures to eliminate dry points or flooding at lube points. Progressive distributor, option instead of metering cartridge, ensures positive lubrication at each point. C Connectwell Industries Pvt Ltd, Dist Thane 421 204. Tel: 0251-287 0766, Fax: 0251-287 0889 Email: firstname.lastname@example.org, Website: www.connectwell.com TURRET PUNCH PRESSES NC turret punch presses (model WELPRO-255) offered by Weldor Engineering have punching capacity of 25 tonnes and can punch up to 6 mm thick MS sheet. These machines have been designed and developed through structural analysis technique. The main aim of the machine is accurate and high-speed productivity with minimum end cost. The machines are useful for automobile industries, white goods industry stainless steel cabinet of refrigerators, SS panel of electrical equipment manufacturers, etc. Features like double construction frame, hydraulic punching, auto indexing, pneumatic clamping of sheets, CNC control, higher hits per minute, incorporation of nibbling, punching & embossing functions, etc, are so designed that the machines have proved to be very successful in operation with smooth process of punching and low noise level. C Cenlub Systems, Faridabad 121 002. Tel: 0129-4113771, Fax: 0129-4113745 Email: email@example.com, Website: www.cenlub.com SEAL LEAK INTEGRITY TESTERS M ultiflo Instruments offers packaging seal leak integrity testers manufactured by MDC Engineering, Inc USA, that are used for pharmaceutical and food industry. Model SureVac manual package integrity tester is designed for fully validatable quality assurances for packaging seal leak detection, seal integrity, package development, altitude simulation, etc. These testers cover standard test methods conforming to ASTM D-6653, ASTM D-3078 and ASTM D-4991. SureVac features consist of vacuum gauge, vacuum pump, high impact vacuum chamber, package hold down and manual drain. Options for various chamber sizes, digital vacuum gauge and NIST traceable vacuum gauge are also available. Weldor Engineering Pvt Ltd, Rajkot 360 002. Tel: 0281-2360242, Fax: 0281-2360466 Email: firstname.lastname@example.org, Website: www.weldor.com DISC GRINDERS P owerMaster bench-type disc grinders offered by Prem Brothers are suitable for edge grinding and radius grinding of components. These disc grinders are available in 0.5 HP disc dia 8", 1 HP 10"/12", 2 HP 14" in different table sizes. They have a heavy-duty direct drive motor, dynamically balanced disc plate, tilting table 45 degrees down and 15 degrees up, disc guard for safety, electrical rotary switch, etc. The disc grinders also come with standing/sitting height pedestal on request. A wide range of polishing, grinding machines and dust collectors are also available. Multiflo Instruments Pvt Ltd, Navi Mumbai 400 710. Tel: 022-2778 0880, Fax: 022-2778 0882 Email: email@example.com Website: www.multifloinstruments.com Prem Brothers, New Delhi 110 064. Tel: 011-2811 7456, Fax: 011-2811 7464 Email: firstname.lastname@example.org, Website: www.powermaster-india.com 222 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 GENERAL PRODUCTS HYDRAULIC VARIABLE DISPLACEMENT PUMPS V ar-Spe hydraulic variable displacement pumps offered by Khoday Hydraulics, represent a new solution for the concept of radial pistons. These variable displacement pumps are made with aluminum housing with the inside body of highly resistant cast iron. The pumps guarantee a high efficiency together with the Var-Spe reliability. They have a high number of devices for speed adjustment and control, either manual, electric, electronic, proportional pneumatic, electro-hydraulic, soft-start or constant power-winders. The pumps are ideal choice for applications that require variable flow rate in both directions, up to 1800 RPM and powers from 0.55 kW to 5.5 kW. They come as standard fitted with an auxiliary system having inbuilt check valves, relief valves and a charge pump for closed circuit working, with a wide range of speeds & torque controls. The hydraulic variable displacement pumps are reliable alternatives for precision operations at medium powers. Khoday Hydraulics, Mumbai 400 014. Tel: 022-2414 0707, Fax: 022-2414 5266 Email: email@example.com, Website: www.khoday.com SPHERICAL BEARINGS ollon Bearings manufactures and offers special spherical bearings that are used for nuclear power plants. The coefficient of friction of these spherical bearings is below 0.1� and the working temperature up to 600�C. These bearings are used for supporting the steam generator guide supports at steam nozzle location in nuclear power plants. They support steam nozzle R D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 225 GENERAL PRODUCTS against loads during normal operating conditions, earthquake and/or pipe rupture events. The special spherical bearings are manufactured with housing in stainless steel and a spherical ball in special alloy bronze fixed with solid lubricant. This arrangement permits free diametrical expansion of steam nozzle, free vertical upward thermal expansion and tilting of steam generator and to transfer the loads from steam generator to supporting structure. The solid lubricant used has very low co-efficient of friction, less than 0.1� and is suitable for high operating temperature, 600�C. Rollon Bearings Pvt Ltd, Bengaluru 560 052. Tel: 080-2226 6928, Fax: 080-2225 0319 Email: firstname.lastname@example.org, Website: www.rollonbearings.com package-type PLC. Three types of CPU units are available to meet applications requiring advanced functionality. Sysmac CP1L is a standard package-type PLC. Complete with a standard-feature USB port, CP1L CPU units are available for applications with as few as 10 I/O points. Sysmac CJ series and Sysmac CS series are building-block PLCs with no backplane and backplane construction respectively. Sysmac CP series is a package PLC that include CP1H & CP1L. Creative Robotics Pvt Ltd, Ghaziabad 201 002. Tel: 0120-278 6473, Fax: 0120-278 6473 Email: email@example.com, Website: www.creative-group.co.in TEST RIGS A Hydraulics offers test rigs for testing hydraulic motors. Well-serviced hydraulic motors can be tested for leakage, RPM, response time and torque generated. These units consist of three parts, namely hydraulic system, electrical console and test stand. The motor to be tested is fixed on the test stand and loaded by a master motor through a torque sensor. All parameters to be checked are displayed on the console. The units are equipped with PLC with MMI and are fully programmable. T PROGRAMMABLE LOGIC CONTROLLERS reative Robotics offers programmable controllers (Sysmac CP1H/CP1L) with a wide lineup of CPU units with USB port on all models, manufactured by Omron Corporation, Japan. Some of the salient features include: allin-one package PLCs with condensed multifunctionality; a wide variety of built-in functions expand application; capabilities & shorten the design time required for the growing; and number & increasing complexity of ladder programs. Sysmac CP1H is the ultimate high-performance C TA Hydraulics Pvt Ltd, Hyderabad 500 037. Tel: 040-2308 7087, Fax: 040-2308 6035 Email: firstname.lastname@example.org, Website: www.tahydraulics.com 226 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 GENERAL PRODUCTS ROTARY DRUM WASHERS A ccurate Trans Heat offers rotary drum washers that consist of drum washing without bag. These drum washers have front loading large door opening with strong door hinges and 180 degree opening makes front loading easier. The capacity available is 100 kgs fabric to 400 kgs/batch. Maximum operating pressure is up to 3.5 kgs per sqcm. Maximum operating temperature is 140�C. Even heating throughout the process is controlled by microprocessor (programmable). Auto temperature control for steam and water is done by electrically operated solenoid valves. The drum rotation is synchronised in forward and reverse direction. Additional inspection and sight glasses are provided to view the internal process. Safeties like valve and pressure switches are also provided. Precise and exacting controls over heat and liquor ratios make the equipment of exceptional choice. Excellent & standard workmanship with SS quality; and AC/DC variable drive (optional) are some other features. Accurate Trans Heat Pvt Ltd, Surat 394 230. Tel: 0261-2397268, Fax: 0261-2397956, Mob: 09825118659 Email: email@example.com, Website: www.accurateindia.com THERMOCOUPLE CABLES ritish Electricals offers ISOMIL-T mineral insulated thermocouple cables. The thermoelectric voltages of the thermocouples are in accordance with the basic standard values within the usual tolerance range. For NiCr-Ni the basic values B D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 229 GENERAL PRODUCTS of the thermoelectric voltage are identical in the German and international standards. For both Fe-CuNi (thermoironthermoconstantan) and Cu-CuNi (thermocopperthermoconstantan) they differ. These thermocouples are available in ISOMIL-T in accordance with the German standard norm DIN 43710 and with the International thermoelectric voltage series (IEC 584). The limit deviation of the thermocouple voltage is available according the following norm: DIN IEC 584-2; and ASTM E 230-93/ANSI.MC.96.1. British Electricals, Mumbai 400 064. Tel: 022-2880 8335, Fax: 022-2888 5192, Mob: 09324408336 Email: firstname.lastname@example.org, Website: www.britishelectricals.com its related current capacity, even at the highest power level. Salient features include: highly efficient current fed parallel resonance converter design; power factor > .96; low power consumption; and can be operated with captive power generators. Stead Fast Engineers Pvt Ltd, Faridabad 121 002. Tel: 0129-4190500, Fax: 0129-4042339, Mob: 09350237208 Email: email@example.com, Website: www.stefengradmaticindia.com LIQUID RING VACUUM PUMPS A INDUCTION FURNACE PANELS tead Fast Engineers offers medium frequency induction furnace panels. A comprehensive range of solid-state power supply for coreless medium frequency induction furnaces that is fabricated using high quality components, like DC choke, transformers, current transformer, thyristor-chillers PCB, bus bars and complete crucibles are available. These are designed at par with Indian and international quality standards. In these systems, single control card replaces elaborate multi-control cards and wiring that provides long-term reliability and easy maintenance. The range of products also consists of a diagnostic problem-solving indicator, which alerts the operator regarding system problem. This can work at approximately half of S cmevac Sales offers liquid ring vacuum pumps that find applications in vacuum distillation, drying, concentration, degassing, crystallisation, gas evacuation, gas conveying & compression, etc; in chemicals, drugs, food, beverage, sugar, fertilizer, paper, metallurgy and allied process industries. These pumps are available in both single and double stages with capacities ranging from 10 CFM to 4000 CFM and ultimate vacuum up to 720 mm Hg. They are sophistically designed and are silent in operation with the result that the silencer is totally eliminated. Mechanical shaft seals design ensures adequate protection to the expensive shaft and provides for ease-ofmaintenance. This leads to minimal time required for servicing, thereby cutting downtime to the barest minimum. These liquid ring vacuum pumps are rugged in design, reliable in performance and easy to maintain. Acmevac Sales Pvt Ltd, Mumbai 400 099. Tel: 022-2837 5837, Fax: 022-2836 4977, Mob: 09223388105 Email: firstname.lastname@example.org, Website: www.acmevac.com 230 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 GENERAL PRODUCTS STEPPING MOTORS E ssence Engineering offers stepping motors that are used to achieve precise positioning, via digital control. These motors operate by accurately synchronising with the pulse signal output from the controller to the driver. The stepping motors, with their ability to produce high torque at low speed while minimising vibration, are ideal for applications requiring quick positioning over a short distance. Also available are closed loop stepping motors & driver package, 5phase stepping motors & driver package, 2-phase stepping motors & driver package with AC input/DC input; and 2-phase stepping motors/5-phase stepping motors with controllers. Essence Engineering, Hyderabad 500 047. Fax: 040-2705 1259, Mob: 09866964469 Email: email@example.com Website: www.essenceengineering.com AUTOMAT LATHES A rrow Machine Tools offers a comprehensive range of single spindle automat lathes (model AM-25) that are extremely efficient when it comes to easeof-operation and smooth error-free turning applications. This range of automats is featured with strong holding force and reduced chucking time. These machines are great for special turning applications. The versatile range D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 233 GENERAL PRODUCTS of Arrow 25 machines is perfect for manufacturing single spindle automat, which have great scope for use in a host of applications in diverse industries. The raw materials used for manufacturing round, square, and hexagonal shape of components are proven quality ferrous and non-ferrous materials, which are the best that is available in the industry (claims the company). The automat lathe machines are fitted with pats, such as cabinet, spindle, guide shafts, slides, etc. Arrow Machine Tools, Chennai 600 053. Tel: 044-2658 2694, Fax: 044-2658 6524, Mob: 09840236534 Email: firstname.lastname@example.org, Website: www.arrowmachinetool.com range of materials from soft plastics to hardened steel, up to Rc60 and a maximum dot density up to 200 DPI. Forbes & Co Ltd, Mumbai 400 072. Tel: 022-2847 1861, Fax: 022-2857 5899 Email: email@example.com, Website: www.bradma.com AIR WASHER UNITS A PIN MARKING SYSTEMS F orbes & Co offers fully-programmable PinStamp single & multiple pin marking systems (model TMP-3200/TMC-420) that are based on Telesis' original patented floating pin technology. Telesis manufactures over 10 versatile PinStamp models, which include portable single pin and multiple pins. These systems are cost-effective in a wide range of standalone or online manufacturing situations. The machines are customised to provide integrated solutions whether it is a fully automated online application or a standalone manual workstation. Models TMP-3200/TMC-420 are rugged PinStamp marking systems featuring a compact 4" x 6" marking window and shutter assembly that protects marking head from solid & liquid contaminates in factory environment. With marking speeds up to six characters per second the machine is capable of marking a wide arco Engineering Projects offers double skin air washer units that are the latest and most advanced factory assembled units. These units come with unit evaporative coolers, comprising inlet louvers, filter section humidification media water distribution systems, pumps, centrifugal fans, motors, SS water tanks, double skin body, etc. Air is allowed to pass through the humidification media at the same time water is added at the top through distributor. Water then gets distributed over the contact surface of the pad by means of special angle flute arrangement. The water gets evaporated when it comes in contact with air. It withdraws the sensible heat of air as the heat of evaporation. The air washer units are available from 5000 CMH to 250,000 CMH and temperature drop with respective atmosphere is 8�C to 10�C. Types of air washers available are cellulose matrix, single spray and double spray unitary. Aarco Engineering Projects Pvt Ltd , Pune 412 114. Tel: 020-2744 3281, Fax: 020-2744 3282, Mob: 09823037806 Email: firstname.lastname@example.org, Website: www.aarcoair.com 234 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 GENERAL PRODUCTS HYDRAULIC FLOOR CRANES V anjax Sales manufactures and offers hydraulic floor cranes that are manually towable cranes avialable in light and heavy-duty versions. These floor cranes have all-steel fabricated frames and come in standard capacities ranging from 1000 kgs up to 2000 kgs. They can also be tailor-made to suit individual customers' requirements up to 5000 kgs. The hydraulic floor cranes are highly suited for automobile garages and toolrooms. These are portable and capable of versatile uses in almost all industrial establishments, small, medium or large. Vanjax Sales Pvt Ltd, Chennai 600 098. Tel: 044-4282 1000, Fax: 044-4598 5700, Mob: 09789976611 Email: email@example.com, Website: www.vanjax.in DIGITAL TORQUE ANALYSERS ummit Engineering Technology offers digital torque analysers for joint analysis manufactured by Crane Electronics Ltd, UK. These torque analysers are used extensively for monitoring joint conditions. The systems consist of TorqueStar OptaTorque indicator and data collector used in conjunction with inline rotary torque transducers with/ without angle measurement option. Transducer can be attached to auto shutoff tools, power, pneumatic and S D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 237 GENERAL PRODUCTS battery-operated, pulse tools and torque wrenches while the joint is being tightened. The systems then download data and the following graphs will be available depending on the type of transducer used. Torque v/s time; torque v/s angle (available only with rotary torque transducer with angle); angle v/s time (available only with rotary angle transducer with angle); and RPM v/s time. The systems are supported with advance storage and SPC modules. Detailed statistical analysis is also available in the form of average, range, standard deviation, Cp, Cpk, Cm, Cmk, etc. Summit Engineering Technology Pvt Ltd, Navi Mumbai 400 708. Tel: 022-2764 2776, Fax: 022-2760 0819, Mob: 9821150858 Email: firstname.lastname@example.org, Website: www.summitengg.com AUTOMOTIVE FORGED COMPONENTS ava Forge manufactures and offers automotive forged components and have facilities and arrangements of forge shop, die shop, machine shop, heat-treatment unit, shot blasting unit, testing laboratory and computerised management. Development and manufacturing of automotive forged components as per drawing, specification and sample of customers and material of MS, SS, EN, brass or aluminium in Indian or international standards are undertaken. Automotive forged components like rocker arms, spindles, connecting rods, cross rods, tie rods, ball joints, rack ends, gear blanks, pitman arms, lower arms, lay shafts, drive shafts, propeller shafts, intermediate shafts, crown wheels, pinions, axle gears, gears, levers, housings, bearing bushes, hubs, caps, forks, spiders, UJ cross, yoke, chock body, spider arms, etc, are manufactured. Such forged components have applications in automobile engines, viz, HCV, MCV, ICV, SUV; off roads engines, viz, excavators, dozers, road rollers, loaders, tractors, bus, trucks, rail road, marine engine and defence vehicle parts, two-wheeler, three-wheeler and four-wheeler vehicles. L Lava Forge Pvt Ltd, Dist Rajkot 360 002. Tel: 02827-253670, Fax: 02827-253770 Email: email@example.com, Website: www.lavaforgepvtltd.com VERTICAL TURNING LATHES osmos Impex (India) offers VTL series vertical turning lathes (model VTL-2000) that are designed especially for high precision, high rigidity, high stability, under super heavy cutting conditions including non-symmetric workpieces. The outstanding rigidity of the structure and design provides mechanical features for super heavy cutting, which achieves maximum machining accuracy and stability. Fanuc spindle motor, high torque and high horse power spindle motor, incorporating a German ZF dual speed gearbox provide high torque and high turning speed allowing the machine to develop and extend its cutting ability to cover all applications of turning operations. Cross roller bearings provide the strength to carry heavy axial and radial loads, thereby ensuring long life heavy cutting with very high precision, stability, low vibration and maximum support for the forces exerted on the main spindle. The heavy box section structure of the column provides maximum support for the sliding cross rail during heavy cutting conditions. C Cosmos Impex (India) Pvt Ltd, Vadodara 390 012. Tel: 0265-3927000, Fax: 0265-3927001, Mob: 09898074696 Email: firstname.lastname@example.org, Website: www.cosmos.in 238 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 GENERAL PRODUCTS TAPPING LUBRICANTS teel Plant Specialities offers non-corrosive, non-toxic and safe-to-handle coolants-cum-tapping lubricants (ESPON-TA) that are very useful in case of difficult to machine materials, like austenitic stainless steel, nickel base alloys and aluminium alloys. These tapping lubricants are designed primarily for improved tapping performance. They can also be used as additional coolants-cumlubricants in turning, milling, shaping, drilling or reaming where continuous cooling may or may not be provided. The tapping lubricants are very useful for manufacturers of machine tools, heavy machines, valves, pneumatic equipment, hydraulic systems, electrical fittings; and to every unit requiring machine tapping/hand tapping. Some of the benefits include: reduced tap breakages & the resultant savings in tap cost; reduced tap wear & improved tap life due to longer retention of sharpness & hardness; improved surface finish of the tapped areas; chips do not get accumulated in the threaded holes; and reduced cutting force & torque in tapping. S Steel Plant Specialities, Mumbai 400 088. Tel: 022-6797 8060, Fax: 022-2555 2459, Mob: 09820712387 Email: email@example.com, Website: www.esponcoating.com PERSONAL SAFETY EQUIPMENT afe-T Engineers manufactures and offers personal safety equipment that filters out noise, but not useful sound of process indicators, emergency instructions, etc; and serve users' S D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 241 GENERAL PRODUCTS Mr L. R. Katrat Managing Director - CEO Katlax Enterprises Pvt. Ltd. "We have been a regular advertiser of our products in leading publications such as SEARCH, Modern Machine Tools and Modern Plastics & Polymers of Infomedia 18 Ltd. We are associated with the publication house for more than 12 years and are utilising these magazines to promote our products aggressively and receiving good response." communication needs. Three concentric tapered flanges to reflect sound waves made of soft, pliable and sturdy synthetic rubbers are provided. They have smooth surface to comfort all day use. The bright colour permits high visibility and makes safety checks easier. The equipments are nontoxic, non-allergenic, reusable up to 6 months. They are easy to fit, wash and maintain; and are best suited to moderate noise environment. The personal safety equipments are suitable for many industries, traffic sound pollution, and factories where noise level is high. Main applications are in construction, wood processing, metal industry or place near engines and turbines, machinery noise, warning alarms, high winds, etc. The personal safety equipments are intended for use where sound quality is an important criterion in the risk assessment. Safe-T Engineers , Coimbatore 641 009. Tel: 0422-654 8728, Fax: 0422-437 7228, Mob: 9894232828 Email: firstname.lastname@example.org PROGRAMMABLE TIMERS J email@example.com Mr Samir Gandhi Executive Director Gandhi Automations Pvt. Ltd. "We are pleased to be associated with SEARCH Magazine for many years now, it has provided us a steady return on our advertising and has helped us to expand our business. One must advertise here to experience growth in one's business." aya Electronics offers low-cost high-performance 6-digit programmable timers that can be used to set the time range of hour, minute, second, milli-second using programmable key fitted with the front panel of the timers. This can be programmed for ondelay time, off-delay time using key mounted on the front panel. These timers work on 230 V, singlephase supply having relay output (SPDT) of 5 A @ 230 V range. The units are available in ABS plastic housings and come in sizes of 72 x 72 x 115 mm. Timers as per customer's specifications are also made available. These are generally used in all industries where timing is the main factor of working. Jaya Electronics, Chennai 600 099. Tel: 044-2371 5458, Fax: 044-2371 5458 Email: firstname.lastname@example.org PAPER CONE PLANTS K email@example.com U Sodalamuthu & Co manufactures and offers automatic paper cone plant for production of textile paper cones for yarn spinning. Sodaltech APC-10000 model is equipped with a unique patented gripper winding system to prevent slippage of cone patterns. The machine is versatile enough to produce cones of various tapers, viz 3 degrees 30', 4 degrees 20', 5 degrees 57' and 9 degrees 15' using kraft board, grey board and millboard reels with minimum changeover time. Programmable controllers facilitate setting up of the machine to desired speeds depending upon the quality of paper. An optional conveyor system is also offered to fully automate material handling to link the winding station to the electric dryer to save substantial labour cost. The plant includes automatic cone finishing machine which does the operations, like lubrication at nose end, bull nosing, base burnishing, velvet finishing, etc 242 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 GENERAL PRODUCTS automatically. The plant is ideal to produce high quality cones with superb consistency in dimensions to meet the demanding standards for usage in auto corners of famous makes. K U Sodalamuthu & Co Pvt Ltd, Coimbatore 641 043. Tel: 0422-244 1223, Fax: 0422-2431279 Email: firstname.lastname@example.org, Website: www.sodaltech.com PORTABLE BALANCERS A BARRICADE & WARNING TAPES afe-T Engineers offers barricade tapes and warning tapes that are used to prevent accidents. These tapes are tied to two ends as a precaution to warn a danger ahead, either a fall or a damaged road. Certain danger messages, like stop caution, stop danger, skull mark, etc, are printed in red ink on a white LD plastic tape. The width of the tapes is three inches and the thickness varies as per requirement. These barricade tapes are available with company's logo and symbol and in various languages for an order of 100 kgs and above. The barricade and warning tapes find applications in construction sites, industries, road safety, factories, farm house, agriculture, mining, defence, project works, apartments, large buildings, water works, ports and harbour, mills, airports, railway station works, etc. S ccurate Balancing Equipments offers portable balancers (model 1000D) that are compact instruments for in-situ balancing of rotors in the speed range of 500-6000 RPM. These balancers display the vibration level in velocity or displacement at the running speed and the stroboscope indicates the angle of the vibration. They are very popular amongst lower users and manufacturers. Results can vary with the rotor, but almost always enhances bearing life by lowering vibration levels drastically. Accurate Balancing Equipments, Mumbai 400 078. Tel: 022-2537 2504, Fax: 022-2536 5294, Mob: 09820027242 Email: email@example.com Website: www.accuratebalancing.com MICRO LEAK TESTERS K Safe-T Engineers , Coimbatore 641 009. Tel: 0422-654 8728, Fax: 0422-437 7228, Mob: 09894232828 Email: firstname.lastname@example.org alpak Instruments & Controls offers micro leak testers (model MELD-1000) that are used for accurate and fast detection of vacuum leak in the component. These leak testers operate on the principle that any vacuum charged component, if leaky will exhibit vacuum drop with reference to time. The vacuum drop in test part is sensed by precision vacuum transducer and compared with preset permissible value, to provide GO-NO GO sorting with audio-visual indication. These vacuum leak testers D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 243 GENERAL PRODUCTS are quicker and more repeatable than traditional water dunking (claims the company). They are easy-to-operate, yet feature rich to meet any complex vacuum leak testing requirements. Features & beneifts include: fully programmable test pressure limits, allowable leak rate, test cycle times to suit individual application; short testing time; low investment and running cost; sufficient accuracy; and user-friendly & fully automatic machine with/without pneumatic/hydraulic fixtures can be provided. Kalpak Instruments & Controls, Pune 411 051. Tel: 020-2434 6802, Fax: 020-2434 6363, Mob: 09890303292 Email: email@example.com, Website: www.kalpakpune.com AXIAL PISTON PUMPS ariable displacement axial piston pumps offered by S M Shah & Company are available in displacements of 28 to 140 cc with nominal pressure of 280 bar and peak pressure of 350 bars with different types of pressure controls. Manifolds are connected with these pumps to control the flow from variable displacement pumps; as the actuators require varying flows and pressures. The pumps are used in hydraulic drives, which require variable flow and pressure as the pumps only supply the actual amount of oil required. Features include: swashplate design for hydraulic open circuit systems; flow, proportional to drive speed & displacement; can be infinitely varied by adjustment of swashplate; ISO mounting flange; flange connections to SAE metric; good suction characteristics with 2 case drain ports; nominal pressure of 280 bar & peak pressure of 350 bars; low noise level & long service life; axial & radial loading of drive shaft possible; high power weight ratio & wide range of controls; and through drive option for multi-circuit system & short response times. V TEMPERATURE INDICATORS & CONTROLLERS N ew Concepts & Systems offers a full range of proportional temperature indicators and controllers in analogue and digital versions for precise measurement and control of temperature for chemical, petrochemical or any process industries. These indicators and controllers are available in different types of enclosures, like DIN standard or compact portable types for mounting on any control panels. They can be offered in any range between 0-100�C to 0-1200�C in RTDs or thermocouple sensors, depending on the application. Most of the indicators and controllers have standard features, like direct reading of temperatures in degree centigrade; sensor break indication; auto manual indication; room temperature compensation; plug in arrangement for easy serviceability; compact DIN standard size; accuracy of �1 per cent; and low-cost, compact with solid-state technology. Also offered are temperature scanners and data loggers with 8/16 or more channels. Input can be thermocouple/ RTD/4-20 mA/0-10 V DC, etc. S M Shah & Company, Mumbai 400 034 . Tel: 022-2352 0108, 2353 0391, Fax: 022-2352 0108 Mob: 9821423821, UpenShah 9328203580 Email: firstname.lastname@example.org, Website: www.hydraulicvanepump.com THREE-PHASE CALIBRATORS M New Concepts & Systems, Mumbai 400 077. Tel: 022-2510 5344, Fax: 022-2511 8057, Mob: 09324787327 Email: email@example.com, Website: www.newconsys.com METERING PUMPS & DOSING SYSTEMS P ositive Metering Pumps manufactures and offers skidmounted chemical dosing systems that can be conveniently used in petrochemical, chemical, oil and gas, paper industries. It is a package for dosing of chemicals, designed and manufactured for space and weight saving. Plunger or diaphragm type metering pumps form the heart of the chemical dosing systems. The metering pumps are designed to API675. A wide range of plunger and diaphragm pumps are manufactured with capacities ranging from 0.7 LPH to 10000 LPH and pressures up to 400 bar. The wetted parts in the systems and pumps are compatible to the chemicals being handled. eco Instruments offers three-phase calibrators (3i-74T) of sinusoidal current and voltage. These calibrators are equipped with an RS232C serial communication interface to facilitate simple and reliable connection to a remote personal computer. The are used for calibration of meters of AC V, A, W, Var, frequency, PF, phase angle & energy; and for calibration of transducers of voltage, current, active & reactive power, frequency, power factor, phase angle & energy. Output power rating is 16 V A per output and per phase. Stability is better than 0.1 per cent per year. Power accuracy is 0.2 per cent FS. Other features include: galvanic insulation between outputs, internal circuits, remote interface; current output circuits breakable under load; and application software supplied with the equipment. Meco Instruments Pvt Ltd, Navi Mumbai 400 710. Tel: 022-2767 3311-16, Fax: 022-2767 3310/30 Email: firstname.lastname@example.org, Website: www.mecoinst.com TUNGSTEN CARBIDE ROD BLANKS lood tungsten carbide rod blanks manufactured by Robin Precision Products are available in comprehensive range of best quality in ground and unground form. These carbide rod blanks are also available in both metric and inch sizes with diameters ranging from �3 to � 25 mm (�1/8" to � 1"), imported from Europe. The blanks are highly precision ground and polished to H6/ H7 tolerance. Intermediate sizes are also available as per requirements. The tungsten carbide precisely ground rods are widely used for plug/ B Positive Metering Pumps (I) Pvt Ltd, Nashik 422 010. Tel: 0253-2381993, Fax: 0253-6601441, Mob: 09326781757 Email: email@example.com Website: www.positivemetering.com 244 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 GENERAL PRODUCTS pin gauges, carbide punches, precision V-blocks, jigs, etc. Cobalt composition in the tungsten carbide material tends to oxidise in the atmospheric air, which results into leeching. This is specially being taken care of in the rods, thereby offering worldclass quality. Robin Precision Products Pvt Ltd, Rajkot 360 003. Tel: 0281-2371722, Fax: 0281-2388431, Mob: 09825422431 Email: firstname.lastname@example.org, Website: www.bloodtools.com HYDRAULIC TRANSFORMER LIFTING TROLLEYS A gromec offers hydraulic transformer lifting trolleys (model AGTR-250) used for handling of transformers in standard capacities of 1, 1.5 and 2.5 tons. The lowered height of the trolleys is 70 mm so that the trolleys can be inserted under all types and models of transformers within seconds. These are ideal machines for lifting and transportation of transformers from one bay to another. No pallets are required in this model. One person can handle easily the transformer without fatigue and accidents, which help very much in production and transportation. Agromec, Meerut 250 103. Tel: 0121-244 0660, Fax: 0121-244 0770, Mob: 09837059058 Email: email@example.com, Website: www.agromecindia.net D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 245 GENERAL PRODUCTS AC GEARED MOTORS P anasonic FHP AC geared motors offered by Strategi Automation Solutions are available in a wide range from 6 W to 90 W. These geared motors come as standard induction, reversible, variable speed, three-phase and with electromagnetic brakes. They can be fitted with a variety of gear heads with ratios ranging from 1:3 to 1:200. Induction motors have 4 leads and can be configured for CW or CCW rotation and are suited for fixed speed continuous duty applications. Reversible motors are suitable for applications that require frequent instant change of direction. Variable speed motors come with a built-in tachogenerator and speed control is achieved using a simple Panasonic speed controller. The motors are very compact and due to the high efficiency of the helical in line gearboxes, produce a very high torque in a compact frame size. Strategi Automation Solutions Pvt Ltd, Bengaluru 560 048. Tel: 080-3248 9798, Fax: 080-4116 3047 Email: firstname.lastname@example.org Website: www.strategiautomation.com STATIC CHARGE METERS Z eebeetronics offers static charge meters that are non-contact, low-cost, static monitoring and locating instruments. These meters utilise a centre-zero meter display to indicate the magnitude and polarity of the electrostatic charge. They have good directional sensitivity and are ideal for measuring electric charges encountered in critical electronic assembly and storage areas as well as antistatic workstations. The static charge meters can also be used for plastics, paper, textiles, food, explosives and pharmaceutical industries. They give direct readings of electrostatic potentials on any surface, when held at a distance of 5 cm. Technical specifications include: indicating range of +5 kV FSD @ 5 cm from object; analogue meter display; accuracy of +10 per cent; test actuation slide switch; power supply of 9 V battery; dimensions 130 mm x 65 mm x 45 mm; weight at 275 gms; calibration recommended once every 12 months; traceability to national standards; warranty of one year; and accessories include carrying case. Zeebeetronics, Bengaluru 560 071. Tel: 080-2535 4206, Fax: 080-2535 1217 Email: email@example.com, Website: www.zeebeetronics.com AUTOMOBILE COMPONENTS CASTINGS M anek Investment Cast manufactures and offers automobile components castings by precision investment casting in any type of ferrous or non-ferrous metal as per customer's needs. Latest sophisticated and ultra modern infrastructure and machines, testing equipment, instruments and facilities to maintain quality assurance to a high precision degree of accuracy is required in process of precision investment castings. Investment castings for automobile parts can be done as per drawings, specifications, material details and samples provided by customers. The automobile components castings have applications in automotive 246 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 GENERAL PRODUCTS four-wheeler vehicles, earthmovers, trucks, tractors, bus, cars as well as three- and two-wheeler vehicles. Manek Investment Cast Pvt Ltd, Rajkot 360 002. Tel: 02827-252355, Fax: 02827-252117, Mob: 09824226454 Email: firstname.lastname@example.org MULTI-FUNCTION METERS ransfra systems offers multi-function meters (model COMBI420) for safety test verifications, power measurements, automatic tests and use of remote probe manufactured by HT Italia. These are innovative meters designed to perform all safety test verifications on electrical installations in compliance to recently standards (VDE0100, BS7671 and so on, measure and save results of environmental parameters, leakage currents and active power, harmonics, power factor measurements on single phase systems. They are very easy-to-use and have a wide number of internal features, which are selectable by using the multi-language menu. The instruments permit to start principal measures by using a special remote prove particularly useful to perform tests in very quickly mode and the auto internal function to perform sequential measurements of global earth resistance, test on RCDs and insulation directly on sockets of civil installations. The newest electronic function selectors give to the meters extreme rugged structure for perfect using on field. T TransEra Systems Pvt Ltd, Chennai 600 024. Tel: 044-2364 1294, Fax: 044-2364 3821 Email: email@example.com D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 247 GENERAL PRODUCTS INDUSTRIAL FILTER CENTRIFUGES mpetus Incorporated offers industrial filter centrifuges from Comi Condor spa, Italy. These centrifuges are used in chemical, pharmaceutical and food processing industries. The range includes inverting filter centrifuges, horizontal axis peeler centrifuges, inverting filter centrifuges, special centrifuges for operation in sterile environments and also vibrating screens for a wide range of applications. Some of the outstanding features include: robustness of mechanical components and their accurate assembly; finish which is particularly important in the pharma industry, meet GMP regulations; clean room installation is possible; automation & remove control of the working cycle; tailored innovative solutions for every client and process; and careful analysis of environmental health & safety issues. I take-up devices, single/double deck to suit the product; different sizes of machines with 8/12/16/24/36 even more carriers to suit the nature of the product and its end use; provision to vary the braided structure and to obtain homogenous braiding; power requirements depending on the number of carriers and the takeup devices; automatic oil lubrication system for the horn gears; mandrel-less as well as flexible and rigid mandrel type machines to choose from; noise level is lower than the standards due to design of doors and enclosures; and data monitoring system with PLC for monitoring production and scheduling maintenance. Penguin Engineers, Coimbatore 641 045. Tel: 0422-2315640, Fax: 0422-2315641 Email: firstname.lastname@example.org, Website: www.penguin.in Impetus Incorporated, Chennai 600 102. Tel: 044-2626 0946, Fax: 044-2626 9334 Email: email@example.com MEDIA PREPARATORS-CUM-AUTOCLAVES E HOSE BRAIDING MACHINES P enguin Engineers offers hose braiding machines that are indigenously designed and characterised by high productivity, simplicity and excellence in performance. The hoses manufactured by these machines are far superior to conventional hoses in strength, appearance and durability. Various features are: different models to use cotton/ nylon/rayon yarns or metallic wires; different models to choose from, like vertical/ horizontal braiding, capstan/caterpillar type quiclave media preparators-cum-autoclaves offered by Medica Instrument Manufacturing Company prepare liquid media agar 3~9 litres in #7415-09 & 12~27 litres in #7415-27. These autoclave/sterilise and cool the media to user-settable temperature within 60-110 minutes. Continuous stirring throughout the cycle assures proper mixing of media and uniformity. Separate large addition port is provided for adding nutrient/blood. The Equiclave controls actual media temperature, as temperature probe is kept immersed in media. Media sterilisation temperature range is up to 122�C. Media dispense temperature ranges from 40~80�C. The Equiclave has removable/exchangeable media vessels and hence is easy to clean and enables back-to-back preparation of 248 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 GENERAL PRODUCTS different media. Inbuilt support pressure mechanism/system avoids over boiling of media during cooling phase. Applications are in pharma & biotech industries, food research & quality assurance labs, agriculture research & quality assurance lab, health care & diagnostic labs, veterinary diagnostic labs, universities, etc. Medica Instrument Manufacturing Co, Mumbai 400 013. Tel: 022-6618 9999, Fax: 022-6618 9996 Email: firstname.lastname@example.org, Website: www.medicainstrumet.com ROTARY VANE VACUUM PUMPS andsky Engineers manufactures and offers UVD rotary vane vacuum pumps of small-to-medium capacity that are designed for a wide range of applications requiring punctual vacuum. While the UVL series is lubricated, the dry UVD series provide absolute air purity. Main features include: air-cooling by motor fan; limited overall dimensions & weight, ideal for applications in small spaces; reduced power consumption compared to liquid ring pumps with same nominal capacity; very low noise level; motor-pump connection ensured by a drive coupling; R A models available in case of suction of water condensate; low maintenance, fits onboard of several process units; and easy-to-handle. L Landsky Engineers Pvt Ltd, Hyderabad 500 026. Tel: 040-2770 1449, Fax: 040-2771 7849 Email: email@example.com, Website: www.landskyindia.com D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 255 INTERNATIONAL PRODUCTS PERMANENT SIGHT GLASS MAGNETS E riez Magnetics is pleased to introduce its first magnet designed exclusively for the plastics industry, the new super strength rare earth permanent sight glass magnets. These powerful magnets remove tramp metal contamination from plastic resin and pellets as it passes through a site glass loader on its way to a moulding machine. The rare earth magnet circuit utilises the strongest magnet material available to remove more fine iron contamination and reduce product wash-off. These advanced magnets feature continuously welded construction, and four sizes are available to fit most site glass loaders. Customers can choose between two different magnet diameters, 1-inch or 5/8-inch (25.4 mm or 15.9 mm). The new permanent sight glass magnets are stronger, less expensive and match (dimensionally) the current industry standard (claims the company). needs, the instruments are available with AC or DC power and in panel, remote or blind DIN rail mounting packaging configurations. Installations are simplified with no special tools required to cut rectangular holes. The included template is just used to drill standard holes and install. The weight controllers include a standard Ethernet 10/100 Base-T with an embedded web server and an RS 232 printer or scoreboard display port. Optional network communications over Ethernet/IP or DeviceNet are also available. The weight controllers include the company's core technologies. Hardy Instruments, Inc Tel: +1-800-8215831, Fax: +1-858-2786700 Email: firstname.lastname@example.org, Website: www.hardyinst.com CONTROL SYSTEMS riangle Microsystems offers BASYX control systems that are specifically designed to provide accurate control of HVAC equipment and lighting systems for owners of convenience stores and gas stations. These systems can control time of day scheduling, temperature and humidity control for HVAC systems as well as monitoring electrical usage and demand. Programmable lighting outputs control interior and exterior lighting. The remote access feature connects, via modem or the Internet to provide access to all historical data and programming features. The control systems are designed for smaller convenience store facility but can be expanded with the addition of multiple panels to control stores of any size. The BASYX CW systems are designed for free standing car wash systems, controls, fans, and heating stages to maintain proper temperatures and automatically adjust bay setpoints based on outdoor temperatures. T Eriez Magnetics, USA Tel: +1-814-8356000, Fax: +1-814-8384960 Email: email@example.com, Website: www.eriez.com MOTION CONTROL SYSTEMS chneider Electric Motion offers the revolutionary new AccuStep motion control technology that, when applied to step motors, prevents the loss of synchronisation due to transient or continued overload, extreme acceleration or deceleration, or excessive slew speed. One version includes integrated step motor, microstepping driver, and internal encoder, while another version adds fully-programmable motion controller. Applications include point-to-point positioning, conveyor control, web handling, rotary & linear positioning to torque specification, and low end camming. The MDrive AccuStep systems offer clear advantages in a low cost package for a wide range of motion control application such as: point-to-point positioning, conveyor control, web handling, drilling, rotary and linear positioning to torque specification, and low end camming. With the addition of torque control, rotary and linear positioning to torque specifications are now possible. And, by enabling variable current control, motor heating and energy consumption can be greatly reduced. S Triangle Microsystems, Inc Tel: +1-800-3345548, Fax: +1-919-8722071 Email: firstname.lastname@example.org Website: www.trianglemicrosystems.net INSULATION BLANKETS F Schneider Electric Motion USA Tel: +1-860-2956102, Fax: +1-860-2956107 Email: email@example.com, Website: www.imshome.com irwin Corporation offers an extensive range of insulation solutions for engines. The insulation products are installed on manifolds, turbo chargers, exhaust piping, silencers, and purifiers. Also offered are industrial sound insulation solutions in partnership with industryleading engine manufacturers and consultants. These are custom-designed, using the latest technology and quality materials, providing exceptional heat and noise control at temperatures up to 2000�F (1100�C). Practical, quality solutions according to users' specific requirements are also offered. WEIGHT CONTROLLERS H ardy Instruments offers a new line of weight controllers with Ethernet/IP and DeviceNet communications. Only three inches deep, the HI4050 general-purpose weight controllers are used in tank farms, batching/blending, filling/ dispensing, check weighing, level by weight, and force measurement applications. To meet users' specific installation SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 Firwin Corporation, Canada Tel: +1-416-7459389, Fax: +1-416-7450782 Email: firstname.lastname@example.org, Website: www.firwin.com MULTI-MATERIAL CUTTERS E raser's model MMC200 multi-material cutters offer users the widest range of industrial cutting applications available today. These units can process round or flat material up to 3.94 inches wide and 5/8 inches thick (100 mm wide & 16 mm thick). Boasting a maximum cutting force of 600 pounds, the units can cut a virtually limitless range of materials, including copper wire and cable, silver solder, power cords, cellophane, fibreglass 256 INTERNATIONAL PRODUCTS sleeving, latex, fabrics, belting, flat and ribbon cable, strapping, hosing and tubing. For many materials, the units are capable of cutting multiple pieces of the same material in one cut, increasing operator efficiency by allowing higher production runs in less time than other cutters. The microprocessor-controlled cutters can be easily programmed to cut any length (in inches or millimeters), with a 1 per cent or better tolerance reliant on material construction. The Eraser Company, Inc, USA Tel: +1-315-4543237, Fax: +1-315-4543090 Email: email@example.com, Website: www.eraser.com GREASE LUBRICATORS hanghua Chen Ying offers CLHP grease manual lubricators and KSC electric grease lubricators for plastic extrusion machines, press and woodworking machines. These lubricators are easy to operate by hand and can be easily installed. Capacity ranges 300 cc, 600 cc, 800 cc, 1,000 cc, and 2,000 cc. A level switch can be added on request. Also offered C D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 257 INTERNATIONAL PRODUCTS are various types of lubricators, viz, oil systems, fluid grease system, distributors, oil pumps, motors, accessories and fittings. All products have been tested and verified by T�V and have CE of machinery safety directive certificate. Changhua Chen Ying Oil Machine Co Ltd, Taiwan Tel: +886-4-2639 3751, Fax: +886-4-2639 3539 Email: firstname.lastname@example.org, Website: www.chenying.com.tw HOT-AIR WELDING GUNS L CONCERT HOISTS ehind the scenes of many concert and stage productions is a network of highly advanced lifting and rigging systems, lifting performers, stage sets and complex lighting and sound systems. Lifting operations have to be executed far more precisely and speedily than in the industrial environment. Black Bear and U-Mega brands of Cheng Day Machinery Works Co create concert hoist to fulfill markets' demands. Features of the concert hoists include: particularly designed & equipped for inverted or normal positions; applying high strength load chain & hooks; meet FEM 2m / ISO M5 level; motor is with good cooling operation; brake automatically engages in the event of a power failure; long life asbestos free brake material; a slip clutch prevents the damage due to overloading; magnetic contactor is high-performance non-fuse circuit breakers; electromagnetic brake will brake synchronously while the power off & ensure the definite safety while loading; and with electrical limit switch & mechanical overload as safety devices. B eister Process Technologies manufactures and offers hotair plastic welding guns (model Leister-1P4) that gives hot air through the nozzles, which is directed to the plastic parts to be welded together. The hot air stream can be adjusted, as finely as necessary for welding of various thicknesses of plastic materials. Temperature is electronically stepless controlled from 20�C to 600�C and hot air flow is adjustable from three to 300 LPM. Other features include: increased carbon brush life of the motors, carbon brushes are easy to change, etc. Under certain conditions it is possible to build the tool into machines and appliances. Low noise level of only 59 db makes the tools pleasant to work with. Typical applications are bending, shrinking, welding of plastics and thermoplastic materials; polymerisation in glassfibres, hot-air welding for roofing membranes made of PVC, ECB, EPDM, CSPE, etc; butt-welding of polyethylene/PVC pipes, tape welding, to make waterproof PVC or polyethylene tarpaulins and covers of any size, etc. Leister Process Technologies, Switzerland Tel: +41-41-6627474, Fax: +41-41-6602061 Email: email@example.com, Website: www.leister.com AUTOMATIC EXTRUSION APPLICATORS he Electromatic X and XV automatic extrusion applicator head series is suitable to extrude hot or cold adhesives, marking fluids, perfumes, silicones, and similar materials, requiring small repetitive amounts to be accurately applied at high rates of speed. It utilises extrusion tips to provide a variety of patterns including dots, lines, multiple lines, etc. Extrusion applications can utilise either a pressure tank or pumping system depending upon material used, viscosity, etc. The Electromatic X and XV guns incorporate a modular concept, which allows the user to remove the entire fluid section, which contains the gun's one moving part, as a unit. Which results in easier maintenance and less down time. Various models are available with difference being in seat orifice size and operating voltage of coil. T Cheng Day Machinery Works Co, Ltd, Taiwan Tel: +886-4-26881581, Fax: +886-4-26881509 Email: firstname.lastname@example.org, Website: www.chengday.com.tw POWER QUALITY ANALYSERS H T Italia manufactures power quality analysers (models PQA823 & PQA824), completely designed in Windows CE technology and permit an easy and wide fast analysis of a huge quantity of data any other system. The interface is incredible user-friendly due to the intuitive icon selection of any kind of feature and a contextual help is available for each screen. Each internal parameter is easy to reach for effect of typical Windows tree structure. Each model permits the visualisation of all parameters both in numeric and graphical mode with large use of waveforms and histograms screens. The vectorial diagram feature permits also to evaluate the mutual phase angle between voltages and current in order to understand the nature inductive or capacitive of the loads on an installation. The PQA82x meters are powered by an internal rechargeable Li-Ion battery, which permits complete operation for more than 3 hours and are external supplied by using a 100/240V AC adaptor. Spraymation Inc, USA Tel: +1-954-4849700, Fax: +1-954-4849778 Email: email@example.com Website: www.spraymation.com SOLID PLASTIC PORTABLE GAUGES D HT Italia srl, Italy Tel: +39-546-621002, Fax: +39-546-621144 Email: firstname.lastname@example.org Website: www.htitalia.com urablock solid plastic portable gauges manufactured by Dwyer Instruments are precision instruments in inclined and vertical styles for measurement of static pressure, vacuum or differential pressure. To assure the accuracy required in instruments of this type, all machining of bores and wells is to the highest standard of precision. Standard accessories include plastic or steel carrying case, two magnetic mounting clips, two rapid shut-off nylon tubing connections, one 9' length rubber tubing, terminal tune and extra bottle. The solid plastic portable gauges are suitable for total pressures up to 100 PSIG, temperatures up to 150�F, accuracy �2 per cent of full scale. 258 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 INTERNATIONAL PRODUCTS Dwyer Instruments Inc, USA Tel: +1-219-8798000, Fax: +1-219-8729057 Email: email@example.com, Website: www.dwyer-inst.com REFRIGERATION GAS COOLING UNITS ankison International manufactures and offers the GCU series non-cycling refrigerated gas cooling units that are key components for processes requiring gas cooling by offering the right combination of technology and simplicity. These cooling units are built with quality components and equipped for 50 to 330 scfm (85 to 561 nm3/ h) operations. The GCU system incorporates compact heat exchanger technology, integral filtration, and energy management monitor (EMM) support. Temperature sensitive applications, such as surface cooling of glass moulds and hot metal parts benefit from a stable supply of cool, clean process air. Blow-off operations gain efficiency by removing excess oils, dust and liquids. The GCU refrigeration gas cooling units guarantee service support when needed and the clean, cool air required for users processes (claims the company). H Hankison International, USA Tel: +1-724-7451555, Fax: +1-724-7456040 Website: www.hankisonintl.com D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 259 INTERNATIONAL PRODUCTS MOTION CONTROL CARDS P erformance Motion Devices offers motion control cards that provide multi-axis motion control (1, 2, 3 & 4) at the board level for brushed servo, brushless servo, microstepping and stepping motors. Navigator PC/104 motion control cards are for servo or step motors and plug directly into a PC/104 connector. PC/104 cards are used in embedded systems for industrial control, automation and robotic applications. Available in 1, 2 & 4-axis configurations, these boards are designed for surface mounting and use PMD's Navigator chipset for DC brush, brushless DC or stepping motors. All PC/104 cards come equipped with Pro-Motion software, a Windows GUI, and C-Motion, an Application Programmer's Interface (API) comprised of a C-source code library for developing applications in DOS or Windows environments. Performance Motion Devices, Inc, USA Tel: +1-781-6749860, Fax: +1-781-6749861 Email: firstname.lastname@example.org, Website: www.pmdcorp.com PID PROCESS CONTROLLERS ashika Boeki Shokai KK, Japan offers SR 70B series PID process controllers that are low-cost auto-tune microprocessor-based controllers with expert PID control. These controllers have dual LED for measured values and set values respectively. They are provided with a key-lock function to avoid erroneous operation resulting from set value or parameter settings. The multi-input feature allows connection to various types of thermocouple, RTD, voltage or current sources with user-selectable ranges. High/low alarm is also available as a basic feature. These units are available in standard DIN panel output sizes and operate on free mains supply from 100 V AC to 240V AC. The controllers are produced as per ISO 9002 quality standards. Precise workmanship ensures a quality product with long-term reliability. T Tashika Boeki Shokai KK, Japan Tel: +81-78-2419035, Fax: +81-78-2422105 Email: email@example.com, Website: www.tashika.co.jp ELECTRIC TENSIONING PUMPS E nerpac offers electric tensioning pumps (series ZUTP) that are 2-stage pumps, which provide high flow at low pressure for fast system fills and controlled flow at high pressure for safe and accurate operation. The Z-class high-efficiency pumps design runs cooler and requires less current draw, which is especially helpful in remote locations. A 20-feet pendant cord enables motor control from a distance. Angled 6-inch pressure gauge, with polycarbonate cover is built into a protective metal shroud for improved visibility and protection. 260 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 INTERNATIONAL PRODUCTS Safety relief valve limits output pressure; and compact, lightweight, rugged aluminum frame for increased durability & ease of handling are some of the other features of the electric tensioning pumps. Enerpac BV, The Netherlands Tel: +31-318-535911, Fax: +31-318-525613 Email: firstname.lastname@example.org, Website: www.enerpac.com Haas Automation, Inc, USA Tel: +1-805-2781800, Fax: +1-805-9886918 Email: email@example.com, Website: www.haascnc.com SOLDERING IRONS H CNC MILLING MACHINES H aas Automation, Inc offers CNC milling machines (model OM-1) that are ultra-compact milling machines designed for office environment. These milling machines bring highperformance and reliability to industries that are unable to fit a normal CNC machines into their facility. Designed for high-production or rapid prototyping of small, precision 2D or 3D parts, the machines fit through a standard 36" door and into most freight elevators. Features include: full enclosure; 50,000 RPM electric spindle; high-speed machining software; coolant system; 4th axis drive; 25 mm precision ball screws; �" collet maximum capacity; 757 IPM rapids; and quick disconnect cord. Some of the technical specifications are travels of 8" (X) x 8" (Y) x 8" (Z); table size of 20" x 10"; T-slots 3 @ 3.375" centres; and machine weight 1,500 lb. akko Corporation manufactures and offers soldering irons (Hakko DASH) that are compact, and lightweight in design with a slender handle for a more comfortable grip. The rod-type ceramic heater brings high insulation, and reduces the handle-to-tip distance for faster soldering with a minimum of movement. Special alloy heating element is printed in the alumina ceramic insulating layer and then sintered to the ceramic main body, thus completely sealing the heating element off from air. This protects the heating element from oxidation, and ensures years of trouble-free use. Hakko Corporation, Japan Tel: +81-6-65613225, Fax: +81-6-65618466 Email: firstname.lastname@example.org, Website: www.hakko.com The information published in this section is as per the details furnished by the respective manufacturer/distributor. In any case, it does not represent the views of SEARCH D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 263 INTERNATIONAL PRODUCTS Safety relief valve limits output pressure; and compact, lightweight, rugged aluminum frame for increased durability & ease of handling are some of the other features of the electric tensioning pumps. Enerpac BV, The Netherlands Tel: +31-318-535911, Fax: +31-318-525613 Email: email@example.com, Website: www.enerpac.com Haas Automation, Inc, USA Tel: +1-805-2781800, Fax: +1-805-9886918 Email: firstname.lastname@example.org, Website: www.haascnc.com SOLDERING IRONS H CNC MILLING MACHINES H aas Automation, Inc offers CNC milling machines (model OM-1) that are ultra-compact milling machines designed for office environment. These milling machines bring highperformance and reliability to industries that are unable to fit a normal CNC machines into their facility. Designed for high-production or rapid prototyping of small, precision 2D or 3D parts, the machines fit through a standard 36" door and into most freight elevators. Features include: full enclosure; 50,000 RPM electric spindle; high-speed machining software; coolant system; 4th axis drive; 25 mm precision ball screws; �" collet maximum capacity; 757 IPM rapids; and quick disconnect cord. Some of the technical specifications are travels of 8" (X) x 8" (Y) x 8" (Z); table size of 20" x 10"; T-slots 3 @ 3.375" centres; and machine weight 1,500 lb. akko Corporation manufactures and offers soldering irons (Hakko DASH) that are compact, and lightweight in design with a slender handle for a more comfortable grip. The rod-type ceramic heater brings high insulation, and reduces the handle-to-tip distance for faster soldering with a minimum of movement. Special alloy heating element is printed in the alumina ceramic insulating layer and then sintered to the ceramic main body, thus completely sealing the heating element off from air. This protects the heating element from oxidation, and ensures years of trouble-free use. Hakko Corporation, Japan Tel: +81-6-65613225, Fax: +81-6-65618466 Email: email@example.com, Website: www.hakko.com The information published in this section is as per the details furnished by the respective manufacturer/distributor. In any case, it does not represent the views of SEARCH D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 263 PRODUCT INDEX To know more about the products in this magazine, refer to our `Product Index' or write to us at firstname.lastname@example.org or call us at +91-22-3003 4684 or fax us at +91-22-3003 4499 and we will send your enquiries to the advertisers directly to help you source better. Product Pg No Product Pg No Product Pg No Abrasive blast rooms 107 Abrasive blasting machines 107 Abrasive feeding systems 218 Absolute pressure transducers 149 Absorption drying machines 15 AC drives 159 AC geared motors 229, 246 AC motors 65 AC/DC panels 164 Access control systems 200 Acoustic enclosures 129 Adapter sleeves 70 Adapters 255 Adhesives 157 Adsorption dryers 205 Agitator seals 88 AGVs 219 Air blasters 184 Air compressors 81, 163 Air plasma cutting machines 223 Air purifiers 269 205 Air receivers Air treatments 133 Air washer units 234 Air-cooled reciprocating compressors 81 Airless shot blasting machines 206 Airport passenger baggage trolleys 247 Alloy wheels 247 Alu-cera polymers 11, 17 Aluma coats 11, 17 Alumina adhesives 205 Aluminium extrusions 139 Aluminium high-precision components 226 Aluminium oxide ceramic composites 11, 17 Aluminium worm geared motors 124 Analogue timers inductive proximity sensors 149 Anti-vibration mountings 184 Arc welding machines 199 Arc welding robots 189 Area sensors 75, 192 69 Assembly technology Auto drains 110 Automat lathes 233 Automated guided vehicles 219 Automatic rolling shutters 25 Automatic torches 196 Automation & process controls 45, 55, 113, 127 Automation & security systems 239 Automation & storage systems 51 Automation solutions 229 Automation 12, 195, 263, 284 Automobile components castings 246 Automotive dealership excellence awards-2010 168 Automotive forged components 238 Axial piston pumps 244 Balancers Ball & roller bearings Ball bearing mounted units Ball bearings Ball transfer units Ball valves Balls Barricade & warning tapes Basket strainers Batteries & chargers Battery chargers Battery-operated pallet trucks Beam lights Bearings 57 10 210 181 247 203, 209 245 243 203 45, 55, 113, 127 197 178 111 10, 181, 227 Belt-type magnetic concentrators Bending machines Billet shearing machines Blasting media Blue torches Bollards Brake motors Brakes/clutches & combinations Brass cable glands Brass castor wheels Brass components Brass inserts Brass meter parts Brass parts Breather valves Brine chillers Bronze wheels Brushless DC motors Brushless motor controls Building automation Butt welding machines Butterfly valves 58 221 16 107 196 25 43, 65, 124, 167 217 226 247 226 226 226 226 203 225 247 22 22 284 97 209 Cable assemblies 217 Cable carriers 227 Cable clamps 177 Cable connectors 227 Cable glands 49, 177, 201, 226, 237 177 Cable markers Cable reeling drums 58 Cable ties 177 Cable tray fixing ties 202 Cables & leads for fixed instaction 51 Cables handling & processing systems 51 Cables scanps 51 Cables 43, 45, 47, 51, 55, 113, 127, 142 Calibrators 12 Capacitive proximity sensors 149 Capacitive sensors 191 Carbide tools 255 Carbides 255 Cast/extruded 207 Castor wheels 247 Castors 247 200 CCTV surveillance CED coating machines 284 Center drills 255 Centralised lubrication systems 222, 234 Centrifugal blowers 81 Centrifugal compressor package 81 Centrifugal finishing machines 209 Centrifugal pumps 41 Ceramic adhesive cement 11, 17 Ceramic electrical heater parts 11, 17 C-frame power presses 16 Chain pulley blocks 167 Chains 227 Chair castors 247 Channel magnets 209 Check valves 140, 203 Chemicals & adhesives 45, 55, 113, 127 Chemlok coating machines 284 Chillers 233 Chucks 255 Circuit protection 45, 55, 113, 127 Circular motion vibratory screens 58 Circular vibratory screens 58 Circular/gyrator vibro machines 209 Cistern type manometers 203 Clutch & brakes 22 CNC cutting machines 284 CNC laser cutting machines 284 CNC lathes 151 CNC machines Back inside cover CNC oxyfuel cutting machines 284 CNC plasma cutting machines 284 CNC profile cutting machines 199 CNC toolings 255 CNC turning centers Back inside cover CNC vertical machining centers 21, Back inside cover CNC Back inside cover Coating machines 284 Coating plants 284 Coating systems 284 Cold form C & Z purlins 60 Cold storage dock houses 25 Cold storage doors 25 Collet chucks 255 Collets 255 Combustible & toxic gas detectors 189 Command panel systems 123 Compressed air division 197, 247 Compressed air dryers 205 Compressed air filters & regulators Back gatefold Compressed air systems 52 Compressors 52, 81, 106, 163 Computer on modules 121 Concrete vibrators 58 Condensate drains 15 Conductors 257 Conference - Manufacturing Excellence 220 Connectors accessories 51 Connectors 8, 26, 45, 49, 55 113, 127, 149, 217, 227, 237 Console systems 123 Container cranes 115 Container side seam 97 Continuous level indicators 248 Control & automation 47 Control cables 142 Control dampers 197 Control valves 209 Controllers 263 Conventional pallet racking 255 Conventional precision lathes 151 Conveyor castor wheels 247 Conveyor trolleys 247 Conveyors & automation systems 25 Cooling tower motors 124 Cooling towers 133, 185 Cooling water treatment 283 Coromill 105 Corothread 105 Counters & power supplies 7 Counters rate product 12 Counters 149 Crab assemblies 243 Crab hoists 167 Crane kits 243 Crane-duty motors 43, 124, 167 Cranes 20, 103, 167, 243 Crimp contact & tools 51 Cross belt-inline magnetic separators 58 Crystals & oscillators 45, 55, 113, 127 Cushion dock shelters 25 Customised product 79 Custom-made cables 51 Cutting machines 284 Cutting products 199 Cylindrical taper & grooved pins 218 SOURCE AUTOMATION & INSTRUMENTATION PRODUCTS @ www.engg-expo.com 264 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 PRODUCT INDEX Product Pg No Product Pg No Product Pg No Data acquisition & controls 121 Data cables 51 DC & AC arc/argon welding machines 223 DC motors 65 DC stackers 241 Dehumidifiers 259 Delstar converter modules 248 Demagnetisers 189 Demand controllers 203 Desiccant dryers 81 DHL import express worldwide .coc Die lifts 241 Diesel engine driven welders 200 Differential pressure transducers 149 Diffused beam sensors 191 Digital almen gauge & almen strips 189 Digital indicators 149 Digital insulation testers 202 Digital mark sensors 75 Digital panel meters 199, 203, 230 Digital signages 121 Digital synergic controls 196 Digital temperature controllers 199 Digital torque analysers 237 Digital vibration meters 206 Dip spin coating machines 284 Disc breaks 225 Disc grinders 222 Discrete semiconductors 45, 55, 113, 127 Display solutions 121 Distribution boards 18 Dock levellers 25 241 Dock lifts 25 Dock shelters Door runners & tracks 247 Doors 25 58 Dosing feeders 243 Double girder EOT cranes Double scissor-lift tables 241 Double-drum/triple-drum magnetic separators 189 Drawer magnets 189, 209 Drill chuck arbours 255 Drill chucks 197, 247 Drill mills 255 Drills & center drills 79 Drills 57, 79 Drives 23, 189, 229 Drum trolleys 247, 255 Drum-type magnetic separators 58, 209 Dry vane pumps 129 Dryers 15 Dual head semi-automatic hot staking machines 97 Dust collectors 107 DVRs 200 Earth leakage relays 203 Edge preparation machines 172 Electric actuators 153 Electric controls 69 Electric dock levellers 255 Electric drives 69 Electric drum lifters 255 Electric forklift trucks 25 Electric hoists 103 Electric lifting platforms 255 Electric pallet trucks 255 Electric scissor lift tables 255 Electric stackers 255 Electric walkie stackers 255 Electric wire rope hoists20, 103, 167, 218, 241, 243 Electrical connectivity 257 Electrical measuring instruments 164 Electrical products cable ties 49, 237 Electrical systems 47 Electro magnetic bin vibrators 58 Electro magnetic ferro filters 58 Electro magnetic vibratory feeders 209 Electromagnetic disc brakes 225 Electronic barriers 200 Electronic connectors 199 Electronic drain valves 205 Electronic energy meters 203 Electronic timers 32, 34, 36, 38, 199 Electronics For You Expo-2011 236 Electronics products 49, 237 Embedded single-board computers 121 Emergency lighting system 111 EMI filters 202 Enclosure cooling units 123 Enclosure systems 123 Enclosures 45, 55, 113, 127 Encoders 7, 229 End carriage assemblies 243 End mills 79, 255 Energy management solutions 203 Energy meters 199 Energy-efficient motors 124 Energy-efficient pumps Front inside cover Energy-efficient solutions 160 Engineering plastic plugs & sockets 32, 34, 36, 38 Engineering plastics 207 EngineeringExpo exhibition 213, 275 Environment industry awards night-2010 228 EOT cranes 20, 103, 167, 241 Everdry 15 Everything About Water Expo-2011 232 Exhibitions 98, 131, 199, 213, 232 236, 240, 275 Expansion valves 204 Extended trolleys 243 Fabtec India-2011 119 Factory automation Front gatefold, 195, 284 Failsafe brakes 225 Fan & filter units 123 Fans 45, 55, 113, 127 184 Fastener tooling systems Fasteners & mechanical 45, 55, 113, 127 Fasteners 57, 226, 237 Ferrous & non-ferrous high precision parts 226 Fibre sensors 75 Fibreglass cable trays 209 Field plate sensors 192 Field plates 149 Filters 15, 205 Filtration systems 283 Filtration technology 15 Finishing machines 209 Fire shutters 25 Fixed mounting hoists 243 Flame arresters 203 Flameproof lights 111 Flameproof motors 65, 124 Flameproof products 12 Flange filters 205 Flange motors 43 Flange mounting motors 65 221 Flanging machines Flat cables 51 Flat igniting electrodes 11, 17 Flexible cables & wires 51 Floor cleaning machines 212 Floor scrubbers & dryers 277 Flooring 245 Flow control valves 140 Flow instruments 155 Flow rate indicators 12 Flow switches 203 Fluid properties sensors 175 Fluid property sensors 194 Fluid 193 Fluidised bed coating machines Flush bottom valves Flux generators Foot mounting motors Force actuation Forged parts Forging presses Forklift trucks Frequency meters Friction drop hammers Friction screw presses FRL spares valve spares Funnel magnets Furniture castor wheels Furniture castors 284 203 58 43 217 226 16 137 164 16 16 110 209 247 247 Gantry Cartesian robots 188 167, 243 Gantry cranes Gantry robots 189 Gap frame presses 257 209 Gas controls & regulators Gas trains 209 Gauge accessories 155 Gear motors 22, 124, 145, 167, 193, 241 Gearboxes 22, 145, 193, 241 Geared & flexible couplings 193 Gears 193 Glide coating machines 284 267 Global cam indexers Globe valves 203 Glue dispensing robots 188 Goliath cranes 103, 167 Grab buckets 103 Grill magnets 209 Grinding media 11, 17 Grinding 57 Ground rods 79 Guard monitoring systems 200 Haconan-free cables 51 Hall sensors 149 Halogen search lights 111 Hammers 16 Hand magnets 209 Handheld vibratory motors 58 Hannover-2010 131 Hard chrome plated bars 221 Harmonic filters 197 49, 237 Heat shrink tubings Heat shrinkable sleeves 96 Heat shrinkable tubes 96 Heat sinks & HVAC 45, 55, 113, 127 Heating elements 190 Heavy industrial steel buildings 60 Heavy-duty caster wheels 247 Heavy-duty casters 247 Heavy-duty CNC machines 229 Heavy-duty industrial casters 247 Heavy-duty machine tools 172 Heli-bevel geared motors 124 Helical gearboxes 241 Helical geared motors 20 Helical-worm gear units 22 Heli-worm geared motors 124 H-frame power presses 16 High-alumina wear-resistant ceramic tiles 11, 17 High-carbon chrome 245 High-carbon steel balls 245 High-efficiency standard motors 124 High-intensity induced roll magnetic separators 58 High-intensity rare earth magnetic separators 209 High-intensity roller type magnetic separators 209 High-precision roll shop machines 172 High-precision turned parts 226 High-pressure blowers 22 High-pressure cleaners 277 COMPLETE ENGINEERING UNDER ONE ROOF @ www.engg-expo.com D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 265 PRODUCT INDEX Product Pg No Product Pg No Product Pg No High-speed doors 25 High-tension igniting electrodes 11, 17 Hi-tech Manufacturing Show 98 HMI/SCADA software 205 HMM technical guidelines 124 HOC dryers 81 Hoists 103, 243 Hollow shaft worm gear motors 22 Home automation systems 200 Hooper magnets 189, 209 Horizontal CNC machines Back inside cover Horizontal machining centers Back inside cover Hose braiding machines 248 Hose clamps 194 Hot brazing machines 97 HRC fuse bodies 11, 17 HRC fuse fittings 199 HSS tools 79 Humidity & temperature sensors/indicators 149 Humidity & temperature transmitters 149 Humidity pressure & temperature indicators 149 Humidity sensors 175 Hump magnets 58, 189, 209 Hydraulic cylinders 194 Hydraulic dock levellers 25 Hydraulic dock shelters 25 Hydraulic drum lifters 255 Hydraulic equipment 241 Hydraulic floor cranes 237 Hydraulic hoses 10 Hydraulic lifts 241 Hydraulic manual pallet trucks 178 Hydraulic pallet trucks 255 Hydraulic power units 140 Hydraulic presses 140, 257 Hydraulic pressure testing machines 186 Hydraulic pumps 140 Hydraulic punching machines 221 Hydraulic scissor lifts 241 Hydraulic shearing machines 257 221 Hydraulic steel working machines Hydraulic transformer lifting trolleys 245 Hydraulic variable displacement pumps 225 Hydraulics cylinders 140 Hydraulics 69 IC counterbalanced forklifts 25 ICs 45, 55, 113, 127 Imaging & vision systems 284 Inclined tube manometers 203 Inclinometers 89 In-cylinder sensors 89 Indexers 267 Indexing machines 107 Indicators & controllers 12 Induction furnace panels 230 Induction pipe bending machines 172 Induction seals/wads 257 Industrial automation 121, 195 Industrial batteries 47 Industrial ceramics 11, 17 Industrial communication 121 121 Industrial computer chassis Industrial computer peripherals 121 Industrial connectors 51 Industrial control & sensing devices 7 Industrial coolers 133 Industrial cooling systems 225 Industrial cranes 115 Industrial electric AC motors 22 Industrial electric power distribution system 18 Industrial filter centrifuges 248 Industrial floorings 245 Industrial heating elements 190 Industrial hoses Back gatefold Industrial motherboards 121 Industrial overhead doors Industrial plugs & sockets Industrial robots Industrial state directory Inline drum-type magnetic separators Inline helical geared motors Instrumentation & controls Instrumentation made cables Instrumentation Insulated doors Inter- & after-coolers Interlocking doors Inverter duty motors Inverter/variable frequency drives Isolators Jib cranes Joining Joystick controllers 25 222 190 261 209 124 29 51 189 25 205 25 124 7 14 20, 167, 243 217 89 Laboratory testing rerods 58 Large bearings 10 Large enclosures 123 Large helical & heli-bevel gearboxes 124 Laser markers 75 Laser sensors 75 Lathes 207 LED module pilot lights 199 LED signal tower lights 32, 34, 36, 38 Level controllers 7 Level gauges 203 Lift & conveyor cables 51 Lift trucks services 115 189 Lifting magnets Light duty castors 247 Light lifting 115 Lighting systems 111 153 Limit switch boxes 32, 34, 36, 38, 199 Limit switches Linear actuators 221 Linear motion vibratory screens 58 69 Linear motion Linear position sensors 89 Linear potentiometers 89 Linear robots 188 Linear technology voltage stabilisers 197 230 Liquid ring vacuum pumps Load managers 203 Loaders 137 25 Loading bay equipment Lock nuts 70 Lock washers 70 Loom switches 199 12 Loop powered isolators 137 Lorry loaders Low lift pallet trucks 25 LV motors 159 LVDTs 89 Machines MAG/MIG & TIG welding machines Magna rolls Magnetic coolant separators Magnetic floor sweepers Magnetic pulleys Magnetic racks Magnetic sensors Maintenance sprays Manometers Manual electric stackers Manual pallet trucks Manual stackers Manufacturing Excellence conference Manufacturing Summit-2010 Material handling equipment MCBs 221 223 58 209 58, 209 58, 189 189 191 9 203 255 25 255 220 240 20, 167, 178 14 MCC & PCC enclosures 123 MCCBs 47, 235 Measurement & inspection 45, 55, 113, 127 Measurement sensors 75 Measuring & monitoring relays 7 Measuring instruments 164 Mechanical seals 88, 206 Media preparators-cum-autoclaves 248 Membrane drying 15 Metal bins 255 Metal cutting tools 141 Metal pallets 255 Metering pumps & dosing systems 244 Metering solutions & relays 47 Meters 47, 164 Micro control switches 199 Micro leak testers 243 Micro milling beads 11, 17 Micro switches 32, 34, 36, 38, 199 Microprocessor welding controllers 97 Mighty tiny series 22 Military circular connectors 217 Mill lining blocks 11, 17 Milling grade 105 Miniature micro switches 199 Modernisations 115 Modular construction electric hoists 103 Modules 149 Moisture separators 205 Molded cable assemblies 199 Motion controllers 212 Motion controls 7 194 Motion sensors 267 Motion solutions Motor control centers 47 Motor protection systems 203 25 Motorised boom barriers 209 Motorised vibratory feeders Motors 43, 65, 229 Multi-axis motion controllers 229 203, 247 Multi-function meters 223 Multi-functional welders Multi-level car parks 60 Multi-speed motors 124 Multi-spot wire cage welding machine 97 47 MV switchgears Namur sensors National conference for manufacturing SMEs Needle roller bearings Needle valves Non-maintained lights Nuts Offices & computers Ohmmeters Oil coolers Oil removal systems Oil seals Oil/coolant coolers On/off ball valves On/off butterfly valves On/off control valves On/off controllers On/off plug valves Online water flowmeters Optical touch switches Optimised distribution solutions Optoelectronics & displays Oscillating tools Overband magnetic separators Overhead doors Overload robots Packaging solutions Packaging test equipment 149 224 10 203 111 70 45, 55, 113, 127 164 233 15 200 225 153 153 153 12 153 222 75 218 45, 55, 113, 127 57 209 25 190 257 257 SOURCE ELECTRIC & ELECTRONICS PRODUCTS @ www.engg-expo.com 266 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 PRODUCT INDEX Product Pg No Product Pg No Product Pg No Paint shop equipment 284 Paint shop machines 284 Paint spray booths 107 Pallet stackers 25 Panel air-conditioners 225 Panel coolers 233 Panels 164 Paper cone plants 242 Paperless recorders 230 Parallel cam indexers 267 Parallel shaft helical geared motors 124 Part ejectors 231 Passive back planes 121 Passive components 45, 55, 113, 127 PBEGL geared motors 65 PC enclosures 123 PD blowers 81 Pedestrian & rider-operated counter balanced pallet trucks 178 Pedestrian low lift pallet trucks 25 Pedestrian pallet stackers 25 Peeing machines 189 Permanent magnetic chucks 189 Permanent magnetic drum pulleys 209 Permanent magnetic drum-type separators 189 Permanent magnetic lifters 58, 184 Personal safety equipment 241 Photoelectric sensors 7, 75 Photoluminescent signages 111 Pick & move cranes 137 PID controllers 12 Piezo products 175 Pilot lamp holders 199 Pilot lights 31 Pin marking systems 234 Pins & sockets 226 Pipe bending machines 172, 221 Pipe cutting machines 172 Planners 207 Planning machines 229 207 Plano millers Plano milling machines 229 Plasma cutting machines 196 200 Plasma welding torches Plastic hosepipes Back gatefold Plate bending machines 221 Plate castor wheels 247 Plate cutting machines 172 Plate magnets 58, 189, 209 Plat-trucks 247 PLCs 87, 159, 189 PMUs 87 Pneumatic & electric on/off valves 209 Pneumatic & motorised control valves 209 Pneumatic actuators 153 Pneumatic equipment 241 Pneumatic parts 226 Pneumatic products 110, Back gatefold Pneumatics 10, 69 Polyacetal 207 Polycarbonate sheets 60 Polypropylene 207 Polyurethane 207 Polywatt power LEDs 248 Portable balancers 243 Portable blasters 107 Portable computers 121 Portable coolant purifying systems 231 Portable oil skimmer with variable speeds 231 Position transducers 175 Powder coating & speedy painting equipment 210 Power & line protection 45, 55, 113, 127 Power cables 142 Power chucks 248 Power distribution components 123 Power magnets 189 Power presses 257 Power quality management systems 47 Precision ballscrews 210 Precision ground bars 221 Precision rolling bearings 10 Precision turned components 217 Pre-engineered steel buildings 60 Prefab shelters 60 Prefill valves 140 Press brake machines 257 Press technology 217 Pressure blasters 107 Pressure boosting systems 283 Pressure gauges 12, 155 Pressure sensors 75 Pressure transducers 175 Pre-treatment systems 284 Process controllers 230 Process cranes 115 Process water treatment 283 Programmable logic controllers 7, 87, 159, 189, 226 Programmable terminals 7 Programmable timers 242 Projection 97 Prong magnets 58 Protective conduit systems 51 Proving rings 186 Proximity sensors 7, 32, 34, 36, 38, 75 PTFE/Teflon products 207 Pull studs 255 Pump seals 88 Pump vane measuring equipment 203 Pumps 13, 41, 129, 147, Back inside cover Punching machines 221 Push button switches 199 Push buttons 31 PVC flap & strip doors 25 PVC hoses 186 Racks & cabinets 45, 55, 113, 127 207 Radio remote controls Rapid flexible doors 25 Rapid roll-up doors 25 RCCBs 14 Re drawer & hopper magnets 58 Re magnetic rods 58 Reach trucks 25 Reamers 79, 255 Rear cylinder hydraulic press brakes 257 Re-crystallised allumina tubes 11, 17 Rectangular lifting magnets 58 Refrigerated dryers 15, 81, 205 Relay sockets 199 Relay units 149 Reliable flooring 245 Relief valves 140, 203 Residential steel houses 60 RFIDs 7 Rigging solutions 165 Robotic cables 51 Robotic liquid gasketing machines 188 Robotic shot-peening machines 190 Roll lifters 255 Roller-type magnetic separators 209 Roof vents 60 Roofing & cladding sheets 60 Roots blowers 129 Rope guides 243 Rotary clean flow magnets 58 Rotary drills 57 Rotary drum washers 229 Rotary indexing tables 267 Rotary position sensors 89 Rotary potentiometers 89 Rotary screens 58 Rotary screw air compressors Rotary vane vacuum pumps Rotating electrical connectors RPM meters RTD sensors RTU systems Rubber products 81 255 257 149 12 186 200 Sack trucks 247 Safety laser scanners 75 Safety light curtains 7 Safety relief valves 203 Safety/light curtain sensors 149 Sandwich ball valves 207 Sawing & cutting machines 57 SCADA & DCS implementation 284 Scanners 12 202 Scara robots Scissor lift tables 255 Scissor lifts 25, 241 58 Scrap-circular lifting magnets Screw thread inserts 184 SDF 235 Seal leak integrity testers 222 Sealants 157 Seals 10, 200 Seam welding machines 97 SEARCH - 13th Anniversary Issue 135 25 Sectional overhead doors Security & audio visuals 45, 55, 113, 127 Security systems 200, 269 Semiconductor modules 45, 55, 113, 127 Semiconductor tools 45, 55, 113, 127 Semiconductors 45, 55, 113, 127 Sensitive part loading/unloading 231 Sensors 45, 55, 75, 113 127, 149, 192, 194 Servo-controlled voltage stabilisers 197 Servomotors 263 Shaft loading machines 231 Shearing machines 257 221 Sheet metal machines Sheet metal working machines 57 Shipyard cranes 115 225 Shoe brakes Shot blasting hoses 107 Shot blasting machines 189 Shunts 164 Sidelock adapters 255 Sight flow indicators 203 Signal conditioners 89 Signal isolators 12 Simpler anodised aluminum piping 81 Single girder EOT cranes 243 Single-twin igniting electrodes 11, 17 Sleeves 70 Sliding & swing gates 206 Slip-ring crane-duty motors 65 Slot single board computers 121 Small junction/distribution boxes 123 SMPS systems 199, 202 Sockets & switches 26 Solar LED flashers 201 Solar LED home lights 201 Solar LED lanterns 201 Solar LED streetlights 201 Solar power packs 201 Solar solutions 201 Solar water heaters 201 Solder pastes 257 Solderless terminals 49, 237 Solenoid valves 110, 209 Solid carbide drills 141 Solid carbide reamers 141 Solid carbide special drills 141 Solid carbide special reamers 141 FINALIZE SUPPLIERS @ 268 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 www.engg-expo.com PRODUCT INDEX Product Pg No Product Pg No Product Pg No Solid carbide tools 79 Special application motors 124 Special refrigeration equipment 225 Special tools 255 Special-purpose machines 207, 229 Special-purpose resistance welding machines 97 Special-purpose welding electrodes 199 Spherical bearings 225 Spiral bevel gearboxes 22 Spiral cables 51 Spiral-cum-helical gearboxes 193 Spot welding machines 97, 199 Spray guns 197, 247 SS high precision components 226 Stackers 241 Stainless steels 245 Static charge meters 246 Static control & site safety 45, 55, 113, 127 Static control devices 75 Static voltage stabilisers 197 Steel balls 245 Steel mill duty & flameproof cranes 103 Steel working machines 221 Step lap laminations 217 Stepping motors 233 Stored energy welders 198 Strip welding machines 93 Structural floor decking sheets 60 Stud welders 223 Submerged arc welding machines 223 Suction blasters 107 Surface processing 57 Surface roughness gauges 186 Surface treatment 157 Suspension magnets 58, 209 Sweeping machines 277 Switchboard meters 164 Switches & relays 45, 55, 113, 127 Switches 14 Switchgear products 47 Switchgears 87, 235 Switching relays 7 System integrators 189 Tail lifts 25 Tapping lubricants 241 Taps 79 Technical ceramics 11, 17 Telescopic doors 25 Temperature controllers 7, 149, 230 Temperature indicators & controllers 244 Temperature instruments 155 Temperature sensors 175, 192 Temperature-resistant cables 51 Terminal blocks 199 Terminal strips 199 Test rigs 226 Testers 45, 55, 113, 127, 164 Thermocouple cables 229 Thermocouple sensors 192 Thermocouples 12 Thread gauges 248 Thread whirling tools 105 Three-phase calibrators 244 Throttle valves 140 Tie mounts 177 TIG air-cooled 196 TIG torches 196 Tilt sensors 89 Timers 7, 12 Tooling solutions 47 Tools & production supplies 45, 55, 113, 127 Tools 255 Torque motors 22, 124 Totalisers 12 Touchscreens 229 Toughened glass & round glass 203 Tower cranes 137 Transducers 45, 55, 113, 127 Transformers 45, 55, 113, 127, 164 Transmitters - 2-wire 12 Trap magnets 209 Traveling machines 20 Triple drum-type magnetic separators 58 Trivalent chromium passivation process 218 Trolley castor wheels 247 Trolleys 247 Truck-dumper body vibrators 58 Tube magnets 58 Tube straightening machines 206 Tubular level gauges 186 Tungsten carbide rod blanks 244 Turned components 226 Turret punch presses 222 Twist drills 255 UF exiter vibratory screens UHMW-PE products UIT Ultrasonic flow meters Ultrasonic processors Unbalanced vibratory motors Uni-force exiters UPS systems USS univents U-tube manometers UV flame sensors Vacuum blasters Vacuum booster pumps Vacuum cleaners Vacuum systems Validation of packs Valve position transducers Valve positioners Valves Variable frequency drives Variable speed drives Variable speed pulleys Ventilators Vertical machining centres Vertical order pickers Vertical turning lathes Vertical turning machines Vertical turning-cum-boring machines Vibrating motors Vibrating reed type Vibrating screen machines Vibration motors Vibration sensors Vibratory bin activators Vibratory bowl feeders Vibratory bowls Vibratory conveyors Vibratory feeders Vibratory fluidised bed dryers Vibratory furnace chargers Vibratory grizzly feeders Vibratory knockout tables Vibratory spiral elevators Vibratory tables Vices Vision sensors Voltage stabilisers Washers Wastewater treatments Water analysers 58 207 197 230 206 58 58 197 60 203 197 107 129 269 129 257 89 153 110, 203 87 22 22 259 210 25 229, 238 207 207 209 164 209 22 175 58 202 209 58 58 58 58 58 58 58 58 197, 247 7 197 70 283 189 Water chillers 225 Water-cooled reciprocating compressors 81 Water faucet & tap parts 11, 17 Water purifiers 269 Water treatments 283 Web 18 software services 208 Welding automation & robots 188 Welding controllers 198 Welding equipment 197, 247 Welding equipment/products 196 Welding holders 198 Welding inverters 198 Welding machines & plasma cutting machines 196 Welding machines & robots 199 Welding rectifiers 200, 201 Welding rotators 198 Wet & dry vacuum cleaners 277 Wet drum-type magnetic separators 58 Wheel assemblies 241 Wheelbarrows 247 Winches 103 Wire & assemblies 45, 55, 113, 127 Wire connectors 49, 237 Wire rope drums 241 Wires 142 Wiring accessories 177 Wiring ducts 201 Withdrawal sleeves 70 Worm gear speed reducers 22 Worm gears 193 Y-type strainers Zirconia polycrystal ceramic 203 11, 17 INTERNATIONAL PRODUCTS Alumina adhesives Apparel & footwear Associations Automatic extrusion applicators CNC healing machines Concert hoists Control systems Cranes Data acquisition systems Data management solutions Data station plus Electric tensioning pumps Elevators Grease lubricators Hoists Hot-air welding guns Hydraulic dock levellers Industrial products Insulation blankets Motion control cards Motion control systems Motors Multi-material cutters Operator interface Panel meters Permanent sight glass magnets PID process controllers Power quality analysers Protocol conversion Refrigeration gas cooling units Scara robots Screw compressors Signal conditioning systems Soldering irons Solid plastic portable gauges Truck tailgate lifts Weight controllers 205 78 187 258 263 258 256 56, 74 19 19 19 260 56, 74 257 56, 74 258 191 78 256 260 256 74 256 19 19 256 260 258 19 259 202 24, 56 19 263 258 191 256 SOURCE HYDRAULICS PNEUMATICS EQUIPMENT @ www.engg-expo.com 270 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 ADVERTISERS' LIST To know more about the advertisers in this magazine, refer to our `Advertisers' List' or write to us at email@example.com or call us at +91-22-3003 4640 or fax us at +91-22-3003 4499 and we will send your enquiries to the advertisers directly to help you source better Advertisers' Name & Contact Details Pg No Advertisers' Name & Contact Details Pg No Advertisers' Name & Contact Details Pg No Abb Limited T: +91-80-22949560 E: firstname.lastname@example.org W: www.abb.co.in Acropolis Engineering Ltd T: +91-22-26441180 E: email@example.com W: www.acropoliscranes.com Action Construction Equipments Ltd T: +91-11-40549900 E: firstname.lastname@example.org W: www.ace-cranes.com ADEA 2010 T: +91-22-30034650 E: email@example.com Advantech India T: +91-80-23374567 E: firstname.lastname@example.org W: www.advantech.in Allied Electronics Corporation T: +91-22-26616619 E: email@example.com W: www.aecconnectors.com Atlas Copco (India) Ltd T: +91-20-30722222 E: firstname.lastname@example.org W: www.atlascopco.com Avcon Controls Pvt Ltd T: +91-22-28221505 E: email@example.com W: www.avconindia.com Ballkings T: +91-161-2534501 E: firstname.lastname@example.org Beko Compressed Air Technologies Ltd T: +91-40-23080275 / 23081107 E: email@example.com W: www.beko.de Bhagirath Heavy Transmission T: +91-11-32222661 E: firstname.lastname@example.org Boge Compressed Air System T: +91-44-43009610 E: S.Sriram@boge.de W: www.boge.in 159 Bonfiglioli Transmissions (Pvt) Ltd T: +91-44-24781035 E: email@example.com W: www.bonfiglioliindia.com Bosch Rexroth (India) Limited W: www.boschrexroth.co.in Bry Air Asia Pvt Ltd T: +91-11-23906777 E: firstname.lastname@example.org W: www.bryair.com Buildcon Consultants Pvt Ltd T: +91-141-4012629 E: email@example.com W: www.buildcon.in C&S Electric Ltd. T: +91-11-30887520-29 E: firstname.lastname@example.org W: www.cselectric.co.in Ceco Electronics Pvt Ltd T: +91-33-22485448 E: email@example.com W: www.cecoelectronics.com Cenlub Systems T: +91-129-4113771 E: firstname.lastname@example.org W: www.cenlub.com Chemical & Industrial Engineers T: +91-22-28822740 Cheng Day Machinery Works Co., Ltd T: +886-4-2688-1581 E: email@example.com W: www.chengday.com.tw Classic Polymers & Resins T: +91-22-24465251 E: firstname.lastname@example.org W: www.classicpolymers.com CM Hydro Systems Pvt Ltd T: +91-40-23222287 E: email@example.com W: www.cmhydraulics.com Coatec India T: +91-172-5063436 E: firstname.lastname@example.org W: www.coatecindia.com 23 Connectwell Industries Pvt Ltd T: +91-251-2870636 E: email@example.com W: www.connectwell.com CRI Pumps (Pvt) Ltd T: +91-422-3260011 E: firstname.lastname@example.org W: www.cripumps.com Darling Pumps Pvt Ltd T: +91-731-2720558 E: email@example.com W: www.darlingpump.com DHL Express (India) Pvt Ltd T: +91-22-66789186 E: firstname.lastname@example.org W: www.dhl.com Diahen Corporation T: +91-124-4300821 E: email@example.com W: www.otcdaihenasia.com Digital Marketing Systems Pvt Ltd T: +91-731-3046800 E: firstname.lastname@example.org W: www.digitalcontrols.org 26 207 69 13 259 137 147 245 168 .COC 121 14 196 8 87 189 106 234 209 203 Dongguan Dacheng Machinery Make Co., Ltd. 191 T: +86-769-8321-7777 E: email@example.com W: www.taillift.net EA Water Pvt Ltd T: +91-11-43100519 E: firstname.lastname@example.org W: www.eawater.com/expo East India Bearing Co. (P) Ltd. T: +91-22-40939200 E: email@example.com W: www.eibc.in Eddycranes Engineers Pvt Ltd T: +91-22-23522710 E: firstname.lastname@example.org W: www.eddycranes.com EFY Enterprises Pvt Ltd T: +91-11-26810601 E: email@example.com W: www.efyexpo.com 232 56 245 207 10 15 140 103 241 52 284 236 Our consistent advertisers 278 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 ADVERTISERS' LIST Advertisers' Name & Contact Details Pg No Advertisers' Name & Contact Details Pg No Advertisers' Name & Contact Details Pg No EL Measure India Pvt Ltd T: +91-80-32904489 E: firstname.lastname@example.org W: www.elmeasure.com Elecon Engineering Company Limited T: +91-2692-236469 E: email@example.com W: www.elecon.com Electro Magnetic Indus T: +91-265-3241361 E: firstname.lastname@example.org W: www.electromagneticindia.com Electrocraft (Asia) Limited T: +852-3163-2250 E: email@example.com W: www.electrocraft.com Element 14 India Pvt Ltd T: +91-80-40003800 E: firstname.lastname@example.org W: www.farnell.in El-Sol Energy Systems T: +91-9825035366 E: email@example.com W: www.elsolenergy.com Empire Cable Industries Pvt Ltd T: +91-11-23874632 E: firstname.lastname@example.org W: www.empirecables.com Engineering Expo T: +91-9920401226 E: email@example.com W: www.engg-expo.com Essen Deinki T: +91-172-4600600 E: firstname.lastname@example.org W: www.essendeinki.com Eureka Forbes Limited T: +91-80-30251500 E: email@example.com W: www.eurekaforbes.com Everest Blowers T: +91-11-45457777 E: firstname.lastname@example.org W: www.everestblowers.com Fabtec India 2011 T: +91-422-2221582 E: email@example.com W: www.fabtecindia.codissia.com 203 Fein Power Tools India Pvt. Ltd. T: +91-44-43578680 E: firstname.lastname@example.org W: www.fein.in Finechrome Shafts Pvt Ltd T: +91-22-29203647 E: email@example.com Fontus Water Ltd T: +91-11-43100536 E: firstname.lastname@example.org W: www.fontuswater.com Forging Machinery Manufacturing Co T: +91-161-5011755 E: email@example.com W: www.nkhhammers.com Freeze Tech Equipments Pvt Ltd T: +91-44-42152387 E: firstname.lastname@example.org W: www.freezetechequip.com 57 Gem Equipments Ltd T: +91-422-3267800 E: email@example.com W: www.gemindia.com 133 193 221 Global Sleeve Solutions T: +91-09501040477 E: firstname.lastname@example.org 70 283 W: www.globalsleeves.com Goliya Electricals Pvt Ltd T: +91-22-24120456 E: email@example.com 164 58 16 74 W: www.goliya.com Grundfos Pumps India Pvt Ltd T: +91-44-24966800 E: firstname.lastname@example.org W: www.grundfos.in Hafa Hoists Pvt Ltd T: +91-22-27694837/838 E: email@example.com W: www.hafahoists.com Hannover Fairs India Pvt Ltd T: +91-22-40050683 E: firstname.lastname@example.org W: www.mda-india.com Havells India Ltd. T: +1800-11-0303;011-41660303 43 131 243 .BC 45, 55, 113, 127 233 201 Frost & Sullivan 220 T: +91-80-41783543 E: email@example.com W: www.frost.com/manufacturing-ITsummit Frost & Sullivan T: +91 (0)44 42044500 E: PriyaG@frost.com W: www.frost.com Frost & Sullivan T: +91-80-41783525 E: firstname.lastname@example.org W: www.frost.com/ms G A Industries T: +91-79-25895577 E: email@example.com W: www.gaindustries.net G L Brothers T: +91-22-66047000 E: firstname.lastname@example.org W: www.pilotindia.com G W Precision Tools India Pvt Ltd T: +91-80-40431252 E: email@example.com W: www.gwindia.in Gandhi Automations Pvt Ltd T: +91-22-66720200 E: firstname.lastname@example.org W: www.geapl.co.in 228 142 213, 275 240 E: email@example.com W: www.havells.com Henkel Adhesives Technologies India 157 199 225 T: +91-80-25357771 E: firstname.lastname@example.org W: www.loctite.com Hensel Electric India Pvt. Ltd. 18 269 247 T: +91-44-24541669 E: email@example.com W: www.hensel-electric.de Hi-Fab Engineers Pvt Ltd 88 129 141 T: +91-22-28879351 E: firstname.lastname@example.org W: www.hi-fab.com 119 25 Hi-Fab Valve Automation T: +91-22-40766539 E: email@example.com W: www.hi-fab.com 153 Our consistent advertisers D E C E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK 279 ADVERTISERS' LIST Advertisers' Name & Contact Details Pg No Advertisers' Name & Contact Details Pg No Advertisers' Name & Contact Details Pg No Hindustan Motor Mfg Co T: +91-22-42500500 E: firstname.lastname@example.org W: www.hindmotors.com Hitachi India Trading Pvt Ltd T: +91-11-40605252 E: email@example.com W: www.hitachi.com.sg Hitech (India) Private Limited T: +91-40-20080092 / 20080093 E: firstname.lastname@example.org W: www.hitechconnector.com Hitech Manufacturing Show T: +91-09820373804 E: email@example.com Hi-Tech Robotic Systemz Ltd T: +91-124-4715100 E: firstname.lastname@example.org W: www.hitechroboticsystemz.com Hittco Tools Ltd T: +91-80-28392265 E: email@example.com W: www.hittco.com Hydro Mech Engineers T: +91-79-25890771 E: firstname.lastname@example.org W: www.materialhandlingindia.com Igus India Pvt Ltd T: +91-80-39127800 E: email@example.com W: www.igus.in Ingersoll Rand (India) Ltd T: +91-79-22820123 E: firstname.lastname@example.org W: www.ingersollrand.co.in Ink Business Media Pvt Ltd T: +91-09820436076 E: email@example.com W: www.inkbusinessmedia.com 124 Jaykrishna Magnetics Pvt Ltd T: +91-79-22970452 E: firstname.lastname@example.org W: www.magneticequipments.com Jindal Aluminium Ltd T: +91-80-23715555 E: email@example.com W: www.jindalalumium.com Jyoti Ceramic Industries Pvt Ltd T: +91-253-2350120/338 E: firstname.lastname@example.org W: www.jyoticeramic.com Jyoti Cnc Automation T: +91-2827-287081 E: email@example.com W: www.jyoti.co.in Kapasi Fastners / Inc T: +91-80-22279217 E: firstname.lastname@example.org 209 Kushal Udyog Manufacturers & Engineers 107 T: +91-291-2720072 E: email@example.com W: www.kushaludhyog.com 163 139 Kwality Tubes And Capillaries T: +91-141 2330476 E: firstname.lastname@example.org W: www.vaishalimetal.com 233 217 11, 17 Lapp India Pvt Ltd T: +91-80-7826000 E: email@example.com W: www.lappgroup.com .BIC Larsen & Toubro Ltd T: +91-22-67525656 E: firstname.lastname@example.org 237 W: www.larsentoubro.com Lenze Mechatronics Pvt Ltd T: +91-20-66318100 211 E: email@example.com W: www.Lenze.in Lubi Electronics T: +91-79-39845300 149 E: firstname.lastname@example.org W: www.lubielectronics.com Maco Corporation India Pvt Ltd 194 T: +91-33-40224106 E: email@example.com W: www.macocorporation.com Macro Tech Equipment Pvt Ltd 181 T: +91-33-24666261 E: firstname.lastname@example.org W: www.macrotechcal.com Manmachine (India) Private Limited 277 178 172 75 160 47 51 98 219 79 Karnataka Small Scale Industries Association T: +91-80-23353250 E: email@example.com W: http://www.kassia.com Katlax Enterprises Pvt Ltd T: +91-2764-286784 E: firstname.lastname@example.org W: www.katlax.com Klipco Pvt Ltd T: +91-22-28684221 E: email@example.com W: www.klipcohoseclamps.com Knowell International Pvt Ltd T: +91-33-22304627 E: firstname.lastname@example.org W: www.knowell.co.in Konecranes India Pvt Ltd T: +91-20-40047470 E: email@example.com W: www.konecranes.com Kriton Weld Equipments Pvt. Ltd. T: +91-265-2642809 E: purohit@kritonwelders W: www.kritonwelders.com Kryfs Power Components Ltd T: +91-22-67859999 E: firstname.lastname@example.org W: www.slingset.com 241 227 81 224 115 T: +91-120-2422727 E: email@example.com W: www.manmachine.in Jaibalaji Controlgears Pvt. Ltd., 32;34;36;38 T: +91-44-26251279 E: firstname.lastname@example.org W: www.jaibalaji.firm.in Jay Equipment & Systems Pvt Ltd T: +91-250-2481806 E: email@example.com W: www.jayequipment.com 255 93 Mather And Platt Pumps Ltd T: +91-20-27442100 E: firstname.lastname@example.org W: www.matherplatt.com .FIC 165 Measurement Specialties T: +91-80-25633475 E: email@example.com W: www.meas-spec.com 175 Our consistent advertisers 280 SEARCH - THE INDUSTRIAL SOURCEBOOK | D E C E M B E R 2 0 1 0 ADVERTISERS' LIST Advertisers' Name & Contact Details Pg No Advertisers' Name & Contact Details Pg No Advertisers' Name & Contact Details Pg No Metalmech Engineering T: +91-288-2566335 E: firstname.lastname@example.org W: www.metalmecheng.com Millenium Instruments Ltd T: +91-11-22456571 E: email@example.com W: www.miepl.com Misumi India Pvt Ltd T: +91-20-66470000 E: firstname.lastname@example.org W: www.misumi.co.in Mitsubishi Electric Asia Pte. Ltd. T: +91-124-4630300 E: email@example.com W: www.messung.com Nanfang Pumps India Pvt Ltd T: +91-22-25425540 E: firstname.lastname@example.org W: www.nanfangpumps.com NI Systems India Pvt Ltd T: +91-80-41190000 E: email@example.com W: www.ni.com Nia Controls T: +91-22-26736864 E: firstname.lastname@example.org W: www.tscindia.com 226 Paras Enterprises T: +91-11-25820571 E: email@example.com W: www.parasenterprises.com Pathak Machines International T: +91-161-2510401 E: firstname.lastname@example.org W: www.pathakeuromachines.com Peschel Dynamics T: +91-20-32416980 E: email@example.com W: www.pescheldynamics.com Pidilite Industries Ltd T: +91-22-33087544 E: firstname.lastname@example.org W: www.pidilite.com Pilot Pneumatics Pvt Ltd T: +91-22-66047000 E: email@example.com W: www.pilotindia.com 96 Rajindra Machines (P) Ltd T: +91-1871-242763 E: firstname.lastname@example.org W: www.rajindra.net Realty Automation & Security Systems T: +91-20-32922630 E: email@example.com W: www.vighnaharta.in Red Lion Controls T: +91-09879540503 W: www.redlion.net Reid Supply Company W: www.reidsupply.com Reva Industries Ltd T: +91-129-4185400 E: firstname.lastname@example.org W: www.revacranes.com Rexello Castors Pvt Ltd T: +91-22-4091777 E: email@example.com W: www.rexellocastors.com Rittal India Pvt Ltd T: +91-80-23519792 E: firstname.lastname@example.org W: www.rittal-india.com Robin Precision Products Pvt Ltd. 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