Page 1

HMS releases several new IXXATÂŽ products for CAN FD

Efficient automated label printing

The next industrial revolution Industry 4.0

Industrial Fiber Patch Placement preforming machine & software market launch at JEC World 2017

Hybrid combination of forging and selective laser melting reduces weight andenables the construction of complex structures

Polymer-coated silicon nanosheets as alternative to graphene

A perfect team for nanoelectronics

Everyone is talking about Industry 4.0. This means the fourth industrial revolution. After mechanization, electrification and automation we now have digitalization. Machines and their components are digitally networked with one another and with their environment. The aim of this networking is to simplify and optimize processes and thus to maximize the value creation chain. In the digital factory, also called the Smart Factory, there will be no more unplanned machine downtimes and resources will be optimally used.

Silicon nanosheets are thin, two-dimensional layers with exceptional optoelectronic properties very similar to those of graphene. Albeit, the nanosheets are less stable. Now researchers at the Technical University of Munich (TUM) have, for the first time ever, produced a composite material combining silicon nanosheets and a polymer that is both UV-resistant and easy to process. This brings the scientists a significant step closer to industrial applications like flexible displays and photosensors.

Bosch sets new standards in bar packaging New technologies for high performance, quality and productivity

Sawing, sorting and stacking – automatic and fully integrated

AN EXCELLENT PRESS MAILING SERVICE Decentralizing the system to reduce space and materials


Mettler-Toledo improves productivity, protection and quality with latest metal detectors

January - February 2017



Janurary - Feburuary 2017/1 Vol.42 

The next industrial revolution Industry 4.0 4

Industrial Fiber Patch Placement preforming machine & software market launch

at JEC World 2017 6 

Hybrid combination of forging and selective laser melting reduces weight HMS releases several new IXXAT® products for CAN FD 8

Efficient automated label printing 10

Pickering Interfaces to Showcase Switching & Simulation Modules at AMPER

: Local/Periodical : (Yerel/Süreli)


Ahmet Pelit

‹mtiyaz Sahibi

Editorial Director

andenables the construction of complex structures 7 

Publication Type Yay›n Türü



Hypertherm announces 2017 webinar lineup offering free, educational training

for welders and fabricators 13 

Limestone Mine Benefits from Leroy-Somer Regenerative VSD Technology 14

ADLINK Introduces Ready-to-Go Smart Camera with MVTec MERLIC 16

New Seco face milling cutter body doubles tool life 18

Innovative composite materials and solutions for automotive applications Henkel

Erdem Ça€layan

Yazı ‹flleri

Advertising Sales Staff Reklam Grubu

Emel fienyüz Fahriye Ziyade Hafise Ergün

Design & Graphics

AjansMik Co., Ltd.

2017 12 

Selver Pelit

Sorumlu Yaz› ‹?leri Müdürü

Hazırlık & Tasarım

Graphic Designer

Mehmet Can Pelit

Grafik Tasarım

Data Processing

Ali Birim

Bilgi ‹fllem

Print by

fian Ofset


Ayazağa Mah. Kemerburgaz Cad. No:13 Şişli-- ‹stanbul

highlights advanced automotive lightweight composite applications at JEC World 2017 20 

ÖZYAŞAR, Wired to Empowering Customer Trust 22

Lights, Camera, Action! Grinding professionals STUDER, SCHAUDT and MIKROSA

present their stars at the annual Motion Meeting 24 

ThinKing October – Material selection in lightweight aluminum-titanium bearings

reduces weight by half while maintaining full performance potential 26 

Hypertherm now shipping FlushCut consumables for Powermax105 and

Powermax125 air plasma systems 28 

Going beyond all horizons - the S11 with extended functionality 30

Bosch sets new standards in bar packaging New technologies for high perfor-

mance, quality and productivity 32 

Sawing, sorting and stacking – automatic and fully integrated 34

Eplan Harness proD 2.6 Comprehensively carefree through to manufacturing 38

NSK ball screws replace hydraulics in powder presses 40

Line of high-temperature ratio pyrometers Expanded 41

Polymer-coated silicon nanosheets as alternative to graphene A perfect team for

nanoelectronics 42 

Mettler-Toledo improves productivity, protection and quality with latest metal

detectors 44 

Combining lightweight high-tech materials with bionic design results in a

groundbreaking logistics concept: CIKONI develops lightweight CRP shelves for the Mercedes-Benz Vision Van 46 

AN EXCELLENT PRESS MAILING SERVICE Decentralizing the system to reduce

space and materials 50 

Defining and Predicting Housing Strength for Mounted Bearings 54


January - February 2017

Head Office / Yönetim Merkezi AjansMik Publishing Advertising Org.& Tourism Industry Trade Co., Ltd. Perpa Ticaret Merkezi B Blok Kat:11 No:1928 Okmeydanı - fiiflli 34384 ‹stanbul / Türkiye Phone : +90 [212] 222 93 71 Pbx Fax : +90 [212] 222 93 74 E-mail : info@ajansmik.com Web : www.ajansmik.com

Representative of Germany EISENACHER MEDIEN WELCKERSTR.22 D-53113 BONN Germany Phone: +49 0228 24 99 860 • Fax: +49 0228 65 00 76 e-mail:info@eisenacher-medien.de Representative of Italy CASIRAGHI INTERNATIONAL ADVERTISING Via Cardano 81 - 22100 Como (Italia) Tel. +39 031 261407 Fax +39 031 261380 www.casiraghi.info Representative of Taiwan Ringier Trade Media Ltd. 9F-2, No. 200, Zhongming Rd., North District, Taichung 404, Taiwan Tel: +886 4 2329 7318 sydneylai@ringier.com.hk www.industrymagazine.com.tr info@industrymagazine.com.tr ISSN 1303-636X©Turkey Industry Magazine Publication Date : 10 March 2017 ‹stanbul - Turkey Baskı Yeri&Tarihi: 10 Mart 2017 ‹stanbul - Turkey All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, including photocopying and recording, without the written permission of the publishers.

January - February 2017



The next industrial revolution Industry 4.0

Everyone is talking about Industry 4.0. This means the fourth industrial revolution. After mechanization, electrification and automation we now have digitalization. Machines and their components are digitally networked with one another and with their environment. The aim of this networking is to simplify and optimize processes and thus to maximize the value creation chain. In the digital factory, also called the Smart Factory, there will be no more unplanned machine downtimes and resources will be optimally used. Network, collect, analyze Half of the population are online today. They communicate via the World Wide Web. But more and more devices and systems are being networked together. The possibilities opened up by the digitalization and networking of machines are immense. Experts from different areas believe that new markets will open up, with an annual turnover of 100 billion euros. It is clear that «Big Data», i.e. the huge quantity of data that is collected, is worth a great deal if it is systematically analyzed and incorporated into processes. This task presents a huge challenge for both industry and society. How does STUDER handle it? The solution: Focus! «A Smart Factory isn't simply created overnight. It is necessary to focus on certain areas», explains Christian Josi, project manager at Fritz Studer AG. For STUDER the basic principle applies,


January - February 2017

that all further developments should lead to a customer benefit. «We work closely together with our customers», Josi explains. But what is STUDER specifically working on? Focus: Simple and secure networking The basis of Industry 4.0 is the networking of machine, logistics, product and our customers' business systems (ERP, SAP). Everyone must speak the same language here. This is achieved through the simple and secure software interface used worldwide, OPC UA (Open Platform Communication Unified Architecture). STUDER has integrated the OPC UA standard into its "StuderWIN" machine software. The machine can assume two roles here: OPC UA Client and Server. This enables STUDER machines to be integrated simply and securely into the environment of the digital factory. Focus: Elimination of unplanned machine downtimes Another focus is on unplanned machine downtimes. The UNITED GRINDING Group (UGG) – of which STUDER is part - tackles this topic methodically, as a group. The aim: The customer will receive a tool, which enables cost-optimized maintenance. In other words, the machine will only be stationary if this is planned and calculated. The UNITED GRINDING Group adopts the «Predictive Maintenance» approach here. In order to make this possible in future, the data of the individual assemblies and components are record-

ed and analyzed. Different measured variables are needed here, to form a clear picture of the individual assemblies and components. This requires continuous learning and is an ongoing process. «Once there is a clear vision, suitable strategies and measures can be precisely planned and the right tools developed», Josi is convinced. Another project that is being tackled: The «One Push Remote Solution». This means that if an assembly or component fails, despite Predictive Maintenance, the problem can be rectified at the press of a button and the customer can be offered optimal support. Who is at the center here? With the use of new technologies and digitalization, we must never lose sight of the customer benefit. STUDER consciously focuses on the individual customer and his requirements. The new technologies and digitalized products must ultimately have a positive effect on the value creation chain. But what is the role of people in the digital factory? «Doubtless the requirements will change and different competencies will become important. However, people will remain an essential part of the system in future», Josi is convinced. Because the fourth industrial revolution should ultimately serve people – not vice versa.


January - February 2017



Industrial Fiber Patch Placement preforming machine & software market launch at JEC World 2017

At JEC World Composites Show 2017 in Paris, Cevotec presents the first industrial solution for the automated production of complex carbon composites in high volumes. As a world premiere at JEC World Composites Show 2017 in Paris, Cevotec presents the first industrial solution for the automated production of complex carbon composites in high volumes. The novel system is based on the Fiber Patch Placement (FPP) technology which enables the fully automated production of complex 3D composite geometries – in a continuous process from digital design to the final fiber product. ARTIST STUDIO, Cevotec’s easy-to-


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use CAD-CAM software, significantly shortens the production preparation as it combines two modules for the digital product development: PATCH ARTIST creates patch-based high-performance laminates with curvilinear fiber direction and variable thickness out of any standard CAD geometry. Powerful, proprietary algorithms optimize the patch overlaps to significantly increase the mechanical properties of each laminate. MOTION ARTIST is using this laminate architecture to perform an automatic and collisionfree offline programming of SAMBA’s two interacting robots, tests them for collision, and simulates the entire production process.

The high-tech production system SAMBA allows for the precise orientation of each patch to achieve a perfect fiber architecture. Strength and stiffness can be increased by up to 150%. While SAMBA’s two robots precisely position the fiber patches, industrial cameras inspect and document the quality of each patch in a continuous quality report. Thanks to additive manufacturing, the system uses up to 30% less of the fiber material, as patches are only placed where necessary. In addition SAMBA significantly reduces scrap and eliminates additional forming processes through direct 3D netshape preforming. www.cevotec.com


Hybrid combination of forging and selective laser melting reduces weight andenables the construction of complex structures

(left) Rosswag GmbH takes advantage of the benefits of forging and 3D printing in order to enable the efficient and low-cost manufacture of solid components with complex inward structures such as this metal turbine wheel. / (right) Some of the various component forms that can be created through Rosswag GmbH’s additive manufacturing process. Using the right process in the right place – that is the guiding lightweighting principle behind Rosswag GmbH in Germany. The company combines the old technology of forging with modern selective laser melting (SLM). In areas where components have a large volume and high-strength is a key requirement, the manufacturer turns to contoured open-die forging. The complex sections of the product are then added through additive manufacturing processes. The basic idea behind the procedure is to create solid components with a large portion of their material volume as close as possible to the final form through open-die forging. This metal core is highly durable and is crafted in line with the direc-

tion of the fiber grain. Afterwards following the CNC processing of the bonding surface, the additive is applied in the SLM® chamber in order to create more complex structures. A recent project has shown the potential of this technology. Thanks to additive manufacturing, this newly developed and optimized process chain allows for more constructive freedom in creating complex geometries and internal structures. In a case study, the shaped blades of a turbine wheel were added to a solid core through additive processing – including all the concave channels designed for the boundary layer optimization. This creates a physically strong material bond that is fused with the core. Rosswag exploits the advantages of both methods in order to create solid compo-

nents with complex internal structures in a resource and cost efficient manner. Such structures are much more difficult to manufacture using conventional production processes, if they can even be created at all. By combining the two manufacturing methods of forging and selective laser melting, new products can be created rather efficiently despite their high complexity. The goal of Rosswag is to refine and optimize the process and increase the efficiency of the production of certain components. This can be achieved through the combination of the benefits of the two manufacturing processes in the different geometric sections of the product. www.rosswag-engineering.de

January - February 2017



HMS releases several new IXXAT products for CAN FD


HMS now extends its CAN FD product portfolio by introducing several new IXXAT® CAN FD products, including new PC interfacesbridges/routers, gateways and analysis tools. IXXAT PC Interfaces now support CAN FD The IXXAT PC interfaces for CAN FD and CAN are typically used for control, monitoring, analysis or configuration purposes. HMS now introduces the IXXAT USB-to-CAN FD — a new USB-connected version which is ideal for mobile analysis and configuration. More interface standards will soon be supported, as IXXAT CAN FD versions for Mini PCIe, PCIe 104, XMC and PMC are currently being developed (CAN FD on PCIe is already supported by the existing IXXAT CAN-IB 500/PCIe and CAN-IB 600/PCIe). Thanks to the wide range of form factors, IXXAT CAN FD interfaces can be easily adapted to various applications. Depending on the version, the CAN FD interfaces offer up to two CAN FD and up to four CAN channels. Customers can also optionally choose galvanic decoupling or add other available interfaces, for example for LIN network connectivity. All CAN FD interfaces come with free-of-charge driver packages – VCI for Windows as well as ECI for Linux and real-time operating systems (VxWorks and RTX for CAN FD and CAN, INtime and QNX for CAN). The driver packages support all IXXAT PC interfaces with a uniform programming interface. Thanks to this, CAN-users can easily change the card type without changing the customer application.


January - February 2017

IXXAT bridges and routers enable flexible CAN FD networking With the new IXXAT CANbridge NT 420, HMS is introducing the world's first bridge/router with CAN and CAN FD support within one DIN rail mounted product. Using the CANbridge NT 420, system integrators can increase the length of their systems, apply filter and translation rules for the message transmission, as well as to de-couple CAN FD and CAN systems. HMS now also launches the IXXAT CAN@net NT 420 Ethernet-to-CAN FD gateway, which can be used to enable network coupling over large distances via Ethernet (operating as a bridge), as well as to connect PCs or embedded controllers to CAN FD systems via Ethernet. The IXXAT CANbridge NT and CAN@net NT are configured and managed through an easy-to-use Windows application. By using IXXAT repeaters and bridges, customers can benefit from increased system reliability and versatile networking. Both

star and tree network topologies are allowed, as well as galvanic protection of network segments. IXXAT canAnalyser now also for CAN FD The IXXAT canAnalyser is a Windows-based analysis tool for CAN – and now also CAN FD. It targets developers and service technicians who are developing or commissioning CAN FD devices and systems. Besides online display and analysis of CAN FD raw data or interpreted signals, the canAnalyser offers flexible message transmission as it can send messages once, cyclically or as command-controlled sequences. Furthermore, messages can be recorded to hard disk, which enables offline analysis of the message traffic. Customer-specific functions can be achieved via a .NET interface to the product. A free, basic version of the tool, the "canAnalyser Mini", is included with all IXXAT PC interfaces and available for download on the IXXAT webpage. www.ixxat.com

January - February 2017



Efficient automated label printing The new Data Automation app from Brady Workstation uses already available data to automatically create identification labels for components, cables, products and packages. Save time and reduce errors Brady Workstation Data Automation is an application that, once set up, receives data from databases such as ERP, LIMS or SAP systems to automatically print the right identification labels. The app eliminates the need to manually copy or retype data that are already available in company systems, which saves time and reduces the risk of typing errors. Data Automation maps selected data to label formats created in Brady Workstation and sends the label directly to pre-selected printers for completion. The app also informs users when their selected Brady printer needs a new label cartridge or ink ribbon to complete the job. Easy to set up The Data Automation app is easy to set up. The app will retrieve information from database exports to a user specified folder. Users can select data sets from the company database for automatic export and printing on several label formats. The company database will also push the amount of prints that are needed and which printer the labels should be printed on. A short, 5 step practical guide is available to set up Data Automation.


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Reliably identify anything Companies can automate identification label printing with the Brady Workstation Data Automation app for power and network cables, components, products, packages, laboratory samples and more. The Data Automation app can be set up with Brady's specialised industrial printers and labels for fast and reliable identification in Panel Building, Datacenters, MRO, FMCG, Logistics,

Manufacturing, Aerospace, Naval and Mass Transit construction and Laboratories. Contact Brady at : emea_request@bradycorp.com for the 5 steps installation guide and download the Data Automation 30 day free trial from workstation.bradyid.com.

January - February 2017



Pickering Interfaces to Showcase Switching & Simulation Modules at AMPER 2017 Pickering Interfaces a leading provider of modular signal switching, simulation, and cabling for electronic test and verification, will showcase their broad catalogue of PXI, PCI, Ethernet LXI, cabling products, and software solutions at AMPER 2017, 21-24 March 2017. These include the following new products: 2-slot USB/LXI Modular Chassis (model 60-104) – This new chassis offers a small lightweight form factor, making it ideal for portable, benchtop and space restrictive applications. It supports one or two 3U Pickering PXI modules and accepts the majority of Pickering’s PXI products. The USB compatible and LXI compliant interfaces enable the chassis to be controlled directly through standard interfaces found on most personal computers—allowing for a very cost effective route into the modular test and measurement market. Millivolt Thermocouple PXI Simulator Module (model 41-760) – A lowvoltage source module ideal for simulating the operation of a thermocouple. This module supports up to 32 channels from a single-slot 3U PXI module, each with an independent output of -100mV to +100mV and a remote sense that allows for the correction of ground voltages on each channel. Switch Path Manager Signal Routing Software – this new signal routing software simplifies signal routing through switching systems and speeds up the development of switching system software. Switch Path Manager supports Pickering's


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PXI, LXI, PCI and GPIB switching modules and the interconnection between these products. Also highlighted in the booth will be their eBIRST Switching System Test Tools. These tools, designed specifically for Pickering’s PXI, PCI, or LXI (Ethernet) products, simplify switching system faultfinding by quickly testing the system and graphically identifying the faulty relays. Pickering Interfaces sister company Pickering Connect will be showing their standard interconnection products including connectors, cables and connector blocks as well as their Cable Design Tool. The Cable Design Tool is a free graphics-based online tool that lets you define a cable assembly to exactly meet your require-

ments. The tool allows very detailed design characteristics including - selection of connector types, wire type, pin definitions, pin and cable labelling, cable bundling, length selection, sleeving and comments. Features include a built-in library of standard cable sets or design from scratch, the ability to store designs in the Cloud and develop them over time and you can create your own library and share with colleagues. Pickering Interfaces stands behind all of their manufactured products with a standard three-year warranty and guaranteed long-term product support. Pricing and availability information is supplied on their website at www.pickeringtest.com.


Hypertherm announces 2017 webinar lineup offering free, educational training for welders and fabricators

Hypertherm, a manufacturer of plasma, laser, and waterjet cutting systems, today announced its 2017 Webinar Series, featuring a new lineup of free, educational webinars on industrial cutting topics for welders and fabricators. The company will kick things off on Thursday, January 26 with industry veteran Jim Colt who will provide an ultimate buyer's guide to light industrial CNC tables. Jim will discuss the differences among tables, show people what to look for when shopping and demonstrate how to connect an air plasma system. Additional webinar topics for 2017 include the integration of Hypertherm CAM software with fabrication management software such as StruMIS and Fabtrol, an introduction to new specialty consumables that simplify the most difficult jobs, and technical advances impacting the cutting of stainless steel. “As we’ve done for several years now, we are excited to once again

bring our experts together for this series of educational webinars,” said Anibal Sepulveda, head of marketing for Hypertherm North America. “Our goal is to provide fabricators with the right tools and information so they can leverage advances in cutting technology for greater productivity, improved cut quality, and reduced operating cost.” The Hypertherm 2017 Webinar Series is open to anyone. Registration is fast and easy. Go to http://response.hypertherm.com/C urrentWebinars, select the webinar you’d like to register for, and then enter in your name and email address. In addition to the live webinars featured as part of the 2017 Webinar Series, Hypertherm also offers a number of on-demand webinars and other training and educational materials on its website at www.hypertherm.com. All of these educational resources are offered at no cost.

Hypertherm designs and manufactures advanced cutting products for use in a variety of industries such as shipbuilding, manufacturing, and automotive repair. Its product line includes plasma, laser and waterjet cutting systems, in addition to CNC motion and height controls, CAM nesting software, robotic software and consumables. Hypertherm systems are trusted for performance and reliability that result in increased productivity and profitability for hundreds of thousands of businesses. The company’s reputation for cutting innovation dates back nearly 50 years to 1968, with Hypertherm’s invention of water injection plasma cutting. The 100 percent associate owned company has more than 1,400 associates along with operations and partner representation worldwide.

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Limestone Mine Benefits from Leroy-Somer Regenerative VSD Technology Leroy-Somer, Mr Phillips said that he chose this regenerative drive technology over other suppliers since he was aware of the company’s good reputation.

A major metal and non-metal mining specialist based in the USA has adopted the latest Powerdrive FX variable speed drive (VSD) with dynamic braking from Leroy-Somer. The product is being used as a regenerative drive on a downhill conveyor at one of the company’s limestone mining facilities. Leroy-Somer was selected as the preferred supplier following a recommendation when the conveyor’s existing drive became obsolete. Privately owned for three generations, Greer Industries has grown to become a diverse network of businesses managed from the company’s headquarters in Morgantown, West Virginia. Morgantown is also the location for three of the company’s four limestone mines operated by group company, Greer Limestone, a highly advanced mining operation with over 500 million tons of quality reserves. Today, limestone production in West Virginia exceeds 10 million tons per year, with much of that supplied by Greer. Limestone is used for asphaltic concrete and concrete production, metallurgical flux, cement, agricultural lime, and construction aggregate and ballast. The best quality limestone is used as rock dust and for chemical purposes in manufacturing and water treatment. “Conveyors are integral to our mining operations and help provide an assured supply of quality material in line with customer requirements,” explained Jim Phillips, Elec-


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The term ‘regenerative’ describes the ability of the drive under braking conditions to convert the mechanical energy of the motor and connected load into electrical energy, which is returned (or regenerated) to the AC power source. In short, less net power usage means lower utility bills for the user. trical Operations Manager at Greer. “Previously, we were using a Saftronics system that used a Fincor DC drive but it became obsolete. Without any access to service or spare parts we thought it wise to source a replacement to help avoid any potential for conveyor downtime and lost production.” Following a recommendation from Jim Parimuha in favour of

“It proved to be a straightforward swap when it came to fitting the Powerdrive FX,” said Mr Phillips. “In fact, it provided a much cleaner connection with our PLC when it was installed in May 2016, than our previous drive. It is also much smaller.” The Powerdrive FX VSD from Leroy-Somer offers a compact regenerative drive solution. Thanks to the latest generation control technology, it is well suited to the sensorless control of magnet motors. Furthermore, its IP54 protection rating against the ingress of airborne particles means that mining sector users such as Greer can benefit from extended operational life. “The integrity and reliability of the Powerdrive FX is very good, while the service support provided by Leroy-Somer is second to none,” concluded Mr Phillips. “I would absolutely consider using more of the business’ products in the future.”

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ADLINK Introduces Ready-to-Go Smart Camera with MVTec MERLIC NEON-1021-M delivers application-supported high performance all-in-one machine vision performance with no programming requirement ADLINK Technology, a leading global provider of trusted machine vision products, today announced the release of its new NEON-1021M Intel® Atom™ E3845 processorbased ready-to-go smart camera with MVTec MERLIC. Equipping its state-of-the-art quad-core smart camera with an easy-to-use machine vision software, the NEON1021-M significantly increases competitive advantage, exceeding basic smart camera advantages for machine vision development. "MERLIC's ease-of-use and its powerful machine vision software tools, combined with ADLINK's state-of-the-art imaging hardware, provide quick deployment of solutions with minimal configuration effort. This makes the combination ideal for facing the challenges of increasingly fast-paced markets". -Torsten Wiesinger, Sales Director, MVTec Software GmbH. ADLINK’s NEON-1021-M features high performance quad-core Intel® Atom™ processors, speedy multiROI image capture, 2MP global shutter image sensors, and PWM lighting control support. Highspeed multi-barcode capture by multi-ROI function shortens image processing cycle time, and opti-


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mized I/O includes one additional slave GigE Vision camera connection, 4x isolated input, 4x isolated output, and VGA output for maximized integration with external devices. Rugged construction with IP67-rated housing and M12 connectors enables the NEON-1021-M to withstand the harshest industrial environments. “ADLINK’s NEON smart camera series breaks the boundaries of smart camera and embedded vision systems, and the integration of the easy-to-use machine vision software MERLIC makes it a simple matter for system integration to fulfill a wide variety of inspection application needs.” Simon You, Product Director, Automation Business Center at ADLINK Technology Inc. MVTec MERLIC is an all-in-one tool for quickly building machine vision applications with no programming requirement. Based on MVTec's extensive machine vision

expertise and combining reliable, fast performance with ease of use, the PC-based complete software solution features an image-centric user interface, intuitively guiding the user through the application. Similar to a WYSIWYG editor (whatyou-see-is-what-you-get), developers can focus on the image-based display rather than complex lines of code or parameter lists. MERLIC is particularly suited to operations that favor a clear, graphical user interface for configuring imaging functions. NEON-1021-M Features: • Image-centered user interface • Machine vision application with no need for programming • Integrated tool library • 2MP 60 fps resolutions, monochrome global shutter CMOS sensors • Multi-ROI function replaces multi-camera barcode reader solution • Additional GigE Vision 1 slave camera support • IP67-rated housing and M12 connectors • EMVA 1288-verified superior image quality

January - February 2017



New Seco face milling cutter body doubles tool life

The new R220.88 face milling cutter family from Seco Tools features inserts with eight cutting edges and optimised geometries that provide excellent tool life and reduced cutting forces. The cutter body’s 88-degree lead angle allows for large depths of cut with smaller insert sizes than do 45-degree lead angle face mills. Its design also allows the new cutter to machine closer to workpiece side walls as well as intricate part clamping workholding systems when necessary. Designed for roughing and semi-finishing applications, the R220.88 is ideal for machining cast iron and steels in the general machining and automotive segments. The cutter body is made of Idun material, a corrosion resistant stainless steel that offers longevity and durability along with being environmentally friendly due to the elimination of the nickel coating process.


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The cutter body is available in diameters ranging from 50 mm to 160 mm on the size 12 insert and 63 mm to 160 mm on the size 16 insert. Each diameter is offered with a standard pitch variant and a closepitch variant to provide the best match to customer needs. The Size 12 R220.88 achieves a maximum depth of cut of 9 mm, while Size 16 reaches an impressive 13 mm maximum depth of cut. Right-hand versions of the cutter body are standard with left-hand versions available on special order, allowing integration into systems with dual spindles performing simultaneous milling operations. The R220.88 is compatible with Seco’s SNMU inserts, which are secured with a center lock or screws, eliminating the need for wedges to secure the insert in the pocket. The eight cutting edges on these inserts offer double the cutting edges over four-edged inserts to help reduce

tooling costs. With its neutral design, the SNMU insert can be applied in right-hand or left-hand milling applications. Available insert geometries include M10 and MD13 for size 12 and MD10 and MD16 for size 16, with an insert grade offering that includes MK1500, MK2050, MP1500, MP2500, MS2500 and F40M. An integrated wiper flat ensures a good surface finish for semi-finishing applications, and optimised geometries for reduced cutting forces with the M10. The heavy edge protection with the MD13 and MD16 inserts are ideal for difficult face milling operations, such as interrupted cuts. For more information on Seco Tools’ face milling solutions, please contact a local Seco representative or visit: http://www.secotools.com/enGB/Global/Products/Milling/Facemilling/R22088-Cutters/


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Innovative composite materials and solutions for automotive applications

Henkel highlights advanced automotive lightweight composite applications at JEC World 2017

Henkel highlights advanced automotive lightweight composite applications at JEC World 2017. At JEC World 2017, Henkel is putting the spotlight on high performance composites that provide car makers with new ways to design innovative lightweight solutions into their vehicles. Henkel, a leading worldwide provider of high-impact solutions based on adhesives, sealants and functional coatings, will be on


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Booth D28 in Hall 6 at the world’s biggest composites show, taking place from March 14 to 16 at the Paris Nord Villepinte Exhibition Center. During the event, Henkel experts will provide information on the increasingly broad range of products and system solutions that the company has created for the compos-

ites industry. Cost-efficient production of composite components on a large scale High performance lightweight composites based on glass or carbon fibers in thermoplastic and thermosetting resins can be tailored to provide the right levels of strength where they are needed. For vehicle makers, that translates into re-


duced fuel consumption and CO2 emissions along with enhanced safety and crash behavior. Henkel works closely with its partners along the value chain to create ideal integrated solutions in composites that can be made cost-effectively, in high volumes, and at high speed. In pole position on the Henkel stand at JEC will be a prime example of what is now possible with automotive composites created with Henkel materials and technical know-how: a ground-breaking leaf spring based on Loctite MAX 2 polyurethane matrix resin and continuous glass fiber reinforcement. The leaf spring, which debuted in late 2014 on the rear suspension of the Volvo XC90 premium crossover SUV, now features at the core of a lightweight rear axle concept implemented on various models. Volvo’s premium V90 estate and S90 models now also incorporate the highly innovative design, which is produced using high-pressure resin transfer molding, HP- RTM. With its low viscosity, Loctite MAX 2 rapidly fills the mold and quickly yet gently impregnates the fiber material, resulting in short injection times. The polyurethane resin’s curing rate is also substantially higher than that of comparable epoxy resins, so total cycle times are shorter too. Many automotive OEMs are also considering carbon fiber reinforced composites for wheels in place of aluminum. Henkel will highlight a new product in its Loctite MAX resin series that is suitable for use in production of such composite wheels, thanks to its very high temperature resistance and excellent toughness. The new Loctite MAX resin withstands service temperatures beyond 200°C and has a very high durability performance. As with

A fiber-reinforced composite leaf spring is being used in the chassis of the new Volvo XC90, a premium crossover SUV of which the innovative rear axle concept is to serve as a platform for other model series as Volvo S90 and V90. Loctite MAX 2, its high curing speed and ability to be injected quickly facilitate high volume production.

adhesives that offer not only high strength but also high elasticity that accommodates these differences.

A new binder technology for use in composite preforms complements Henkel’s resin portfolio with. Loctite FRP 2000 has excellent compatibility with both polyurethane and epoxy matrix resins. Its high mechanical strength means that only small amounts

Answering this call, Henkel will present a new adhesive for such hybrid material concepts at JEC World 2017. Loctite UK 2015, which is based on two-component polyurethane technology, is ideal for use on structural body parts, regardless of whether they are made of fiber-reinforced plastics, e-coated steel or e-coated aluminum.

of the binder are needed in the preforming process; it is also well suited to production of parts with complex shapes. Industrial adhesives for bonding multi-material assemblies Henkel will also present its newest innovations for adhesives designed to meet automotive composite industry needs for a reliable and easy production process. As automakers increasingly turn to fiber-reinforced plastics to at least partly replace steel or aluminum, there is a growing need to find effective ways to bond these different materials to one another. In addition to their chemical characteristics, metals and composites also differ in terms of their coefficients of thermal expansion (CTE) the amount they expand and contract as ambient temperatures rise and fall. Producers of lightweight hybrid structures need

Henkel will also highlight how its close cooperation with customers in development of resins, binders and multi-substrate adhesives facilitates their incorporation into new composite concepts. Last year, Henkel opened the Composite Lab, a state-of-the-art test facility, in Heidelberg, Germany. Here automotive customers can work with Henkel experts to develop and test composite parts, and also optimize production process conditions. They can carry out trials on Henkel’s own HP-RTM equipment, which has resin injection units for polyurethanes and epoxies coupled to a 380-ton press. More information on Henkel’s composites know-how, portfolio and technologies is available at www.composite-lab.com.

January - February 2017



ÖZYAŞAR, Wired to Empowering Customer Trust - Could you give us some information on Özyaşar Tel ve Galvanizleme and its products? Özyaşar Tel ve Galvanizleme Sanayi A.Ş. is a company that produces cold-drawn wires, galvanized wires, annealed wires and lubricated baling wires, particularly for the cabling sector but also for sectors such as automotive supply industry, packaging, construction and agriculture, as well as manufacturers of steel wire rope and perimeter security systems such as fence panels. Our company, which is one of the most prominent business organizations in Turkey as a firm that has been listed among the first 1000 export firms and the second 500 industrial companies of the country, exports its products to a total of 46 countries from various points of the world, particularly in the regions of the Americas, Europe and Middle East. The company has headquarters in Istanbul and four extensive wire galvanization facilities with a total surface area of 70.000 squaremeters, as well as a monthly production capacity of 8.000 tons, annual turnover of 70.000.000 USD and an approximate total employee number of 350. Operating with the experience and expertise brought on by nearly 60 years of involvement in trade activities and over 35 years of wire production, Özyaşar is well aware of its responsibilities towards customers and the Turkish economy, and has adopted a strategy of dy-


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Dr. Feridun ALKAN - General Manager-CEO namic structuring, product diversification, and continuous development and progress in services and technologies on a sectoral basis.

Özyaşar Tel ve Galvanizleme Sanayi A.Ş. has proven its commitment to fulfilling responsibilities against customers, quality requirements, employees and the environment by acquiring TSE & TSEK, ISO 9001-2008, TS 18001:2004 OHSAS and ISO 14001:2004, ISO/IEC 27001:2013, TSE/EN 10244-2, TSE/EN 10223-1, TSE/EN 10223-6 and TSE/EN 10223-7 certifications. - Would you tell us your take on 2016 in respect to the activities of


products instead of high-quality products and services, as well as the freight costs that are incurred in the markets we endeavor to develop, and cost-increasing procedures that arise during export processes.

your company? Have you achieved the production and sales figures you were aiming for? We reached our goals for 2016 by achieving a production amount of 90.000 tons, and exported over 50% of our total output to all markets within our target regions, particularly in the Middle East and Europe. While there was a certain period of stagnation in the last quarter of 2016, we made the best of it by using the period to search for new markets. - What is your approach to innovations and R&D? Could you share with us some information on the activities of your company in this respect? Innovations and R&D operations form the foundation on which efficiency and value-added product manufacturing are built. They constitute the key to success in maintaining leadership in the competition environment. In this sense, we continue our product development and R&D activities within scope of improvement and advancement projects. Özyaşar Tel ve Galvanizleme is the first company in Turkey to use rosette-shaped coiling technology in production of galvanized wires, nitrogen gas wiping systems in production of galvanized goods and cold drawing processes with rolling cassettes in wire drawing during production operations. We have

the means to manufacture and design all the machines and production lines we use for our products. The production development and improvement activities of Özyaşar, as well as the operations for establishment of an R&D center, continue at full speed. - What are the problems you experience in production and sales? Could you tell us about the current developments in the sector and your target markets? Our greatest problem in production is the inability to train proficient workers or find well-qualified workers in the sector for employment, as well as the rate at which employees change jobs, in spite of the many investments we make in constantly changing and developing technologies. The greatest shortterm difficulty we experience in sales, on the other hand, is the fact that customers prefer cheaper

- Could you share your objectives and insights in respect to 2017 with us?

We expect for the demand in the domestic market to decrease in 2017 but believe that the return from international markets will be more than enough to bridge the gap. Therefore, we aim to lower costs by focusing on value-added products and increasing efficiency and, in turn, achieve a growth rate that is higher than that of 2016 by 10 to 15%. Our other goals for 2017 include increasing the share of export in our total turnover to a rate around 60%, as well as enhancing and maintaining customer satisfaction with an approach based on supply of high-quality goods and services. Through a high installed capacity, wide product range and superior production quality, Özyaşar Tel ve Galvanizleme continues to expand by constantly growing stronger and maintaining its position among the most prominent wire manufacturers in not only Turkey and Europe, but the rest of the world as well.

January - February 2017



Lights, Camera, Action! Grinding professionals STUDER, SCHAUDT and MIKROSA present their stars at the annual Motion Meeting

The management of STUDER and SCHAUDT MIKROSA (from left to right): Gerd König, Fred Gaegauf, Jens Bleher Lights, Camera, Action! Grinding professionals STUDER, SCHAUDT and MIKROSA present their stars at the annual Motion Meeting. Only the best of the best can play in the world stars' league. And yet - do the cylindrical grinders have a place on the Walk of Fame? «We make our customers more successful, by responding to their requirements», states Fred Gaegauf, CEO of STUDER and SCHAUDT MIKROSA, at the annual press conference. To do this, you first have to understand the customer's individ-


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uality. Easier said than done, in a time when the complexity of processes is steadily increasing and customer requirements are also growing significantly. And yet the three companies achieve this, also thanks to their flexibility in production and constant pursuit of innovation. It is for good reason that STUDER, SCHAUDT and MIKROSA are global leaders in the industry with their products. «We are well on track, even if we have not met all our targets», confirms Gaegauf. To this end the cylindrical grinders have invested heavily in their pro-

duction technology and hugely reduced processing times, which ultimately also benefits the customer. Incoming orders 2016 started very positively for STUDER after a successful Grindtec trade fair, but this trend could not be maintained throughout the year and Fritz Studer AG finished the year below target. What are the reasons for this? «The VW diesel scandal, the weak economy in China and the continuing effects of the euro exchange rate as well as political uncertainties in many countries


caused us problems», explains Jens Bleher, Managing Director of STUDER and CSO of the Cylindrical Grinding Technology Group. STUDER's most important sales markets are Western Europe, followed by Germany, China and North America. SCHAUDT MIKROSA was unable to continue the success of 2015. After a strong spring, incoming orders remained clearly below the set targets. Orders in Germany, with a percentage of 25%, primarily come from automotive manufacturers and their suppliers. Another big market is China, with a percentage of 26%. Customer Care achieves a star on the Walk of Fame. Thanks to process improvements both efficiency and adherence to deadlines have been increased. In the long term STUDER's Customer Care department expects a clear increase in sales in the double-digit percentage range. SCHAUDT MIKROSA also plans to better utilize the potential in after-sales in the next few years and further expand the service segment. Efficient value creation in the operation segment STUDER, SCHAUDT and MIKROSA focus on strengthening core competencies along the entire value chain and have invested around 40 million CHF in their plants during the last few years. New buildings have been added and new machine tools have been installed and networked based on optimized logistical criteria. The cylindrical grinders have integrated central manufacturing processes into their own value creation chain in order to guarantee a high process stability. At the same time they have founded their own PuLs® Six Sigma Academy with the internal PuLs® philos-

ophy, based on the Lean Six Sigma method. This enables the employees to shape their own working culture and to constantly examine and improve processes and systems. Customer requirements are central for STUDER, SCHAUDT and MIKROSA. The focus is on the avoidance of losses and waste in all divisions of the company. They identify negative developments at the point of origin and eliminate them. Transparency and an open problem-solving culture are therefore important concepts for the companies. An impressive example: The introduction of flow-line assembly at STUDER. Thanks to the implementation of flow-line assembly in 2015 processing times in final assembly have been reduced by up to 50%, process stability has been significantly increased and quality risks have been significantly reduced. «We strive to achieve perfect processes, so that we can provide excellent products and services. We want to impress our customers with our effectiveness», says Gerd König, COO of the Cylindrical Grinding Technology Group. Standing still is not an option! During the next few years the companies will continue to focus on expanding the existing locations and will continue to invest heavily. The future starts now In order to maintain the innovation leadership of STUDER, SCHAUDT and MIKROSA in the future, the focus will be on the following projects: • «Industry 4.0». The fourth industrial revolution concerns the digitalization and networking of machines with their environment. Here the cylindrical grinders are focusing on the acquisition of machine and process data. The goal is

predictive maintenance. The aim is to avoid unexpected downtimes for customers and to make production more plannable and efficient. • «Smart Sensors». Here STUDER, SCHAUDT and MIKROSA develop active, autonomous sensors to fully measure and also actively support the grinding process. • «Universal Series» Following the successful market launch of the completely revised internal grinding machine series, STUDER is continuing to work on issues that make the customer more successful, as is the norm for a trendsetter. • «Cooling Lubricant»: In cooperation with IRPD AG, which operates in 3D printing, STUDER is developing coolant nozzles for laminar flow conditions. These allow the lubricant to be accurately directed into the grinding slot, so that the optimal cooling effect is achieved at the desired location. Stars and starlets An application which only STUDER can offer worldwide: STUDER-WireDress®: This enables incredibly complex geometries to be produced efficiently and with very high cutting ability. It helps to reduce process times and make the customer more successful. «We were able to reduce grinding wheel wear by 75%» confirms one enthusiastic customer. So do STUDER, SCHAUDT and MIKROSA have a place on the Walk of Fame? «Yes!», Gaegauf puts it in a nutshell. If you consider the difficult circumstances in which Switzerland finds itself, it is astonishing how impressively the grinding professionals have been able to assert themselves and still remain the global leader in cylindrical grinding.

January - February 2017



ThinKing October – Material selection in lightweight aluminum-titanium bearings reduces weight by half while maintaining full performance potential

(left) aluminum-titanium bearings. / (right) The draping gripper system takes two dimensional textile materials and forms them into three dimensional forms during transport. Source: wbk Karlsruhe. Reducing the weight of cars can make them more fun to drive and increase their performance dynamics while keeping fuel and material consumption low. The newest generation of spherical bearings manufactured by HIRSCHMANN SPERICAL BEARINGS is making its own significant contribution to this trend: aluminum-titanium lowweight bearings which perform just as well as the normally used standard bearings, but with only half the weight – and at a reasonable price.


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The Development Agency for Lightweighting Baden-Wuerttemberg is proud to present this innovation as its October ThinKing. The Leichtbau BW GmbH hands out this distinction each month to feature impressive products and innovations in the lightweighting sector in Baden-Wuerttemberg, a federal State in the southwest of Germany. Inside titanium, outside aluminum The innovative development by HIRSCHMANN consists of a highstrength outer ring made of alu-

minum, and inner ring made out of titanium and the unique HIRSCHMANN liner which the company produces out of PTFE and stainless steel support plates. Compared with other standard bearings made out of steel, these bearings weight about 50 percent less. This translates into better performance in nearly every driving situation from braking and accelerating to performance in the curves. In terms of its value for the money, the new product is certainly par


Automated wrapping of Tie Rods. for the course, costing about twice as much for standard slide bearings. The added value comes from the significant weight reduction that results from the sum of all of the spherical bearings in the vehicle. Racing teams have long realized the advantage of weight reduction, and HIRSCHMANN lightweight bearings were used in the Porsche 919 hybrid car which won the 24 Hours of Le Mans sports car race. Aluminum-titanium bearings benefit many lightweighting sectors Titanium has similar properties to ceramics when it comes to weight reduction. The metal is however much more attractive to customers in a direct comparison due to its lower price. On the other hand, titanium is difficult to process and cold reforming can be a challenge. This is why HIRSCHMANN has opted to use a combination of different

loads and impact forces both radially and along the axial axis.

Inner ring made of titan materials in its lightweight bearings and uses aluminum for the outer ring. The aluminum outer ring reduces weight by about two thirds, and the titanium inner ring cuts weight down by about a third compared to steel.

The aluminum-titanium bearings can be used in several areas in which lightweighting and weight reduction is a necessity. In addition to the automotive sector, the aerospace industry, model construction and the healthcare technology sector offer huge areas of potential. Modern airplanes which require a significant number of spherical bearings can benefit from the lightweight aluminum-titanium bearings which reduce weight leading to a significant fuel cost reduction. www.hirschmanngmbh.de

The engineers at HIRSCHMANN have designed the aluminum-titanium bearings to handle static and dynamic transfers of forces from several directions. The product is built to withstand high alternating

January - February 2017



Hypertherm now shipping FlushCut consumables for Powermax105 and Powermax125 air plasma systems

Hypertherm, manufacturer of plasma, laser, and waterjet cutting systems, today announced the release of FlushCut™ consumables for select PowermaxŽ air plasma systems. Available for Powermax105, and 125 systems, the consumables provide users with the ability to cut closer to base materials than ever before. FlushCut consumables feature an angled nozzle bore that delivers the plasma arc at a 45 degree angle ideal for challenging removal applications. Instead of locating the nozzle


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opening at the tip as is typically done, the FlushCut nozzle orifice is located on the side. This essentially bends the plasma arc, causing it to exit the torch at an angle nearly parallel to the workpiece. As a result, Powermax users can cut closer, or more flush, to the base metal than ever before, significantly reducing grinding work and increasing the opportunity to reuse lugs and attachments.

aration of two metals. The consumables allow users to more easily remove lugs, temporary weld supports, and pad eyes without damaging the base material holding the piece in place. In addition, the flush cutting process simplifies the cutting of weld access holes in Ibeams, and also makes it easier to remove bolts or other parts from metal plate. For more information please visit:

The new flush cutting process is helpful for a number of applications including jobs that require the sep-

www.hypertherm.com/FlushCut. “Strong investment in research and development along with a drive


to continuously innovate has led our engineering team to develop a truly groundbreaking consumable design,” said Brenda Mahoney, a product manager for Hypertherm torch and consumable products. “This new process has the potential to save companies a substantial amount of time while reducing operator fatigue and increasing safety on the jobsite.” The introduction of FlushCut consumables is just one more example of how Hypertherm is helping customers address challenging metal cutting and removal applications.

The company’s engineers have developed numerous torch and specialty consumable options including consumables for gouging, extended reach cutting, marking and fine feature cutting.

Hypertherm designs and manufactures advanced cutting products for use in a variety of industries such as shipbuilding, manufacturing, and automotive repair. Its product line includes plasma, laser and waterjet cutting systems, in addition to CNC motion and height controls, CAM nesting software, robotic software and consumables. Hypertherm systems are trusted for performance and reliability that result in increased productivity and profitability for hundreds of thousands of businesses. The company’s reputation for cutting innovation dates back nearly 50 years to 1968, with Hypertherm’s invention of water injection plasma cutting. The 100 percent associate owned company has more than 1,400 associates along with operations and partner representation worldwide.

January - February 2017



Going beyond all horizons - the S11 with extended functionality This will particularly please users of the new S11 - the smallest production cylindrical grinding machine in the STUDER Portfolio: Now they can profit from the diverse advantages of the STUDER standard grinding cycles and the grinding software for offline programming StuderGRIND**. Using the software, StuderWINfocus together with Fanuc control provides the basis for a flexible scope of use, which increases customer benefit significantly. "The customer naturally still has the opportunity to design his program as flexibly as possible using micro functions. With the STUDER standard grinding cycles, however, he has even more convenience and support with the S11," explains Christian Josi, Project Manager at STUDER. The uniform control platform guarantees program consistency on all machines running Windows operating systems. This is regardless of whether the program is programmed directly on the Control or is generated externally with StuderGRIND. Extended scope of application The conversion to the new control in the S11 provides even more advantages for users of the small, powerful production cylindrical grinding machine. Up to now, they were only able to work at grinding wheel speeds of 50 m/s (in exceptional cases max. 80 m/s). Today thanks to the combination of a


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The S11 gives you great performance in a minimum of space. Fanuc Control and StuderGRIND HSG machining is possible with CBN grinding wheels and grinding speeds of up to 140 m/s. A new high-speed spindle has been designed especially for the S11. The S11 achieves an extremely high abrasion performance in a minimum amount of space. Similarly, the S11 now also enables typical C-axis applications such as thread and form grinding. This is made possible by a new version of the workhead with C-axis function in combination with the soft-ware modules StuderThread or

StuderForm. The new and reprofiling of grinding wheels thanks to an optimized clearing strategy with StuderDress and machining of longitudinal contours with StuderContour extends the scope of application of the S11. Above and beyond this, the new S11 also features the SBS Dynamic Balance System. This combined system for contact detection by means of vibration measuring and for semi and fully automatic bal-ancing of the grinding wheels, reduces downtime thanks to less air grinding. It also enables the pro-cess to be


new casing is optimized for ver-tical loading with a top hatch. It is perfect for inter-linked production in which the machines are loaded and unloaded via portal cranes. Both designs stand out with their excellent accessibility and ergo-nomic features. * The programming software StuderWIN focus with its standard grinding cycles is perfect for a the most different grinding operations and includes optimized input masks in which the user simply has to enter the application specific grinding parameters. With the external tools from StuderGRIND and the new chuck workhead, even threads and polygons can be ground with the S11.

** The offline programming software StuderGRIND is made up of a variety of modules. The following modules are available on request for the S11: StuderDress for optimized clearing strategy, for profiling grinding wheels. StuderThread for thread grinding. StuderForm for form grinding. StuderContour for grinding longitudinal contours. StuderGeoImport for convenient use of workpiece geometry straight from a DXF file.

The new HSG spindle enables cutting speeds up to 140 m/s.

monitored, for example observation of grinding level noise. Optimized accessibility and automation casing

STUDER offers the S11 in two different casing designs: The existing version is specially designed for manual loading or to be combined with small handling systems. The

January - February 2017



Bosch sets new standards in bar packaging New technologies for high performance, quality and productivity

• Innovative linear motor technology for improved flexibility and speed •Industry 4.0 solutions support operators and increase efficiency •Single-source solution, from bar production to secondary packaging Whether chocolate, muesli or protein - consumers are increasingly asking for more individual bar products. “The rising number of bar variations requires highly flexible pro-


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duction machinery with short changeover times. In order to prevent bar products from cross-contamination by allergens, meeting food safety standards is a must,” says Josua Schwab, product manager at Bosch Packaging Technology. New standards in bar packaging thanks to linear motor technology In order to live up to manufacturers’ growing demands for increased productivity, flexibility and excel-

lent quality, Bosch will be unveiling an advanced version of its bar production system at interpack 2017. The seamlessly integrated system reaches a constant output of up to 1500 bars per minute in primary packaging with secondary packaging matching this high speed of the flow wrapper. The latest innovation is the intelligent Sigpack FIT product infeed with linear motor technology. It allows for push-button format


the primary and secondary packaging.

change, as well as a very fast, noncontact product feeding.

The Bosch Contiline for bar production encompasses the entire production process, from mixing, slab forming, pre-cooling, lengthwise cutting and fanning out bars to crosswise cutting, coating and final cooling. Combined with the bar packaging system, manufacturers can rely on one single source for their bar production process with a complete system solution.

The cross-sealing station of the Sigpack HRM flow wrapper is based on high precision direct drive technology and reaches film speeds of up to 150 metres per minute. With the same setup, bars of varying sizes can be packed, substantially reducing the time required for format change. A highlight in secondary packaging is the new intelligent Sigpack PFI feeding module using linear motor technology. To transfer the product from the flow wrapper into the Sigpack TTM topload cartoner, the new module gently turns and feeds the products into the grouping chain. It works exceptionally smooth at high speed without using vacuum. The Sigpack TTM forms, loads and closes up to 150 cartons per minute. Industry 4.0 solutions for optimal operator support Industry 4.0 solutions of Bosch Packaging Technology support operators in their daily work. For example, the biscuit system supports

format changes using RFID-tags. If a different format is needed in production, operators can scan the RFID-code of the respective format part, thus ensuring that it is installed on the right place. This increases efficiency and reduces potential errors. Complete solution for bar production enables high productivity Manufacturers can maximize their productivity levels with a singlesource solution which goes beyond

Of course, productivity is also key in bar production. At interpack 2017, Bosch presents, amongst others, the WRF 600 Flex roller former. The smooth slab former features easy and tool-free adjustments for precise edge cutting of slabs in different sizes, minimizing or eliminating trim and product waste. In contrast to comparable machines on the market, the working width of the WRF 600 Flex can be adjusted during machine operation, completely eliminating downtime. Visitors to Düsseldorf’s interpack 2017 can experience the innovations in bar production live at Bosch’s stand C30 in Hall 6.

January - February 2017



Sawing, sorting and stacking – automatic and fully integrated A recently installed fully automatic KASTOtec FC 4 band saw has led to an enormous increase in productivity for a machine tool supplier in Austria. Not only is the saw designed for use with carbide blades, KASTO has equipped it with a robot-assisted system for sorting cut-off parts. By linking up the saw with the manufacturing management system, the user is able to keep track of all the production data, which ensures a reliable, safe and low-manpower operation. Southern Austria is mainly renowned for its natural scenery. Sunny meadows and gently rolling hills attract hikers and bicyclists in summer. In winter, a number of skiing areas offer perfect conditions for winter sports enthusiasts. It thus comes as a surprise to discover that highly specialised machine tool components are being manufactured at a location in this region, between Graz and Klagenfurt. This is where an Austrian family-owned company operates the largest of its production plants. The company develops, manufactures and sells solutions for managing torsional vibrations in large diesel and gas engines. Its product range includes torsionally and resiliently flexible couplings and torsional vibration dampers made of steel and composite fibre materials. They are used in ship propulsion systems, power plant generators, bulldozers and rail locomotives, to give a few examples. Parallel use of different sawing


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KASTO Performance Cutting (KPC) is an equipment variant for quieter operation and improved cutting performance. methods One of the first production areas is the sawing unit. Round and flat steel stock, mostly tempered steel supplied as bar material, is cut to precise lengths. The high-grade ma-

terials are very hard to cut. Since December 2014, a KASTOtec FC 4 automatic band sawing machine made by the sawing and storage technology specialist KASTO has been in operation here. The saws in use before that time were unable to

A magazine with space for four bars with a length of up to 3,500 millimetres supplies the saw with material‌


… and a robot places the cut sections on one of four pallets. meet the increasing demands on cutting performance. The company therefore decided to purchase a new saw that easily meets the more exacting requirements. Higher sawing efficiency by KASTO Performance Cutting The company didn’t take long to discover KASTO Maschinenbau

GmbH & Co. KG. With the KASTOtec FC 4, KASTO offers a solution which is perfect for jobs of this kind. With its cutting range of 430 millimetres and smallest cutting dimension of 10 x 10 millimetres, it can efficiently handle materials of different diameters. Moreover, the added feature KASTO Performance Cutting

Purchased back in the 1980s, this KASTO hacksaw is still running perfectly.

(KPC) makes the saw suitable for using carbide saw blades. “KPC includes a number of measures to improve the guidance of the saw blade, to prevent vibration and to optimise damping of the sawing tool,” explains Sönke Krebber, head of strategic predevelopment at KASTO. “For example, vibration is effectively damped by a pair of springloaded guides on the return blade, ensuring quieter operation.” Before opting for this solution, the Austrian company’s managers paid a visit to KASTO in AchernGamshurst, Germany, and were impressed by the new technology. They also appreciated the professional treatment they received. Another reason for their decision was the system’s excellent value for money and the fact that KASTO was able to offer everything from a single source. The company not only decided to buy a new saw, it also purchased a robot-assisted sorting system for cut-off parts in order to

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face quickly guides the operator to the required functions. The link to the MES allows many processes, such as switching between orders, to take place fully automatically. This makes work easier and ensures greater safety. If a process does not run in the usual correct manner, KASTO sawing specialists and robot programmers work together at one location and are ready to help. They can obtain remote access to the system at any time and rectify any problem in short order. Productivity boosted by a factor of three to four

The EasyControl sawing machine controller ensures simple and intuitive operation of the KASTOtec. automate the monotonous and time-consuming task of removing and stacking. KASTO solved this problem by supplying an ABB industrial robot with interchangeable magnetic grippers for picking up parts and depositing them at one of four pallet locations. Integrated flow of information and materials The saw is supplied by a magazine that can hold four bars with a length of up to 3,500 mm. This allows production to run fully unattended even for long periods. The


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KASTOtec receives data on orders and dimensions from the manufacturing execution system (MES), which is linked to the saw via a custom interface. In this way it is ideally connected with all upstream and downstream production processes – an important step towards implementing Industry 4.0. As a result, the production process is considerably more transparent. The EasyControl sawing machine controller ensures simple and intuitive operation of the KASTOtec. A clearly structured graphical inter-

For the user, the KASTO solution has become indispensable. The carbide sawing system has boosted productivity to three to four times the previous level. Tooling times and cycle times are low in spite of the company’s need for some 1,000 different lengths and cross sections to manufacture its many products – due to automation and connectivity of the sawing machine. The robotassisted sorting of cut-off parts has proved so successful that the company plans to use the new technology for an additional saw. KASTO’s efficient combination of sawing machinery and automatic storage technology made an especially big impression. The user sees this as an excellent model for later growth. The user is convinced to have found the right partner for the future. “The KASTOtec provides us with the capacity we need to meet the challenges of the years ahead,” explains a company representative. “And we saw from the very start that KASTO puts a big emphasis on quality and long service life,” he adds with a smile, pointing to a hacksaw next to him. It too comes from KASTO – and has been doing its job perfectly since the 1980s.

January - February 2017



Eplan Harness proD 2.6 Comprehensively carefree through to manufacturing

Wires with predefined length can now easily be routed in Eplan Harness proD in an intuitive fashion. During the design process, the current as well as the targeted length are exactly depicted and users can recognise at a glance how the wires can optimally be routed. Efficiency ranks first, but the joy of designing doesn’t get short shrift: the new Eplan Harness proD version 2.6 is an intuitive 3D/2D software that covers all of today’s requirements for wiring and wire harness engineering. New features include enhancements to production specifications, which include cable drawings in addition to the nail board. Cable dimensioning is now automatic. If desired, cables with predefined length can easily be routed in an intuitive fashion. Cooperation between mechanical and


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electrical engineering becomes true team-work with open interfaces. The new Eplan Harness proD version 2.6 software from Eplan for convenient cabling and wire harness engineering is ready for release. Based on the 3D model of the mechanics and electrical schematics, the wire harness can be designed in an intuitive manner. The next step is the handover of this data to manufacturing, and there have been major updates in this area as well: integrating 2D cable drawings,

which are automatically derived from the 2D/3D design environment and that specify both dimension points and connection points. This allows for automatic dimensioning, saving valuable time and ensuring correct results. Stripping lengths and wire coatings can now also be defined in the design phase, and professionally depicted in the manufacturing drawings. This provides users with a quick and comprehensive overview of their projects.


2D wire drawings are now integrated, which are automatically derived from the 2D/3D design environment and specify both dimension points and terminal points. Determining lengths Wiring harness software normally offers the suitable tools of the trade to easily calculate cable lengths. In Eplan Harness proD 2.6, this now also works the other way around: users may predefine a fixed length – for antenna cables (as an example). During the design process, the current as well as the targeted length are exactly depicted and users can recognise at a glance how the wires can optimally be routed. This simultaneously allows for the reduction of variations, resulting in cost savings in warehousing and manufacturing. Additional functions for the creation of cable units allow elements to be grouped together as well as the assignment of component numbers to cable units, thereby providing a more comprehensive project overview.

Individual fields of application

Optimally integrated The connection to Eplan Platform and system openness to MCAD and ECAD ensure a continuous workflow between electrical engineering and mechanical engineering. Another new feature is that Eplan projects can be transferred directly into the wire harness software with version 2.6. Not only that, but Eplan Platform’s central parts management supports integrated data storage as users must only maintain master data in one system. This allows for integrated working processes for wire harness engineering from the schematics to manufacturing. The ease of use and integrated data in every phase of design through to manufacturing thereby lay the groundwork for quick and efficient results.

Numerous functional enhancements in the system contribute to making cabling design and wire harness projects more efficient and to accelerating customers’ workflows. Eplan Harness proD supports all industries in which cables and wire harnesses must be routed, for instance special vehicles, equipment manufacturers, wiring/wire harness prefabrication, machinery manufacturers and company divisions where interdisciplinary cooperation is required.

January - February 2017



NSK ball screws replace hydraulics in powder presses Switzerland-based Osterwalder AG is replacing hydraulic drives with servo-electric drives featuring NSK HTF series ball screws in its latest range of powder presses. As a result, users of the new systems can achieve a reduction in energy consumption of around 80% and produce pressed parts with far higher dimensional accuracy. This reduces the amount of finishing work, such as grinding with diamond wheels, and cuts process and material costs. Metal-cutting tools such as carbide inserts are typically produced using powder press technology. This entails filling a metal powder alloy into a die and pressing into the desired shape before final sintering. At the end of the process, tool manufacturers require inserts that are as close as possible to the final profile, as additional finishing is both expensive and challenging; the sintered inserts are extremely hard. Focused on providing customer solutions that overcome issues such as these is Osterwalder AG, which is based in Lyss, around 15km from the Swiss capital, Berne. To help deliver extra precision into the powder pressing process, the company recently took the decision to introduce new drive systems: the CA SP Electric and CA HM Electric series. This ‘Direct Drive Technology’ (DDT) with servo-electric motors and NSK ball screws, replaces the former hydraulic drives, which are now only used in presses requiring exceptionally high forces. Using DDT, pressing is performed


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NSK ball screws are used to drive the upper and lower die together simultaneously on Osterwalder’s latest powder presses with far greater accuracy, as Michael Sollberger, development engineer at Osterwalder, confirms: “We can position these systems to within 1µm and achieve very high repeatability levels.” Heavy-duty ball screws from NSK’s HTF (High Trust Force) series are responsible for the linear motion of Osterwalder presses. Precise synchronisation of movement is important as any interruptions or irregularities in the process can lead to dimensional errors, or even cracked

inserts during sintering. HTF ball screws also permit very high traverse rates, thus helping to minimise cycle times. Furthermore, extremely high axial force can be delivered, with patented geometry ensuring equal load distribution over all of the balls in operation. In combination with special ball separator technology, this prevents premature wear and assures very high reliability. Along with high precision and good controllability, users of Oster-


walder powder presses featuring the new drive systems can also achieve energy savings of around 80%. A powder press with a hydraulic drive and pressing force of 160kN has an energy consumption of up to 15kW. In contrast, a servoelectric system requires only 2.53.5kW. Since Osterwalder customers typically operate between 10 and 70 powder presses, the potential cost savings are vast. A further advantage of adopting the ball screw drive solution is that the presses now take up much less space. In addition, servicing can be reduced because there are no hydraulic control valves or other highmaintenance components, while working temperatures are more constant as no heat is being pro-

duced by the hydraulic system. Noise reduction is another benefit, as Mr Sollberger explains: “Our hydraulic systems operate at just below the 75dB limit, whereas the servo-electric systems are very quiet, only 58 to 60dB.” Various NSK ball screws are used in the CA SP Electric and CA HM Electric series, moving the upper and lower die together simultaneously. Osterwalder first introduced servo-electric drives on its 160kN presses, then its 320kN models. In total, more than 100 such presses are now operating successfully in the field. Looking ahead, this trend could continue as NSK states that pressing forces of up to 4000 or even 5000kN can be sensibly transmitted with the HTF series.

HTF ball screws are available in a variety of diameter, recirculation systems, lead and seal options, and can be complemented by heavy-duty NSK ball screw support bearings (TAC series) and linear guides (RA series). NSK is the only company that can deliver a complete mechanical powertrain from a single source, perfectly matching the different parts. As well as carbide pressed parts, the technology is equally applicable to components made from iron powder, ceramic and magnetic materials. HTF series ball screws have also been adopted widely by manufacturers of plastic injection moulding machines.

Line of high-temperature ratio pyrometers expanded Wider temperature range, new application areas Fluke Process Instruments has added four new single-color and two-color pyrometers to the Endurance series. The series now covers measured temperatures from 50 °C to 3,200 °C. The manufacturer has enhanced the maximum optical resolution from 150:1 to 300:1, enabling measuring of even smaller targets from a distance. A new low-temp ratio pyrometer for demanding applications measures temperatures from 250 °C. The sensors feature galvanically isolated inputs/outputs and a stainless steel IP65 housing. They withstand ambient temperatures up to 65 °C or up to 315 °C using cooling accessories. Application areas include primary and secondary metals manufacturing, carbon

New high-precision ratio pyrometers enable continuous visual process monitoring in the harshest industrial environments processing, silicon production, and now also foundries and welding, as well as rubber and thick plastics. The Endurance series offers a versatile range of models with wide temperature ranges and different wavelengths for precise process data that will help manufacturers reduce reject rates, improve product quality and uniformity, maximize throughput, and minimize energy costs. The

sensors operate with Power over Ethernet or DC power and interface to Ethernet, ProfiNet, and RS-485. A backlit rear-panel with tactile feedback allows for easy, intuitive navigation. The PC-based Endurance software simplifies configuration and deployment, and a built-in web server enables archiving of historical data for traceability, process troubleshooting and remote viewing. Various lens, sighting, and focus options are available, for example, an on-board camera for video sighting via Ethernet. A dirty lens alarm helps avoid unneeded periodic lens cleaning checks. All Endurance series pyrometers are offered with a best-in-class four-year warranty.

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Polymer-coated silicon nanosheets as alternative to graphene

A perfect team for nanoelectronics

Extruded spiral made of polymer-coated silicon-nanosheets glowing in UV light - Photo: Tobias Helbich / TUM Silicon nanosheets are thin, twodimensional layers with exceptional optoelectronic properties very similar to those of graphene. Albeit, the nanosheets are less stable. Now researchers at the Technical University of Munich (TUM) have, for the first time ever, produced a composite material combining silicon nanosheets and a polymer that is both UV-resistant and easy to process. This brings the scientists a significant step closer to industrial applications like flexible displays and photosensors. Similar to carbon, silicon forms two dimensional networks that are only one atomic layer thick. Like graphene, for whose discovery Andre Geim and Konstantin Novoselov received the Nobel Prize in 2010, these layers possess extraordinary optoelectrical properties. Silicon


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nanosheets might thus find application in nanoelectronics, for example in flexible displays, field-effect transistors and photodetectors. With its ability to store lithium ions, it is also under consideration as an anode material in rechargeable lithium batteries. “Silicon nanosheets are particularly interesting because today’s information technology builds on silicon and, unlike with graphene, the basic material does not need to be exchanged,” explains Tobias Helbich from the WACKER Chair for Macromolecular Chemistry at TUM. “However, the nanosheets themselves are very delicate and quickly disintegrate when exposed to UV light, which has significantly limited their application thus far.”

POLYMER AND NANOSHEETS – THE BEST OF BOTH WORLDS IN ONE Now Helbich, in collaboration with Professor Bernhard Rieger, Chair of Macromolecular Chemistry, has for the first time successfully embedded the silicon nanosheets into a polymer, protecting them from decay. At the same time, the nanosheets are protected against oxidation. This is the first nanocomposite based on silicon nanosheets. “What makes our nanocomposite special is that it combines the positive properties of both of its components,” explains Tobias Helbich. “The polymer matrix absorbs light in the UV domain, stabilizes the nanosheets and gives the material the properties of the polymer, while at the same time maintaining the remarkable optoelectronic properties of the nanosheets.”


The first successful application of the nanocomposite constructed by Helbich was only recently presented in the context of the ATUMS Graduate Program (Alberta / TUM International Graduate School for Functional Hybrid Materials): Alina Lyuleeva and Prof. Paolo Lugli from the Institute of Nanoelectronics at TU Munich, in collaboration with Helbich and Rieger, succeeded in building a photodetector based on these silicon nanosheets.

Alina Lyuleeva at the atomic force microscope with which the nanosheets were characterized - Photo: Uli Benz / TUM LONG-TERM GOAL OF NANOELECTRONICS – IN LEAPS AND BOUNDS TO INDUSTRIAL APPLICATION Its flexibility and durability against external influences also makes the newly developed material amenable to standard polymer technology for industrial processing. This puts actual applications within an arm’s reach.

The composites are particularly well suited for application in the up and coming field of nanoelectronics. Here, “classical” electronic components like circuits and transistors are implemented on scales of less than 100 nanometers. This allows whole new technologies to be realized – for faster computer processors, for example. NANOELECTRONIC PHOTODETECTOR

To this end, they mounted the polymer embedded silicon nanosheets onto a silicon dioxide surface coated with gold contacts. Because of its Lilliputian dimensions, this kind of nanoelectronic detector saves a lot of both space and energy. The research is part of the ATUMS Graduate Program (Alberta / TUM International Graduate School for Functional Hybrid Materials (ATUMS; IRTG 2022)) in which German and Canadian scientists in the fields of chemistry, electrical engineering and physics collaborate closely. Their goal is not only to create novel functions based on nanoparticles and polymer materials, but, at the same time, to develop first applications. The work is funded by the German Research Council (DFG) and the Natural Science and Engineering Research Council of Canada (NSERC).

Silicon wafer coated with the nanocomposite - Photo: Uli Benz / TUM

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Mettler-Toledo improves productivity, protection and quality with latest metal detectors Mettler-Toledo Safeline Limited, a market leading provider of metal detection systems for vertical packing applications, has launched a series of enhanced features for Profile Throat metal detectors and Gravity Fall systems. These enhancements allow manufacturers to benefit from increased productivity, enhanced brand protection and improved product and process quality. The four elements are aimed at making metal detection a smoother, safer, less disruptive process that adds to the profitability of operations. Reduced Test (RT) Mode is the first area of improvement. RT enables a significant reduction in the frequency of metal detector testing. For example, a customer who was testing metal detector function every two hours can extend this to every 12 hours with RT, providing the extended test period is still within the customer's quarantine period for the product concerned. On-board technology permanently checks the performance of all critical components within the system, analysing them 100% of the time to ensure they are in a state of good health. As the system is able to track and identify any elements that may lead to a reduction in performance there is no need for such frequent testing throughout production runs. Reduced Test Mode will identify any issues that could potentially affect the performance of the


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keep downtime to an absolute minimum. ATS automatically introduces three test pieces into the metal detector's aperture in a controlled manner via a pneumatic system one ferrous, one non-ferrous and one stainless steel - at the touch of a button. A 4-test sample option is also available, to facilitate testing for aluminium. ATS improves the efficiency and repeatability of performance testing to enhance quality processes.

metal detector including operator involvement and alert users before the system goes out of specification. Mike Bradley, Head of Sales at Mettler-Toledo Safeline, commented: “We have a customer in the UK that was testing their "throat" metal detectors every two hours. Now, since applying Reduced Test Mode, they test every 12 hours, which gives them a major productivity benefit. Testing still takes between three and five minutes, but now they only have to do it twice a day. This particular customer has in excess of 24 metal detectors, so the overall savings in time alone were substantial.” In order to reduce that five minute testing window, the Automatic Test System (ATS) was developed to

Mike Bradley continued: “The whole process now takes less than 30 seconds to test the metal detector. It still stops production, but just for 30 seconds as opposed to five minutes. In addition, it only takes one person to run the test, whereas in many existing situations it takes two people. ATS, therefore, provides improvements in productivity and operator efficiency. Operator safety is also significantly enhanced as the ATS reduces the need for operators to work at height to conduct performance monitoring tests, making the whole process virtually riskfree.” He adds: “Food manufacturers who install Safeline's latest metal detectors for vertical packing applications will experience a lower total cost of ownership, and benefit from improved Overall Equipment Effectiveness (OEE).” In terms of performance, new eDrive™ technology drives greater power to the transmit coil of the metal detector, enabling it to detect


significantly smaller real life metal contaminants. Fitted with eDrive, Mettler-Toledo’s latest throat metal detectors and gravity fall systems deliver up to 20% increased spherical sensitivity. This translates into significantly improved wire length detection capabilities, for enhanced product quality, increased consumer satisfaction and greater brand protection. The fourth element is called Emulation. Using VNC technology, Emulation allows operators to mirror the Human Machine Interface (H-

MI) of one or multiple Profile metal detectors onto remote networked devices, including mobile phones, tablets and laptops. The customer downloads a free of charge application from the app store and links it directly to the metal detector. This means quality personnel can log in from an office, for example, and remotely monitor the current status of the detector, view any setting changes that have been made, and review access log statistics without having to be directly in front of the metal detector.

“Often, metal detectors are installed in inaccessible places on the line. By enabling operators to control the device remotely it gives easier access to run performance monitoring sequences or adjust settings for product changeovers if required to improve overall efficiency. Emulation essentially supports a ‘top-floor to shop-floor’ monitoring system that can be connected via Wi-Fi or an existing network. In addition, the ability to access and control the detector remotely means operators no longer have to risk working at height to access the control panel. Safety is a very high priority for our customers and Emulation has been developed with this firmly in mind,” concluded Mike Bradley. The latest Throat metal detectors and Gravity Fall metal detection systems featuring these four enhancements will on display at MettlerToledo’s stand at interpack 2017 (Hall 11, Stand B55). For more information, visit www.mt.com/mdpve-news

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Combining lightweight high-tech materials with bionic design results in a groundbreaking logistics concept: CIKONI develops lightweight CRP shelves for the Mercedes-Benz Vision Van Loading and unloading of transport vehicles can often cost valuable minutes – and of course time is money. With traffic jams becoming commonplace and the traffic in inner cities more crowded new concepts are needed to ensure rapid delivery times. The German startup CIKONI is making an impressive contribution towards this goal with its lightweight shelves which are featured in the new Vision Van by Mercedes-Benz Vans. The shelves combine high-tech materials with bionic design. Mercedes-Benz Vision Van - Exterior © Daimler AG

The Development Agency for Lightweighting Baden-Württemberg is presenting this innovation as its ThinKing for February 2017. Leichtbau BW GmbH presents this title each month to provide a free promotion platform to innovative products and services in lightweighting sector of the German Federal State of Baden-Wuerttemberg.

for the final end-point deliveries of products – even using on board drones for the final stretch of the delivery. The manufacturer itself states that it is setting new standards for performance requirements and solutions for future generations of delivery vans.

Mercedes-Benz Vans presented a revolutionary transporter concept study for urban areas in 2016 with the Vision Van. The van integrates a number of innovative technologies

The centerpiece of the vehicle is the intelligent cargo space management. It provides assistance both in loading at the logistics center as


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One-shot loading saves time and costs

well as in making the final delivery of packages to the recipients more efficient. The so called one-shot loading helps save the operator time and money during the loading procedure. The lightweight shelf system developed by CIKONI is designed to be placed into the cargo area after being fully loaded. At the point of delivery, the packages are automatically removed by machines and handed over to a courier or to a delivery drone for the final delivery.


The lightweight shelf system is designed to be placed into the cargo area after being fully loaded. Source CIKONI This process reduces delivery time as well as the time required for the vehicle to be parked. All in all, the throughput of the vehicle can be significantly increased.

grated functional surfaces minimize wear from friction and shock absorbers protect the shelves while reducing the need for additional components.

the futuristic look of the Vision Van. Despite all these difficult requirements, the CIKONI shelves were designed and built in an extremely short time.

The shelf itself is made of an intelligent material mix of carbon fiber reinforced plastic (CRP), aluminum and sandwich design concepts. This design guarantees high stability under hard braking conditions and sharp curves while at the same time keeping weight low. The designers cleverly took advantage of the attributes of the different materials. Weaknesses of the individual materials can be targeted and eliminated by combining different materials. Integrated support points for the load bearing elements using inte-

Racks must be practical and visually appealing

The design of the shelves was based on a bionic principle inspired by the structure of a tree. Topology optimization and computer aided optimization (CAO) were used intensively to finalize the design. The shelves were then crafted using the bionic design out of an aluminum hybrid blend and numerically optimized by utilizing the degrees of freedom of the fiber reinforced construction. The completed structure is extremely anisotropic, integrating material only where it is needed to bear specific loads.

The shelves are expected to fulfill several difficult requirements. They must be designed to make the most out of the van’s cargo space while at the same time keeping weight to a minimum and maintaining stability under a load of up to 500 kilograms each while the vehicle is in motion. The racks must also be easy to handle to meet the robust requirements of the logistics industry. A bold new design was also requested in order to fit visually with

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The shelf itself is made of an intelligent material mix of carbon fiber reinforced plastic (CRP), aluminum and sandwich design concepts. Source CIKONI The construction of the shelves was carried out in close collaboration with established companies such as UBC and Hermann Blechtechnik, both from the same region. The manufacturing process depends on adaptable development methods and rapid concept turnaround. Dr. Farbod Nezami, managing director of CIKONI, commented on the project noting, “Everyone involved was open for innovative developments and that is not always a given.” Startup forming partnerships with established companies Thanks to the use of high-tech materials, CIKONI was able to make optimal use of the available cargo space. Both volume and weight have a direct influence on the effi-


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ciency of the system. The startup company from Stuttgart was able to use its expertise in the area of multi-material lightweight construction throughout all stages of the process from conception, numerical optimization and function validation to detailed construction, FE calculation and the final delivery of the installation ready rack and loading system. In order to cover all of these bases, CIKONI had to build up a wealth of know-how. According to Nezami, “We have highly specialized development engineers who supervise the entire process from conceptualization to simulation, construction and manufacturing processes for small and largescale serial production. This know-how is

coupled with creativity and clear customer focus. Our primary goal is always to spark excitement – with our customers and the customers of our customers.”

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AN EXCELLENT PRESS MAILING SERVICE Decentralizing the system to reduce space and materials Promotional postcards and flyers, membership cards, coupons and other info materials fill up our mail boxes daily and encourage shopping tailored to you. Do we ever ask ourselves where all this comes from? The answer is probably from creative minds based in marketing companies. That’s true, when it’s about the idea. However, who produces and makes all of this? A mailing house. Cor-rect! But how? The answer is provided by engineers and planners at C.M.C. srl with the support of Kollmorgen’s decentralized solutions. C.M.C. srl is an Italian company based in Città di Castello (Perugia) since 1980. They are leaders in developing solutions and innovative

systems in the fields of mailing, graphics and packaging on demand. The company is able to offer highspeed machines for managing envelope inserts which are completely integrated within the production line,reading and printing systems. C.M.C. is a proud pioneer in automated mailing: C.M.C. machines can process up to 30,000 envelopes per hour with detailed digital printing tailored to your needs. Thanks to our strong engineering and informatics department, the company is able to promptly deliver on clients’ needs and can speed up the variable packaging program when sending out the materials and in the finishing process. One of the last challenges this

company took on was that of creating a customized plant which could an-swer to the needs of a major enterprise at European and international level. It consisted in printing and sending out publicity materials which needed to print promotional coupons in a short frame of time] and at the highest quality as well as being custom made. A head start we had on this project was consolidated technology that is market proven. Its strength, however, was the winning idea: the machine was revolutionized and tailored to the needs of the client, thanks to our own research and development department, strong communication with the client on the one hand and the support of Kollmorgen on the other.

CMC 400- Machine CMC 400 for printing and sending promotional material as direct mail.


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The challenge was to produce high quality print on fine coated paper, customize, pack and send the materials with the maximum precision, quality and possible speed. “For years we tried to reduce the switchboard dimensions” said Enrico Martinelli – Production Manager Mailing Department, and Maurizio Giacchi, Sales Manager. Thanks to Kollmorgen’s solutions- we were able to decentralize each drive along the three production lines that are part of the plant”. AKD-N AKD-N decentralized Multiaxis Servo System is perfectly compatible with any type of motor and allows you to utilize non-stop all the advantages of systems with single power cable.

Every line is made up of three machines equipped with 24 stations matching the number of coupons,

Centralized versus Decentralized Advantage of Decentralized Solution, less cabeling and smaller cabinet

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drives can offer complex Motion Control systems with EtherCAT fieldbus and/or other automated interfaces such as ProfiNet, EtherNet I/P and Modbus TCP/IP. The system offers everything that’s necessary for new generation machines without losing out on the simplicity. Power supply as well as safety (STO) and EtherCAT fieldbus are combined in one single hybrid cable of only 11mm diameter. On the motor side there is also only one cable needed for power, brake control and feedback. This leads to more than 80% of machine cable savings. AKD-N Servo Amplifier Benefits AKD-N in CMC Machine Decentralized Servosolution inside the machine and close to the motors some which were customized, whilst others were standardized. The objective was achieved by removing the control panel drives used previously and therefore drastically reducing the size of the switchboard, number and length of cables involved: from a four-frame stand-alone one built on alongside the machine and two meters wide, we moved to an integrated electric switchboard, saving in the process some external space. The AKD-N series drives, installed close to the motor only have one connection cable. The client also benefits from this since they are able to save space for the materials: this transformed the machine to improve ef-


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ficiency at reduced cost (Total Cost of Ownership). AKD-N Multiaxis Servo Amplifier System: the winning input The keystone to this project was the use of the AKD-N Multiaxis Servo Amplifier System, an innovative technology with excellent performance that comes in extremely compact size. Thanks to the robust structure and the IP67 protection class, the new decentralized AKD-N Kollmorgen servo drives can be placed close to the motor. Plug-in connections, freedom of choice of motor , most suitable mounting point , and wide range of functions: these decentralized AKD-N servo

• More compact machines • Smaller and lighter integrated switchboards • Servo amplifier placed closer to the machines • Robust structure made of protection class IP67, no need for protective casing • Easy to clean and service for hygienic environments • High operating security - thanks to the robust structure • Faster machine debug and test thanks to less cabling • Higher flexibility in machine design (modularity and scalability) C.M.C. has attained the highest benchmark through Kollmorgen components and in choosing a de-


AKM Family AKM Servomotors from Kollmorgen available in 8 Sizes – a perfect match centralized solution. Kollmorgen is a specialist in Motion Control solutions offering a wide range of servo drives, servo amplifiers, pre-wired cabling and technical support with the highest level of experience, providing step-by-step support to the client during the entire project development. The global scale of the Kollmorgen brand has enabled C.M.C. to venture in the US and to tap into established markets. AKM Servomotors, a step further In terms of motors, even the wide range of AKM™ Servo Motors contributed to C.M.C. choosing Kollmorgen as their partner in this project: AKM™ practically has an unlimited number of configurations and therefore allows for unprecedented choice and flexibility as well as toplevel performance and an ex-cellent power density. It is worth noting

that the AKD™ servo drives are easy to set up and use thanks to their plug-and-play motor recognition and self-adjustment.

to undertake new challenges ahead together, with the added value that has allowed us to stand out to date”.

Conclusion “I’m really pleased to be working with the C.M.C. team, it’s a dynamic company, full of innovative ideas, with young and talented staffs – concludes Fabio Massari, Senior Sales & Key Account Manager at Koll-morgen. Working closely from the start with the management team and being able to share our respective needs has allowed us to provide a solution, which in this specific case has brought about a reduction in the amount of cabling used; from the old system which required 1,500 meters down to 240 meters. We were able to save on more than one entire kilometer of cabling. I hope that we will be able

Fabio Massari Author: Senior Sales & Key Account Manager, KOLLMORGEN Italia

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Defining and Predicting Housing Strength for Mounted Bearings Why It Matters for Optimizing Your Operation Florin Constantin, Principal Application Engineer, The Timken Company

Abstract Design engineers across industries rely on pillow block bearings for a variety of tough and unconventional applications. Having access to data that backs housing strength performance claims is an integral part of choosing the right bearing to keep operations running optimally. What design considerations must be made when the application demands a pillow block installation on a non-horizontal orientation? What happens when bearing load is not applied through the base of the u-


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nit? The Timken Company answers these questions with physical testing, advanced modeling and realworld experience to facilitate the selection of pillow block bearings for specific applications. Why Strength Matters The roller bearing is an essential component of countless industrial applications around the world. The reliability and repeatability of the processes where differing types of roller bearings provide functionality is of paramount importance for countless everyday operations.

For most industrial operations, designers seek to maximize uptime with the selection of components that offer extended service life. In most applications where rolling-element bearings are applied, bearing static and dynamic load capacities are crucial parameters when estimating operating life. Static load rating: The maximum load a bearing can withstand before permanent damage to the raceways or rolling elements; indicates a load being applied in a constant, unchanging direction under non-rotat-


ing conditions. Dynamic load rating: The radial load under which a population of bearings will achieve an L10 of one million revolutions. The load value is used to estimate bearing life based on the actual applied loads and speeds. For pillow block (also known as plummer block, mounted bearing or housed unit) applications, the strength rating of the housing itself is a critically important performance attribute—and is why Timken performed an evaluation of housing strength and permissible load across its roller housed unit product line. Solid block housings: One-piece housings that are factory assembled, pregreased and sealed, offering simple installation direct from shelf to shaft. Split block housings: Two-piece housings that are split in the middle with bolts fixing the two halves. These allow for simpler installation, and replacement of the bearings and seals without removal of the housings. Industrial operators rely on these specialty bearings and housings for supporting shafts, gears and other rotating or oscillating components in a variety of unconventional loading orientations. Also, they often necessitate special design considerations. For instance: What changes in design must be made when the application requires a pillow block to be installed upside down? What if the bearing load is not applied through the base? The equipment designer relies on housing static load carrying guidance to make the appropriate selec-

tion of pillow block bearing for a given application. Thus, it’s critical

need for consistent housing strength data when designing equipment. In these types of applications, housings handle extreme forces in varying directions and allow the bearing to be mounted in positions where the load may not be applied directly through the base. These orientations are most common in large conveyor systems and in extreme applications like industrial crushing machines or hammer mills.

that these decision makers have access to housing strength information to optimize the effectiveness of equipment. The Need for Reliable Housing Strength Data The demands of today’s operations require bearings to work harder and longer. This means the housing must work harder, too. Applications that generate more than one loading orientation on bearings require housings that can bear the same loads, hence the

Spherical roller bearings are commonly used in general industrial applications, providing dependable performance and capacity in supporting radial loads with limited axial loading. A common question when seeking replacement mounted bearings is: What kind of load can be applied to my bearing? Answering this question is critical to selecting an appropriate bearing for the application. The geometries of mounted roller bearing housings can be complex and varied in shape, based on the size and type of bearings they support, making it complicated to estimate housing strength. The Timken testing methodology for generating housing strength data combines advanced modeling techniques and experimental testing, all backed by real-world experience for the purpose of providing answers for customers. Housing Strength Testing Methodology Loads can be applied to pillow block bearings in virtually limitless ways. Testing every housing to failure in every loading orientation is impractical, requiring a consistent

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modeling technique to maximize available usable data. Timken developed a method of generating breaking strength data based on laboratory testing, advanced modeling calculations and the company’s history in the metallurgical engineering field. Finite ele-


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ment analysis (FEA) is combined with experimental testing to create calibrated models that calculate the limiting static strength of the bearing housing. Housing strength design rules were then established and appropriate strength values published.

Modeling/Finite Element Analysis (FEA) FEA is deployed primarily to account for the diversity in mounted bearing housing shapes and complexities. For housing strength, FEA is desirable over simplified analytical expressions’ limits in accounting for complex shapes.


FEA can account for the interaction between complex housing geometry and non-linear material properties when calculating stress and strain. Three-dimensional solid models of housings are prepared as a first step for incorporation into the FEA model. Based on the loading and geometry symmetry, a half model was created to reduce the size of the model and the subsequent solution time. These models were first solved to get a rough estimate of the breaking strength of the test parts to estimate experimental tooling requirements. The models were later refined to include failure criteria validated through experimental results. (See Figure 1.) Cast iron is commonly used for mounted bearing units, desirable

for its relative structural rigidity, strength under compression and corrosion resistance. However, some applications require very high impact loads or non-horizontal mounting, where cast iron does not provide adequate strength. Cast steel offers a strong alternative. It has approximately twice the yield strength as comparable cast iron and offers greater breakage resistance in tougher applications. Ductile iron also far exceeds cast iron in strength and can be advantageous for certain housing geometries. Through FEA modeling, Timken is able to calculate and define accurate fracture strain and stress values. Breaking strength for cast steel housings is estimated with a non-linear elastic-plastic analysis

with an isotropic hardening model. Based on the housing’s material properties, ductile damage data is entered into the FEA models to check the maximum strain of each element. As the housing load is increased, the material hardens while elements elongate and exceed critical strain thresholds. The load on the housing reaches a maximum, followed by ductile fracture. Typical strain patterns are illustrated in Figures 2 and 3. Simulated modeling that follows an established method, as outlined above, allows Timken to predict housing strengths, enabling the customer to create a more reliable and dependable design. Modeling is only part of the process. Testing is also used to verify the modeling assumptions and provide better and more realistic model parameters. Physical Testing FEA simulation assumptions were based on findings for housings loaded to the point of fracture. To determine these figures, Timken housings of different sizes were selected and loaded in a hydraulic press outfitted with specialized universal tooling then tested at a range of loads. The universal tooling used for these experiments is able to break housings in 180-, 150- and 90-degree loading directions based on differing setup configurations, reflective of the unconventional angles in which pillow blocks are installed in the real world. Since the estimated load necessary for housing fracture in these simulations could exceed the bearing static limit, no bearings were used in this exercise. Instead,

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they were replaced with round bars. Various styles of solid block housings and split block housings were physically tested. Each test was performed using properly controlled loading cycles. Hydraulic fluid was slowly metered into the load piston using a control valve. A computer recorded the values of the load cell throughout the test so the maximum loads could be determined. Multiple replicates were tested in each of the loading directions. The results of the test indicated variability between the replicates in load magnitude as well as breaking location. For example, a four bolt housing had three different failure locations when loaded in the 180-degree direction. The attachment bolts through the base flange had to be supported in each test to prevent bolt breaking and force a housing break. This was necessary even when using Grade 9 quality bolts. The housing break failures, as seen in Figure 6, were ductile in nature, as demonstrated by the visible deformation in the housing before fracture occurred. These results were consistent with the expectations for cast steel material and assumptions based upon FEA findings. Large plastic deformation was seen at the bolt attachment area on the flanges, though no ultimate fractures occurred there. Breaking load, displacement and break location data were collected from each test. The methodology for analyzing and testing split housings was similar to that of solid housings. The testing showed that the gray cast iron housings had a more brittle


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introduced another failure mode, which was bolt fracture on some of the housings. To account for this, FEA models were enhanced to include bolt ductile damage failure criteria. (See Figure 5.) Housing Strength Test Results The Timken methodology for determining housing breaking strength can help equipment designers and end users make informed decisions on the advantages and benefits of each of Timken’s housed units. Through this rigorous testing process, Timken established not just the strength of its materials, but also the unique applications in which its portfolio of mounted bearings and housings will best perform, backing housing strength estimates with conclusive data. Failure modes may vary based on casting geometry, casting material, and cap bolt size and grade. Split housings enable a simpler assembly and can help reduce overall installation cost, but do not maintain the same overall strength of comparable single-piece, solid block housfailure mode with little deformation before fracture. Breaking loads were lower than the cast steel due to the material strength difference. The ductile iron housings had larger strains than the gray iron at fracture, but not as great as the cast steel parts. (See Figure 6.) In the FEA, the gray cast iron housing failure criteria were defined using an extended fracture mechanics model. In comparison, the ductile iron housings used the same failure model as the solid block housings, but with a smaller fracture strain definition. The split housings also

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ings. Solid cast steel housing strength values generally exceed the bearing capacity regardless of load direction. Using a conservative approach, published housing strength values for solid block housed units were established using minimum material properties. Gray cast iron generally has a smaller load-carrying capacity at varying orientations than ductile cast iron. While gray cast iron can be a more cost-effective material than ductile iron, it may not be the appropriate choice for more demanding applications in non-horizontal load bearing applications. Easy-to-use safe load guidelines for Timken split housings, where load is not applied directly into the base or if the base is unsupported (P0) have been developed. The safe load is the maximum suggested load to be applied to the housing depending on the direction of the load. The safe load guidelines for split housings account for the breaking strength of the housing and the


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breaking strength of the cap bolts. A commonly accepted safety factor of five is used for the breaking strength of the split housing material, and a safety factor of three is used for the cap bolt breaking strength. Additional safety factors may be applied by the user for safety-critical applications. The published safe load values assume the housing has been properly secured to the base structure and proper torque has been applied to the cap bolts. Figure 7 shows a comparison of housing safe loads for both cast iron and ductile iron relative to shaft size and angle of the applied load. This shows the importance of housing design and material selection in selecting the proper housing for a given application. By using FEA results calibrated with experimental testing, Timken has created a methodology to predict housing strength without testing each unit.

Through this combination of advanced modeling and real-world experience, Timken is able to provide estimated housing strength of its mounted bearing offerings. Actionable, accessible data is one more way Timken meets the increasing demands of heavy industry every day. All specific data relevant to housing strength based on the Timken method is available within the company’s latest housed unit catalog.

January - February 2017



January - February 2017

January - February 2017



January - February 2017

Turkey Industry Magazine January-February 2017  

Turkey Industry Magazine January-February 2017

Turkey Industry Magazine January-February 2017  

Turkey Industry Magazine January-February 2017

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