Page 1

0 6 | M AY 2 0 1 4

Industry

Asia Pacific The industry magazine for Asia.

SC-System: New family of signal conditioners from Pepperl+Fuchs

@bourdonbybaumer

25

Customer event 28th May at 2 pm

TRITEX II™ AC POWERED ELECTRO-MECHANICAL ACTUATORS

2pm: Zürich 4pm: Dubai 9am: Houston Ask your question about Bourdon (Baumer Group) on a Twitter Event !

6

Industry Asia-Pacific | MAY 2014

29 New KSSM8+™ Face Milling Platform for Cast Iron

31


BAUMER

BALLUFF

05

04 ARC INFORMATIQUE

KEYENCE

10

12

HMS

KENNAMETAL

14

16 PEPPERL+FUCHS

SECO TOOLS

19

20 EXLAR

PROSOFT

21

22


NEWS

Balluff vision sensor BVS-E Universal

Universal sensor for all applications

T

he new BVS-E Universal vision sensor from Balluff with integral processing electronics, lighting and two digital outputs is a genuine all-rounder because it combines the functions of the proven BVS-E Advanced and BVS-E Ident vision sensors in a single device. For the first time, a single model is suitable for almost all inspection tasks and simplifies stock management considerably. Not only can the BVS Universal inspect a large number of characteristics in one pass, it can also simultaneously perform various tasks such as checking brightness, comparing contrasts, counting edges, checking positions, detecting patterns and reading codes at speed. New additional tools such as a 360° contour, barcode and data matrix check as well as the option of counting and checking contours offer virtually unlimited application possibilities. The result of the check is issued either as an OK or error signal via the digital outputs or the RS 232/Ethernet interface. The position of the detected part can be transmitted to a PLC or robot control, for example, so that the part can be aligned for subsequent process steps.

More Information 06 | Industry Asia-Pacific | MAY 2014

4

The universal device is extremely fast. Up to 40 barcodes and data matrix codes are located per second, and then

read and verified independently of their position. The code data is available for further processing via an interface. In addition, an optical character verification (OCV) function can verify printed sequences of characters and numbers such as batch numbers or minimum shelf life dates. The BVS-E Universal vision sensor is available with different lens versions. Powerful integral red light or infrared LED lights illuminate the image area perfectly. The power supply and peripherals are connected via two industry proven M 12 connections. The robust, high-end sensor the size of a credit card is easy to use via the supplied ConVISÂŽ software with its intuitive user interface. The user only has to connect the sensor to a PC to configure parameters and operate the sensor using free configuration software. It runs on Windows XP and Windows 7 and also offers the option of storing up to 10,000 inspection images on the computer for troubleshooting purposes, for example.


NEWS

Success principle flexibility: photoelectric and ultrasonic sensors with the same design

The U500 ultrasonic sensor completes Baumer’s new performance category.

T

he story of the new performance class continues to be written. With the U500 sensor, Baumer now expands the portfolio of NextGen sensors to include ultrasonic technology. The new sensors are identical in design and size with their series O500 electronic counterparts. This OneBox design also applies to every available sensor principle and offers the user maximum flexibility during the planning phase. Not only that: Also with subsequent modifications in a system’s requirements profile, the sensors can be exchanged quickly and easily without any additional conversion measures. In addition to the U500 and O500, the smaller O300 completes Baumer’s new performance category for applications with limited space.

possibilities. The fast response time also increases flexibility in applications. A further advantage is the narrow, symmetrical sonic beam. It has a diameter of only 80 mm at an object distance of 500 mm. This allows the U500 to be used in applications with very cramped spaces. Furthermore, the sensor is distinguished by extraordinary reliability, which is based on large excess gain. Reliable operation is therefore guaranteed. The robust housing (IP67) and new transducer also contribute to making the U500 an extremely resilient sensor. It is unaffected by dirt, water droplets or even cleaning agents. The versatility is also shown by the availability of the U500 in three sensor principles: As a proximity switch, distance measuring sensor and reflective light barrier.

While the photoelectric sensors are predestined for applications with very small objects and high speed thanks to their precise light spot, the great advantage of ultrasonic sensors is that they detect almost every object. They do not depend on color, characteristics or transparency, even under harsh conditions with large amounts of dirt. The U500 has a special place in the range of ultrasonic sensors due to its versatile performance. With 1000 mm, it offers the longest range in its class, with many application

More Information 06| Industry Asia-Pacific | MAY 2014

5


@BourdonbyBaumer

Follow us on Twitter @BourdonbyBaumer and  participate in the press conference on 28th May at 2 pm (Zßrich 2pm. / Dubai 4pm: / Houston 9am). Martina Mergl, responsible for Oil & Gas d epartment in Baumer will answer your questions.


NEWS

«Bourdon Original» by Baumer: A historical innovation

The Bourdon tubes are checked for leaks and undergo an overpressure cycle to eliminate tensions in the materialv

W

hile the wheel of innovation turns faster and faster in the process industry, a more than 160-year-old technology is still used for pressure measurement today.

The «Bourdon tube» developed by Eugène Bourdon in 1849 and named after him is still the most common method for mechanical pressure measurement in the gas and oil industry today. After the takeover of the Bourdon-Haenni company in 2005 and its integration, the Baumer Group is the owner of the only «Bourdon Original» label today. Baumer Bourdon Haenni is now the competence center for mechanical measuring instruments within the Baumer Group. The principle of the Bourdon tube merges with the Baumer innovation know-how to create latest generation mechanical pressure gauges. For many years, Baumer has reliably been providing them to the petrochemical industry, power stations, water treatment plants, aviation and marine applications, and the food industry. These Bourdon-tube pressure gauges are easy to handle and maintain. In addition, they are capable of a wide pressure range and offer a high level of accuracy (up to 0.1 % of the end value). Since they do not require an external

06 | Industry Asia-Pacific | MAY 2014

8

power source, they are not prone to voltage fluctuations or power outages. Baumer continues to rely on this proven Bourdon principle for its mechanical pressure gauges. At its production site in Vendome (France) however, the traditional principle is updated by implementing -the latest quality methods which offer decisive benefits in demanding oil and gas applications. Bourdon tubes, which have different dimensions depending on the nominal sizes of the measuring device and the measuring range, are manufactured from long stainless steel tubes in a bending machine. T he Bourdon tubes are given their typical C shape and a flattened cross section. The Bourdon tubes are welded to the connection piece of the measuring device at one end and to the tube end piece at the other end. The welded measuring systems are checked for leaks and undergo an overpressure cycle to eliminate tensions in the material. Then they are welded to the pressure gauge housing in an automated laser welding plant. After assembly of the pointer mechanism,the pressure


Sophisticated and proven products, ultra-high precision and competent expert support – Baumer is up to any challenge raised by the petrochemical industry.v

gauge is adjusted and checked upon compliance with measuring range and accuracy class.

R - reliability according to the «zero defects philosophy» (Reliability)

This is done in a patented, semi-automatic process which virtually eliminates adjustment errors. The pressure gauge is completely assembled, sealed, and packed for shipment.

A – automation by a computer-based calibration and certification system (Automation)

On request, every pressure gauge comes with a calibration certificate issued by a computer-based system with optical scanning of the pointer position. The certificates are archived and can be allocated to the measuring device at any time.

C – consistent optimization based on lean management, KAIZEN (Consistency) E – excellence for highest quality (Excellence)

At Baumer, this completely documented and traceable process is called BTrace, which stands for «Baumer Traceability System». It describes a unique method in order fulfilment. Combined with lean philosophy, it provides the customer with measurable added value in cost efficiency, reliability, and traceability. BTrace comprises several elements: B - Baumer Business System for effective production and management processes T - traceability throughout the entire order process (Traceability)

More Information 06| Industry Asia-Pacific | MAY 2014

9


NEWS

Tough drives for fast climbers: NORD DRIVESYSTEMS supplies STROS for international projects

S

TROS, the largest manufacturer of construction hoists in the Czech Republic, supplies customers all over the world. Three systems ship per week. Eight of the high-rises at “Moscow City”, a major construction project in Russia, are being built or have already been completed with STROS hoists. The hoists reach heights of 300 m or more and have to withstand wind speeds of up to 20 m/s. Safety is therefore fundamental. STROS has been working with NORD DRIVESYSTEMS as its single-source drive supplier for more than 15 years. STROS specializes in rack-and-pinion mast-climbing equipment which allows for extended service heights and can be quickly installed. The gearbox output shaft is fitted with a gear that meshes with a rack attached to the guide mast. This robust drive method withstands extreme environmental conditions over long time periods. Apart from building equipment hire and construction companies, STROS frequently supplies power plants, industrial plants, and offshore facilities. Completed projects include locations beyond the Arctic Circle and in the tough climatic conditions of the tropics.

06 | Industry Asia-Pacific | MAY 2014

10

The NOV series of personnel and material hoists reaches maximum lifting speeds of 100 m/min and load capacities up to 3,200 kg. The highest hoist to date was erected at the “Moscow City” construction site. The complex consists of several high-rise buildings, eight of which are equipped with STROS hoists. One of the hoists serves the Mercury City Tower which at 340 m is currently the tallest building in Europe. The NOV 2032 hoist has a 350 m lifting height, a 2 ton load capacity and a 70 m/min rating. With a control panel that allows the operator to select the floor number, the hoist provides the same level of control comfort as a standard elevator in an apartment block. The drive unit consists of three helical bevel geared motors with external braking resistors. “The motors are equipped with electromagnetic disc brakes which can be released by hand”, says Zdenek Coubal, Chairman of STROS. “This is a custom solution from NORD DRIVESYSTEMS. And it exemplifies our cooperation: whatever new challenges we meet, NORD provides consulting and tests and develops a solution.” A control cabinet inverter with hoist function controls all three motors. It enables soft starts and stops and high leveling precision.


For example, we are not limited to standard gearboxes. The units are assembled exactly to fit the requirements. And NORD customizes drives for us when we need it, supplying reinforced bearings or special gear case materials, or ATEX and NEC-compliant drives for refinery applications.” Initially, STROS only used geared motors. As the manufacturer built only relatively slow hoists at that time, start and stop control via the motor switch was fully sufficient at speeds up to 40 m/min. But with the growth of the customer list, the projects grew accordingly. STROS started building hoists for higher and higher buildings. Consequently, the cages had to travel faster to decrease waiting times. New models have rated speeds of 55 to 100 m/min and are always equipped with variable frequency drives. In addition to geared motors, NORD supplies control cabinet inverters that control motor speed and enable precise braking. Sophisticated positioning and safety functions such as STO and SS1 for safety requirements up to SIL3 are also available. The 2008 collapse of the construction industry severely affected suppliers such as STROS. To survive, the company sought applications for its technology apart from construction hoists and branched into hoists for permanent use on buildings, chimneys, or technological equipment. This new field makes up a large part of STROS projects today. For example, the company built a 150 m high permanent elevator on a chimney at the Siekierki power station in Poland’s capital Warsaw. The NOV 514 elevator has a load capacity of 500 kg and a rated speed of 46 m/ min. The elevator was equipped with a frequency inverter which ensures soft starting and braking and includes a POSICON position control. The project was immediately followed by a contract for a second, 200 m high elevator for another chimney at the same plant. Coubal says, “We are working very closely with the construction companies. They say that our technology saves time and money.” The STROS engineering team has designed a mechanism to safely stop hoist cages in the event of a failure. If the nominal lowering speed is exceeded, the safety device will trip and engage its pinion with the rack to gradually stop the hoist cage. The centrifugal mechanism is individually set for each machine model. The STROS safety device is certified by the internationally recognized German technical testing authority TÜV SÜD. The cooperation with NORD as their sole drive supplier began in 1997. At that time, STROS’ predecessor company made the first serious foray into international markets. NORD Pohánĕcí Technika, s.r.o., the Czech subsidiary of NORD DRIVESYSTEMS, convinced the management in the course of the first trial projects. NORD supplied the reliable, long-living products STROS needed. But even then, the most important factor for STROS was NORD’s ability to guarantee service even in remote locations. Coubal says, “NORD is very good as a one-stop supplier. They suggest the best solution for any application that crops up in our everyday business.

If a hoist does not work, the entire construction site will come to a standstill. Therefore, the drive must never break down under any circumstances. The NORD concept for STROS hoisting equipment with up to three autonomously working drives prevents costly downtimes. Looking back on 15 years with NORD as their sole drive supplier, STROS Chairman Coubal says, “NORD technology is reliable, and the service is excellent.” And how is the outlook? “According to the trend in the USA, Canada, and Russia, we can expect more demand for greater-performance drives and inverters due to increasingly larger cages, load capacity, and speed. We have our work cut out for us.”

More Information 06| Industry Asia-Pacific | MAY 2014

11


NEWS

Champagne producer Veuve Clicquot chooses PcVue to supervise its tanks

The operators control the PcVue supervision software via a 42» touch screen installed at the entrance to the fermentation cellars.

World-renowned top-quality champagne house Veuve Clicquot uses instrumented and automated facilities. Thanks to PcVue, it now has a smart system that supervises fermentation in its 400 fermentation tanks.

V

euve Clicquot is a French champagne house known the world over. Founded in 1772, this prestigious house is now a subsidiary of LVMH. Its reputation is obviously no accident. The house does not compromise on quality and its motto is ‘Only one quality – the finest’. In order to ensure that it always makes the finest champagne, it also needs to be able to closely supervise its production systems. That is why, in late 2012, Veuve Clicquot revamped its fermentation cellar supervision system.

The fermentation cellars are where the house makes its wine from harvested and pressed grapes. Supervising the tanks in which alcoholic and malolactic fermentation take place is crucial. However, the software being used by Veuve Clicquot was at the end of its life and the publisher was no longer supporting it. It was therefore necessary that the house replace its 10-year-old supervision system by a more

06 | Industry Asia-Pacific | MAY 2014

12

recent and better performing solution. «We needed to replace it by a lasting solution that would be supported for many years to come,» says Franck Berruyer, sales engineer at Arc Informatique, the company behind the PcVue supervision system installed at Veuve Clicquot. «In addition to various technical factors, we chose the PcVue 10 software suite because of the relationship of trust we have maintained with Arc Informatique and because the cost of the licences is economically suited to Veuve Clicquot’s needs,» says Stéphane Fournier, manager of SF2I, the company that developed and integrated the supervision software. Another advantage of PcVue is that it has the same HMI as the previous software, meaning that the operators were able to use PcVue immediately. Furthermore, Guy Jendryka, manager of the electricity, automation and industrial computing department at Veuve Clicquot, stresses that one of PcVue’s strengths is that it is easy to adjust and program. «With the previous system, you really had to be an IT specialist to be able to upgrade the software. PcVue is much easier to modify as needed.» The development architecture is based on PcVue objects


Five web-based clients allow the cellar managers to view the supervision system and select its setpoints via their PC. Operators can also monitor and control the software via a 42» touch screen that is installed in the lobby and within view of all visitors. The software communicates with the programmable logic controllers (PLCs) over a Modbus TCP/IP network while a VPN (virtual private network) link is used to collect information from the tanks in the house’s other fermentation cellars. Fourteen fermentation modules are housed in the main cellar in Reims and four others are located in various towns across the Champagne vineyard at distances of 30 to 200 km from the main cellar! The VPN saves a tremendous amount of time. «Being able to supervise all our fermentation cellars from one place eliminates the need to drive to each cellar. The supervision system issues an alert if a serious temperature control issue crops up,» says Stéphane Fournier. Mr Jendryka can now monitor all his tanks from his desktop PC. «PcVue supervisor has made our fermentation cellars smart. We can monitor every aspect of temperature control from just one place.» Encouraged by this positive experience, Veuve Clicquot’s technical teams quickly realised how PcVue could be used elsewhere. Not only does it supervise the fermentation of wine in the tanks, it also monitors the production of cold during cold stabilisation after final blending.

and greatly facilitated the supervision software’s design. Because Veuve Clicquot’s fermentation cellars contain 400 tanks of various types and volumes (50 hl to 725 hl), the developers had to be able to use models so as to reduce programming, and hence maintenance times. Depending on their type, the tanks are fitted with up to three temperature-control sensors and manual or automatic valves. The application manages some 40 variables per tank for a total of 16,000! «The object development architecture saves time and simplifies operations. Once the model was made for the dozen existing tank models, it was simply a matter of instantiating the objects and automatically generating the communication variables,» says Mr Fournier.

PcVue does not control these operations; it is used simply to view their settings and archive, log and track temperatures, faults and other data. It is also used for effluent monitoring purposes at the two treatment plants – it manages acid and sodium-hydroxide levels, tracks pH and flow-rate values (weekly dashboard report for Dreal, the regional directorate for the environment, land-use planning and housing) – and to e-mail resupply alerts to the managers when levels become low. And that’s not all! PcVue is being deployed to other areas of Veuve Clicquot’s operations. By the end of the year it will be running on the wrapping line (placement of foil capsules and labels on bottles prior to shipment). «We are going to use it in particular to retrieve production orders from SAP and provide the laser ID to be affixed onto the glass and back-label,» says Mr Jendryka.

With its virtual architecture, PcVue runs on a server that is installed in a secure, air-conditioned and filtered room protected from the damp. The application’s maintainability and portability on new physical machines is thus simplified. The fact that, in such a virtualised environment, the software is decoupled from the hardware means that reinstallation and commissioning times in the event of failure are considerably reduced.

More Information 06| Industry Asia-Pacific | MAY 2014

13


NEWS

Keyence’s IM Series Speeds Up and Simplifies Inspections for Timex

Keyence’s image dimension measurement system puts much faster in-process inspection within everyone’s reach.

T

imex is America’s leading watchmaker and is present in more than 80 countries. Fralsen, its French entity, makes watch movements using three technologies — plastic injection moulding of small parts with very fine details; turning and cutting of parts such as wheels, pinions, arbors and rivets; and cutting and coiling of complex springs. These precision parts must be inspected with contact sensors (comparators, Cary equipment, feeler-spindles) and optical systems. «We wanted more modern and more efficient optical inspection equipment. In other words, we wanted to be able to inspect more parts in less time,» says Sylvain Scotto of Fralsen’s Quality Control Department. «We also wanted a machine that could be operated by non-specialists and be able to log measurements.» The tolerances and accuracies are 15 μm for concentricity and ± 10 μm for centre-to-centre spacings and distances. There are at least five critical points per part. «With conventional inspection equipment, measurements took too long. As a result, we couldn’t measure many parts and there was a risk of overlooking signifi cant variations

06 | Industry Asia-Pacific | MAY 2014

14

within batches. Before obtaining the IM Series, we used a variety of equipment. Our optical measuring device, which, although very accurate, is not very practical for quick measurements on a daily basis. Furthermore, it requires a high level of skill to operate. The shop microscopes provide accurate measurements,but are tricky to operate and severely limit the number of measurements and parts. In addition, a reference point for truing-up has to be created. Lastly, due to the sometimes long inspection times, our templates and projectors allow only a limited number parts to be measured and there is a risk of misinterpretation,» adds Sylvain Scotto. «The IM Series is simpler to operate, saves time and eliminates variations of interpretation of measurements. Results are conveniently displayed green (for good) or red (for bad). Keyence’s solution allows several parts to be measured simultaneously. The size of the parts and the number of elements making up the program are the only limits. There is no need for manual truing-up because the system does it all by itself by recognising each part’s geometry. Furthermore, results can be saved and statistics tracked. Part profiles can be compared against master profi les imported from CAD fi


les. As a result, we no longer need to position templates on parts and measure differences in shape by eye. The machine does so automatically and extracts an image of the contour showing the difference with the tolerance. All in all, measurements are fast and do not require special skills.» The new IM-6500 Series image dimension measurement system reliably measures features in almost no time at all. Simply place a target on the stage and press the button. Up to 99 points are measured in a matter of seconds with a repeatability of ± 1 micron. Targets are found and measured regardless of their position or orientation and there is no risk of measurements being affected by variations in operator skill levels. Thanks to the iPASS shape detection method, the system determines the position and angle of targets, making measurements automatic. «Getting to grips with the system was easy because all you have to do is adjust the focus and load the program for the part being inspected. All the QC technicians in the Quality Department use the machine for fi nal inspection of parts before their placement in stock. The operators in the cutting shop also use it to measure certain parts during production. The programming is completely user-friendly.

The faster inspection times enable us to track dimensions better and thus improve the quality of a large number of the parts we deliver. What’s more, we haven’t received a single complaint from clients about any of the parts measured on the machine. For example, we use Keyence’s IM-6500 to inspect the concentricity of every single cut wheel and automatically record the measurements,» says Sylvain Scotto. The contour of the stator is superimposed on the CAD file. With the old method (template and projector), this process was long. Now, three parts can be inspected in less than one minute instead of five in five minutes. The profile also allows the Mechanical Engineering Department to see where parts need reworking. The red contour shows that the stator is at the tolerance limit in places (blue zone).

More Information 06| Industry Asia-Pacific | MAY 2014

15


NEWS

Configure PLCs and machines remotely with Netbiter® Remote Access

The M7000 also excels by its marking performance and unparalleled ease of use, in particular thanks to its built-in touch screen.

H

MS Industrial Networks now introduces Netbiter Remote Access into the Netbiter Remote Management solution.

Remote Access is a technology that provides an instant, secure communication tunnel to remote equipment, such as PLCs and machines. It allows users to employ their usual PLC configuration software such as Rockwell RSlogix® or Siemens TIA Portal®, just as if they were connected to the machine on site. This makes it possible to instantly take action in case an operational problem occurs and reduces the need to travel to the site. Netbiter Remote Access makes it possible for machine builders, system integrators, OEMs and end users to instantly connect to devices, equipment or machines from any location. The solution provides a secure communication tunnel for PC-based software applications and allows PLC programmers and machine owners to configure, reprogram and debug the machinery from any location saving both time and travel costs while improving customer service.

06 | Industry Asia-Pacific | MAY 2014

16

How it works Users first connect a Netbiter EasyConnect™ 300-series gateway to their remote device or machine. By running the Netbiter QuickConnect™ software on a computer, a secure tunnel is created to the Netbiter gateway and the device/machine to which it is connected. PLC programmers or machine owners can simply open their regular configuration software (such as RSLogix or TIA Portal) and configure or debug just as if they were on site. The secure connection is established via the cloudbased Netbiter Argos data center. This means that there is no need for opening inbound ports in firewalls or setting up VPN connections on site. The result is a secure connection which is set up a matter of minutes. Simplicity and security “Simplicity and security are the main traits of Netbiter Remote Access,” says Henrik Arleving, Product Line Manager at HMS Industrial Networks. “After connecting the Netbiter gateway to a machine,


users can access their machines and be up and running within minutes from any location. This is a much sought-after functionality that will save machine builders, system integrators, PLC programmers and maintenance staff a lot of time and effort, not to mention substantially decreased travel costs.� Solid security Data is encrypted both to and from Netbiter Argos and it is also possible to choose a two-step verification method (logging in with a password and also getting an SMS to verify the user’s identity). This ensures secure data connection to the remote equipment. Since the connection is made through the Netbiter Argos, which acts as a routing portal for all communication, there is no need to bother with fixed IP addresses or holes in the users’ firewalls.

More Information 06| Industry Asia-Pacific | MAY 2014

17


NEWS

New tools and strategies take on ISO S materials

Unique geometry maximizes smooth cutting and chip flow, minimizes stress

New Beyond MR (medium roughing) inserts from Kennametal are a “synergy of geometry and grade,” with smooth cutting action and higher wear resistance among the results.

T

he ISO S classification of workpiece materials includes heat resistant superalloys (HRSA) and titanium alloys. The hot hardness and strength of these materials prompt their use in a wide range of critical aerospace, energy and other applications. The alloys’ beneficial properties, however, also produce machining characteristics different than those of traditional irons and steels. In response, makers of cutting tools have developed products and application strategies that address material machinability and enable reliable, consistent and relatively economical processing of ISO S group alloys. These toolmakers also now seek to educate manufacturers on the new tools and strategies as well as convince machinists to rethink any outdated machining techniques that, most likely, will not apply to today’s advanced materials.

06 | Industry Asia-Pacific | MAY 2014

18

Machinability factors The term machinability describes a metal’s responses to the machining process. Machinability includes four basic factors: the mechanical forces produced in machining, chip formation and evacuation, heat generation and transfer, and cutting tool wear and failure. Excessive effects of any or all of these factors can cause a material to be deemed “difficult to machine.” Machinability issues arise with regard to tool life, process time and reliability and part quality when HRSA and titanium alloy machining is attempted with the same tools and techniques used over many decades on, for instance, steels and irons. Only in the last few years have tools been developed with nickel-based and titanium-based alloys in mind. Machining these relatively new materials is not necessarily more difficult than machining traditional metals; it simply is different. For example, the usual approach to machining a “difficult” material is to proceed cautiously and use less-aggressive cutting parameters – including reduced feed rates, depthsof-cut and speeds. However, with cutting tools developed specifically for these high-performance workpiece materials, a basic rule is to, instead, increase depths-of-cut and feed rates. Tools engineered to handle these more


aggressive parameters include fine-grained carbide grades that provide good high-temperature edge strength and coating adhesion, with particular attention to resistance to notching caused by work-hardened workpieces. Ceramic and PCBN tools have also been developed for roughing and finishing of these high-performance alloys (see sidebar below). Regarding specific machinability factors, HRSA present mechanical or force-related issues that are not vastly different to tough irons or steels. There is a major difference, however, in the generation and dissipation of heat. Heat is generated when metal cutting deforms the workpiece material, and chips generated in cutting processes can carry heat away. However, the segmented chips produced by these materials often fail to do the job well. In addition, the heat-resistant materials themselves are poor conductors of heat. Temperatures in cutting zones can be 1100Ëš - 1300Ëš C., and when heat cannot be dissipated, it builds up in the tool and the workpiece. The result is reduced tool life and even deformation of the workpiece and changes in its metallurgical characteristics. To help solve this problem, a change in perception about cutting tool strength is necessary. Sharp-edged cutting tools are generally

considered to be weak, but one way to control build up of tool temperatures is to use sharp cutting tools that cut the material more than deforming it, thereby generating less heat. Executing this strategy requires tools engineered for edge strength, applied on machine tools with sufficient power, stability, and vibration resistance. Tendencies toward strain and precipitation hardening also complicate the machining of HRSA. In strain hardening, material in the cutting zone becomes harder when subjected to the stress and high temperatures of the cutting process. Nickel- and titanium-based alloys exhibit greater strain hardening tendencies than steel. In precipitation hardening, hard spots form in a workpiece material when high temperatures activate an alloying element that was otherwise at rest. With either tendency, the structure of the material may change significantly after only one pass of a cutting tool, and a second pass will have to cut through a much harder surface. A solution is to minimise the number of passes. Instead of removing 10 mm of material with two 5-mm-deep cutting passes, for example, it would be better to use one pass at 10 mm depth-of-cut. In many situations single-pass machining is not possible, but it is the theoretical goal.

06| Industry Asia-Pacific | MAY 2014

19


NEWS

This approach also requires rethinking the finishing process, which traditionally involves multiple passes at small depthsof-cut and light feed rates. Instead, machinists should look for possibilities to increase the parameters as much as possible. Doing so can improve tool life as well as surface finish. A slightly deeper depth-of-cut for a finishing pass also positions the sharpest part of the cutting edge below any strain- or precipitation-hardened areas of the part. However, too deep a finishing pass may generate vibration and negatively affect surface finish. Finding the optimum balance between aggressiveness and caution is the key. With today’s tools and strategies developed specifically for nickel- and titanium-based alloys, machining can be accomplished essentially without technological problems. The ongoing challenge is not simply machining the workpiece, it is machining the workpiece correctly in a given time at a given cost. The goal is to improve process reliability and production economics. Considering the high cost of advanced workpiece materials and the components made from them, machining processes must be totally reliable. Manufacturers cannot afford to produce scrap parts while seeking a reliable machining process. Using appropriate tools and machining parameters help ensure consistent machining results. Regarding machining parameters, increasing depthsof-cut and feed rates contributes to productivity. Higher cutting speeds also can expedite part processing, but that opportunity has yet to be fully exploited. The speeds employed today in nickel- and titanium-based alloys are still lower than those used with steels. But current research is focused on developing cutting tool properties that will allow even higher cutting speeds while still maintaining reasonable tool life. In addition to cutting tools, other components of the metal cutting process such as use of a high pressure direct coolant (HPDC) system can also help increase productivity. If cutting speeds for an ISO S material is 50 m/min., HPDC can permit cutting speeds as high as 200 m/min and thereby quadruple output. Tool life is another element of productivity that can be viewed from a new perspective when machining HRSA. The traditional measure of tool life counts minutes of cutting before required replacement. Another measure is cost. If, for example, producing a certain workpiece takes 2 hours and tools must be changed every 20 minutes, then 6 tools must be purchased to complete the part. Along those lines of thinking, the goal would be to reduce tool cost and get 30 minutes of tool life instead of 20.

More Information 06 | Industry Asia-Pacific | MAY 2014

20

Tool cost, however, is a very small portion of the overall value of the parts when processing costly components made from HRSAs or titanium alloys. A more relevant measure is tool utilisation, also called a tool’s utilisation index. When comparing two sample tools, if one lasts 10 minutes and produces one workpiece, the tool cost is one

tool per workpiece. Another tool, applied in a different way, might last only 5 minutes, but produce two parts. Even though the second tool’s life in minutes is half that of the first tool, the output of parts is doubled. The goal is to create the maximum number of correct workpieces in the shortest time at an acceptable price. Considering the high cost of parts made of HRSAs, the tool utilisation index is a better gauge of true productivity. As is always the case, the key factor in maximising the benefits of newly developed metal cutting technology is the knowledge of the best way to apply it in a particular operation. As progress in high-performance workpiece materials such as HRSA and titanium-based alloys continues, toolmakers will also continue to engineer new ways to maximise productivity in machining processes for the new alloys. Manufacturers will benefit from awareness of the availability of the new tools as well as the toolmakers’ comprehensive knowledge of the best ways to apply them. Stainless steel, patented in a variety of forms about 100 years ago, was the initial step toward modern HRSA. In the first stainless steel alloys, chromium was added to steel to resist oxidation and corrosion – basic stainless steel alloys have minimum chromium content of 10.5 percent by weight. Subsequently, nickel also was added to improve stainless steels’ hardness and toughness. The percentage of nickel grew as the alloys were applied in increasingly harsh environments, and nickel eventually became the materials’ main alloying element. Today’s familiar HRSA Alloy 718 – known commercially as Inconel 718 – has nickel content of 50 to 55 percent, chromium 17 to 21 percent and other elements 10 percent, with the remainder being iron. Modern HRSA and titanium-based alloys provide excellent strength, heat and corrosion resistance and reliability. When confronted with these new challenging workpiece materials, manufacturers first try to apply familiar machining practices. However, they only truly gain maximum productivity when they incorporate tools and techniques engineered for use with these specific materials and operations. For example, in the mid-1980s Seco established what it called its Alpha Group of scientists and engineers to find ways to machine stainless steels more productively. The group worked with a number of stainless steel makers to develop new carbide grades and geometries and also specific cutting methods for stainless steel. In the 1990s the effort was expanded to include higher-performing HRSA materials. Other developments intended to increase tool life and productivity in HRSA machining include technology such as Seco’s Jetstream Tooling high-pressure direct coolant (HPDC) system, which delivers coolant close to the cutting edge. The jet of coolant lifts the chip away from the rake face, improving chip control and tool life and enabling application of more aggressive machining parameters. In some cases the rapid cooling of the chip makes it brittle and more likely to fracture.


NEWS

Seco further expands solid carbide end mill range

S

eco recently expanded its already comprehensive Jabro®-Solid2 line of solid carbide end mills to include new inch sizes, geometries and flute versions.

Such additions allow an even greater range of applications to benefit from this highly versatile series of cutters that balances economy and performance. The JS522 long-flute finishing tool, which is capable of meeting the aerospace industry’s stringent criteria for perpendicularity, fine surface finish, high metal removal rates and more effective machining, now comes in standard inch sizes. As a result, more manufacturers can now reduce their cycle times and achieve more effective machining through single-pass finishing as well as easily maintain high-quality standards in a wide range of workpiece materials. In 2013, four new geometries joined the Jabro®-Solid2 family known as the JS400 series. These cutters allow users to optimise chip formation and achieve higher cutting data in general machining and aerospace applications involving aluminium alloys. To further adapt the series for aerospace part production,

the JS453 now features an expanded programme of radii (1,0; 2,0; 2,5; 3,0; 4,0 and 6,0 mm) and overhang lengths to serve a broader application range. www.secotools.com/jabrosolid2. With respect to the Jabro®-HSS-Co family, Seco has extended the JCO710 range of solid HSS-E end mills to now include zn-4 flute versions in the complete diameter range that increase process security in full slotting operations, especially in less-than-ideal cutting conditions. Furthermore, new lengths have been added in the zn-6 flute designs providing users an efficient and effective solution for side milling high shoulders of up to 4xD in a single pass.

More Information 06| Industry Asia-Pacific | MAY 2014

21


NEWS

NORD gearmotors help to improve aperitif quality

TMCI Padovan Group is the reference technological partner of the wine industry and, more generally, of the food and beverage industry.

T

MCI Padovan supplied to a known italian producer of flavoured drinks an award-winning Dynamos machine provided with NORD gearmotors. The machine is targeted to the final processing of the grounds resulting from the cross flow filtration of vermouth-base wines and from clarifications with decolorizing carbon. The customer was looking for an innovative solution to replace a traditional vacuum filter. Due to the large volumes processed, a reliable and low-energy machine was required, able to operate every day of the year for 8 to 10 hours on average. After identifying in Dynamos filter a possible solution to the problem, the customer asked TMCI Padovan to perform a test in the production plant. Provided with NORD gearmotors, Dynamos offers many advantages, that were conclusive for the final choice. First, the software flexibility, that allowed to match the operating parameters to the final products. Second, the compactness and the cleanliness in operation: the cross-flow filtration in closed room allows a better hygiene and reduces the overall size. Besides being a cost advantage, the operation without adjuvants is also a benefit in terms of safety and environment. Moreover, during filtration energy consumptions are decreased.

06 | Industry Asia-Pacific | MAY 2014

22

Temperature pick-up is neglectable and, being Dynamos a closed system, the product oxydation is virtually null. Also the reduction of filtering adjuvants and therefore of wastes resulting from operations was among the points that lead to replace with Dynamos the traditional filtration technology previously used.

An awarded rotary cross flow filter TMCI Padovan’s Dynamos is the first rotating dynamic cross flow filter provided with an innovative calibrated backpulse system, a new machine that, from now on, is going to be the most valid alternative in the filtration of must and wine grounds without adjuvants, i.e. liquids having a high level of suspended solids. The principle used is cross flow filtration applied on disks. This low energy consumption process prevents lock-ups and allows an easy cleaning. It requires long filtration cycles (up to 72 hours without interruptions) and high rated yelds (25 to 50 l/m2/h with no lees), without reduction of the red colour and with low oxygen absorption. The available models, compact and easy to operate, are in the range 2 to 40 m2 and multiples.


Recently, Dynamos received the prestigious Innovation Award during SIMEI 2011 fair, the most important international event in wine-making industry, thanks also to cutting-edge technologies that allowed a unique system to be assembled. Like NORD technologies, widely used in Dynamos filters. In fact, on the smaller machine there are 4 NORD SK3282AF parallel axes gearmotors with SK205E inverter on board and a 2.2kW motor. The larger machine has a double number of drives: as the NORD gearmotors rotate the filtration disks, their number varies as a function of the number of disk-holding shafts (1 to 16) on the machine. Finally, the machines have one or two tanks for the product; in each tank there are four gearmotors, therefore it is necessary to double the gearmotors when the tanks are two. The gearmotors with sensorless vectorial inverter on board – an inverter that doesn’t require any speed sensor - and the SK205E inverters ensure a time-constant rotation, resulting in a good quality of the process. The drives adjust the system speed by communicating with the control PLC through fieldbus. The Dynamos filters are also provided with a 4-pole 3kW motor with a NORD SK205E inverter for the circulation pump.

SK 200E inverters are available in models either for the installation beside the motor or integrated in the motor, with the same function range of the centralized inverter series SK 500E for cabinet installation. Besides offering a large overload capacity of 200%, the distributed inverters allow the users to place the driver with high accuracy. The relevant posizions (incremental or continuous axes) or the absolute values (rotating tables/repeatible fixed positions) can be controlled by binary values entered through SK 200E inputs and stored in the drive. As an alternative, they can be set through a fieldbus system. The positions can be detected through incremental encoders (in the basic supply of inverters an on-board reference function is included), or it is possible to directly set the values provided by an absolute encoder on CANopen. The configuration is simply, quick and essential – it is enough to set only few parameters for commissioning and optimization. Winning features Many features of NORD products contributed to the success of the application. In particular, the high rotation accuracy (that is directly related to the quality of the final product), the energy saving function that allows to use only a fraction

06| Industry Asia-Pacific | MAY 2014

23


NEWS

of the rated power when the filter doesn’t require the full rated power, the mounting simplicity due to the great compatcness, the local storage of all the programming data on removable EEPROM and the possibility of matching safety standards like EN 61508: SIL3 were fundamental. Moreover, the possibility to talk with the PLC through the fieldbus specified by the customer using a single node for multiple users, allows to interface the gearmotors with the CANOpen-based fieldbus always present on inverters, resulting in cost savings. A further cost saving results from the smaller size of the inox steel electric cabinet, due to decentralization of inverters on the motors. Finally, is to be noted the fully modular construction of the assemblies, the extremely simple solutions for the addressing of nodes, the full set of status LEDs on-board the gearmotors and the diagnostics that can be read via RS232 both on inverters and on distributed nodes through a free software for computer interfacing to a scope function tool. NORD supported the customer in the selection and commissioning phases of the machines, and ensures the customer an accurate supply and service. “We selected NORD mostly because of the quality, the robustness and the typology of material, that we consider to be suitable for prolonged industrial use,” says Narciso Gatti, Purchase and Operations Manager, TMCI Padovan. “Our company already used NORD products, specially for vacuum filters, vegetal oil processing machines and tunnel pastorizers. NORDE is a supplier of TMCI Padovan since many years. The first contact was established about 11 years ago following a research that we made internally”.

More Information

advantages, like a greater energy saving, a greater reliability, a more simplified machine design and a greater safety for operators,” says Gatti. “In the future, we will probably use NORD solutions also in other products of ours. In particular, we’ll replace the current transmissions based on motors and pulleys with toothed belts and in plants for industrial use”. Notes on TMCI Padovan Group The roots of TMCI Padovan were thrust in the soil of history until 1919, when the Officine Meccaniche Padovan were established, specialising in machines for the wine industry. They developed on a worldwide level in 1984, when they were bought by the TMCI international Group, and then ramified with increasing success in the food sector. Padovan is the reference technological partner of both the wine industry and, more generally, of the food and beverage industry, with a constantly growing turnover. TMCI Padovan Group is specialized in five areas: Wine & beverage industries (TMCI Padovan); Food industries (Parma Food Machinery); Food packaging (TMCI Newpack); Bakery, candies, cocoa and jelly industries (TMCI Chemtech); Brewery industry (TMCI Brewtech). In the Wine area, the full range of machines for filtration, clarification, pastorization, evaporation and refrigeration for which TMCI Padovan is a world leader, results from the professional experience acquired in almost one century of activity. The top quality with superior performances combines with simplified functionality and long life guarantee, making company products unique.

Before NORD gearmotors with on-board inverter, belt transmission motors were used in Dynamos filters. “The new technology allowed us to obtain several

06| Industry Asia-Pacific | MAY 2014

24


NEWS

SC-System: New family of signal conditioners from Pepperl+Fuchs

A

width of just six millimeters, an extended temperature range up to 70 °C, and high longterm stability, reliability and precision—this is what characterizes the signal conditioners of the new SC-System that will be presented for the first time at this year’s Hannover Trade Fair.The SCSystem is a completely new development that combines the most powerful features of comparable products in a family of devices.

products can be operated.The SC-System uses high-quality 3-way isolation between input, output, and supply which withstands a working voltage of up to 300 V and a test voltage up to 2.5 kV. The risk of short circuits in coils within the signal conditioner is counteracted by the use of PCB transformers. In this design, the transformer coils are integrated into the PCB, so that short circuits in coils due to faulty isolation are eliminated.

For example, calibration is performed by fully automated laser trimming of fixed resistors. This means: the best calibration results without production spread, and the risk of interference from trimming potentiometers due to their slider contact point is eliminated.

Effective use of the switch cabinet space is achieved by a compact design: the housings, which are just 6 mm wide, reduce the space requirement of the signal conditioner modules to a minimum. The housing height is so low that the modules fit between the narrow-seated cable channels.

Electrolytic capacitors have been omitted, and alternative components used instead. The temperature-dependent reduction of the capacitance values observed with electrolytic capacitors, as well as signs of aging, is thus effectively counteracted. By replacing the electrolytic capacitors, the SC-System signal conditioners can be operated at an ambient temperature of up to 70 °C.

Transmitter power supplies are an integral part of the SC-System. They transfer the 4 mA … 20 mA signals from connected signal converters, and at the same time deliver the supply voltage for them. Transmitter power supplies are available with a signal splitting function and as SMART devices which, in addition to the analog signal, can transmit multiple HART variables. Temperature converters, loop-powered current repeaters, and universal signal converters for bipolar signals are also part of the portfolio of the new SC-System.

The low-power design, which ensures low self-heating, contributes to the wide temperature range in which the

More Information 06| Industry Asia-Pacific | MAY 2014

25


NEWS

New Code Readers Open up Wide Range of Applications: reliable readings on reflective surfaces using polarization filter

OPC120P—the code reader for highly reflective surfaces

A

new series of camera-based code readers now comes equipped with special polarization filter technology, which significantly expands the devices’ application area. This is because the barcodes and Data Matrix codes are often located on shiny, reflective surfaces, which can significantly interfere with the read operation. The new code readers are reliable at suppressing these kinds of reflections and even enable fast, reliable readings on metallic material. The new OPC120W and OPC120P Series 1-D code and 2-D code readers from Pepperl+Fuchs cover an exceptionally broad range of applications. The OPC120W models offer an excellent cost-benefit ratio and are all-rounders suitable for a host of standard applications at standard speeds. The OPC120P model is perfect for more difficult tasks: It can handle highspeed applications with movements up to 10 m/s or 100 readings/s, and is equipped with unique polarization filter technology. Reliable code reading is guaranteed on highly reflective surfaces, such as metals, plastics, PCBs, under films, and on curved surfaces.

More Information 06 | Industry Asia-Pacific | MAY 2014

26

Other highlights offered by this device include a rotary encoder input for path synchronization and the ability to

read barcodes up to 200 mm in length through multiple image capture. The high depth of focus enables readings over a long distance without needing to make parameter changes. Moreover, the code readers are available in a range of interfaces that include PROFINET, RS232, and Ethernet. The OPC120 Series devices read the DataMatrix, Code 2/5, Code 39, Code128, EAN13, and Pharmacode code symbologies. In addition, they can detect varying textures, expiration dates, and the presence and position of logos. The code readers are characterized by many other features: These include outputting the code quality, automatically saving fault patterns, formatting the output string, and the match code function. These functions can be applied to up to four separate regions of the captured image. Its wide variety of features and protection category IP67 mean that the new code readers are suitable for a broad range of applications and industries.


NEWS

Fast and efficient – the new CAN FD PC interfaces from HMS

Under the IXXAT brand, HMS is bringing a new CAN PC interface series for CAN FD to the market, supporting it with an extensive suite of drivers and tools.

W

ith the new CAN-IB 500 and the CANIB 600, HMS offers two interface cards (passive/active) that support not only CAN but also the new CAN FD standard.

Both cards are for the PCI Express standard. They have up to two CAN interfaces, which can be operated in either CAN or CAN FD modes. Galvanic isolation of the channels is optionally available. The active CAN-IB 600 also has a built-in microcontroller, so it can even be used in applications with increased requirements for data preprocessing such as high-precision timestamps or active filtering of the messages to be sent from and received by the card.

maximum transmission rate of 1 MBit/s, is part of a wide variety of applications, not least due to its favorable price and versatility. Applications that require the transmission of larger quantities of data, however, have had to move to other technologies until now, which is of course associated with higher costs. Now, with its capacity of up to 64 bytes of payload data and a higher bit rate for payload transmission, CAN FD is eliminating the old limitations of CAN, making it attractive also for applications that have never been able to work with CAN. You can find more information about the new CAN FD cards at www.ixxat.de

The cards are supported by both the IXXAT Windows driver packages (VCI) and the real-time driver packages (ECI for Linux, RTX, Intime, QNX). The IXXAT APIs for CANopen and SAE J1939 also support the new interfaces in CAN mode. For the analysis of CAN and CAN FD networks, HMS offers the IXXAT canAnalyser, a powerful Windows tool. Classical CAN, with its eight bytes of payload data and a

More Information 06| Industry Asia-Pacific | MAY 2014

27


NEWS

Prosoft Releases the Ethernet to Belden® 9463 Blue Hose® Industrial Media Converter

T

he Ethernet to Belden® 9463 Blue Hose® Industrial Media Converter allows EtherNet/IP™ to run communications over the existing AllenBradley® Remote I/O™.

ProSoft Technology® is pleased to announce the release of the Ethernet to Belden® Blue Hose Industrial Media Converter. Using patented technology, we will help you upgrade your Allen-Bradley® Remote I/O™ systems with minimal downtime. Features include: - Run Allen-Bradley® Remote I/O™ & EtherNet/IP™ data simultaneously - Plug & Play, no set up required, guaranteed! - Simple enough to run during scheduled down time - Allows upgrading of individual nodes in phases. - Supports both 57.6K and 115.2K baud rates.

More Information 06 | Industry Asia-Pacific | MAY 2014

28

- Maximum distance of 400m with simultaneous Ethernet and Remote I/O data, 530m for Ethernet data alone.

- Repeaters available for up to 3,000 m For more about ProSoft Technology’s legacy Remote I/O Migration Solutions – including the Ethernet to Belden® 9463 Blue Hose Industrial Media Converter visit: http://psft.com/eiprio5.


NEWS

TRITEX II™ AC POWERED ELECTRO-MECHANICAL ACTUATORS

Tritext AC Powered Linear Actuator

E

xlar announces the Tritex II™ Series electric actuators, offering up 1500 Watt, AC powered operation and digital position control within a single, space-saving housing. These actuators combine a brushless servomotor with either rotary or linear (output) actuation, assembling all elements into a compact, sealed housing for demanding environments. With their built-in mechanical converters, Tritex II actuators eliminate the need for traditional ball screw or gear reducer mechanisms—they incorporate all the required position control and power electronics into the actuator itself, providing a complete system solution. This design additionally eliminates the inconvenience and expense of an external servo amplifier and cables, which are often required with typical servo systems.

The new Tritex II actuators operate from 100-240 VAC, allowing direct connection to factory power sources. Enhanced software features include 16 programmable indexes, linked moves and firmware flash upgrade capability via the actuator’s Modbus port. This port, via a RS/485 protocol, allows complete control, programming and monitoring of all aspects of the Tritex II actuator as it performs an application. Planned communications options include Modbus, Ethernet/IP™, HART, Modbus TCP/IP, CANopen, and CAN J1939 protocols.

The Tritex II actuator has ample I/O capability: 8 digital inputs, 4 digital outputs, plus one analog input and output. Feedback choices include analog hall effect (standard), incremental encoder for higher positioning resolution and an absolute feedback option that eliminates the need for performing home routines after power loss. The new Tritex II design offers excellent connectivity with internal terminals accessible through the actuator’s removable cover. Tritex II also offers a provision for Imperial or metric threaded ports for cable sealing glands, optional M23/M16 connectors for power and I/O, with an M8 connector for the RS485 port. Tritex II linear actuators provide the same form factor as hydraulic and pneumatic actuators and provide for simple, clean all-electric retrofits in what were formerly fluid power applications. They are available with many different mounting options (metric or imperial) such as front flange, rear clevis mount, side mount, trunnion mount, extended tie rod, and rear flange. Tritex II rotary actuators are available in standard IEC metric dimensions. Direct drive units, as well as units with integral planetary gearing, provide compact, powerful solutions for most rotary applications. Custom mounting and options for both rotary and linear actuators are available to meet a wide range of installation requirements.

More Information 06| Industry Asia-Pacific | MAY 2014

29


NEWS

First products in Anybus® CompactCom™ 40-series offer fast communication to EtherCAT, POWERLINK, EtherNet/IP, PROFINET and PROFIBUS

The new Anybus CompactCom 40-series enables multi-network connectivity also for demanding and high-performance industrial devices.

T

he Anybus CompactCom range of embedded communication solutions from HMS Industrial Networks have provided automation devices with connectivity to any fieldbus or industrial Ethernet network for more than a decade. With the new Anybus CompactCom 40-series, HMS now introduces a new technology generation. The existing Anybus CompactCom 30-series (based on the Anybus NP30 network processor) has been installed in millions of automation devices and systems around the world and is tailored for general purpose automation such as AC drives, weigh scales, valves, barcode scanners, sensors, HMIs etc.

More Information 06 | Industry Asia-Pacific | MAY 2014

30

The new CompactCom 40-series is based on HMS’ Anybus NP40 network processor and is especially suitable for high-end industrial applications that require fieldbus or real-time Ethernet connectivity. Offering close to ”zero delay” between devices and real-time networks, the 40-series is ideal for high-performance applications such as servo drive systems, which require fast network cycles and synchronization capabilities. The CompactCom 40-series will support all major industrial networks, and the first release in April 2014 includes connectivity to EtherCAT, POWERLINK, EtherNet/IP, PROFINET and PROFIBUS.

Like all CompactCom solutions, the 40-series covers all types of industrial networks — traditional fieldbuses as well as industrial Ethernet. Device manufacturers that choose to use CompactCom get access to all networks through one single development project, during which the user simply integrates the generic Anybus interface (hardware/ software). After this, any CompactCom 40-series product can be connected, offering instant connectivity to industrial networks. The CompactCom 40-series extends the level of flexibility even further since it uses a common reprogrammable hardware to support several Ethernet networks. For example, it is possible to install the CompactCom 40-series Ethernet hardware into an industrial device and simply download ready-made firmware to connect to the desired network (for example POWERLINK, EtherNet/IP, PROFINET IRT or EtherCAT). “With the Anybus CompactCom 40-series, we can offer a complete communication solution suitable for both general automation devices and high-performance applications, says Leif Malmberg, Product Line Manager, Embedded, at HMS. “Users get the performance and accuracy they need for demanding applications, and the flexibility to adapt to different networks by simply downloading a new firmware.”


NEWS

New KSSM8+™ Face Milling Platform for Cast Iron

OPC120P—the code reader for highly reflective surfaces

W

ith eight cutting edges, the new KSSM8+™ face milling platform from Kennametal is focused on maximum metal-cutting performance in cast irons and steel workpieces at the lowest

possible cost. Cutting cast-iron parts is tough and it should be. Cast-iron pump housings, brake calipers, turbine housings, and many other parts are critical foundation components for entire industries, including automotive, heavy equipment, energy, and fluid power. Achieving the highest level of milling performance at the lowest cost per cutting edge is essential for success. The IC10 size provides a 9mm (0.354 in.) depth of cut, while the IC 12.7 achieves a 6mm (0.236 in.) DOC. Both have high lead angles (88 degress and 87 degrees, respectively), making them good choices in applications where fixture limitations or part designs call for close to 90-degree shoulders. The double-sided insert design with eight cutting edges provides users with the lowest cost per edge, while the –LD geometry’s positive rake face and honed edges result in lower cutting forces and good floor finishes in medium and finish machining.

While face milling is a common, everyday metal-cutting task, it is one with many critical considerations. Depth of cut must be balanced against maximizing speeds and feeds for long tool life. High surface finish requirements must be factored into achieving high production efficiencies. That is why a range of insert grades for the new KSSM8+ platform is available for face milling steels, stainless steels, and wet or dry machining of ductile cast irons. Together with the choice of medium- and fine-density cutter bodies makes KSSM8+ the right solution in addition to the preferred low-cost choice when milling cast irons. For more information, visit www.kennametal.com

More Information 06| Industry Asia-Pacific | MAY 2014

31


NEWS

Energy-efficient pump drive solutions

NORD DRIVESYSTEMS integrated pump drives can store up to four operation modes that can be displayed and changed directly at the control unit

P

ermanently full speed? Not such a good idea for pump drives! Speed control balanced to actual requirements greatly enhances the energy efficiency of pump systems. NORD DRIVESYSTEMS supplies complete pre-assembled distributed drive units for a wide performance range to 22 kW. In addition to energy savings of up to 60%, users benefit from reduced noise emissions, low wear, and increased plant service life as well as the ecological advantages. The SK 200E series comprises reliable and economical frequency inverters especially tailored to pump applications that precisely adjust power output as required. They are compatible with mains voltages worldwide.

More Information 06 | Industry Asia-Pacific | MAY 2014

32

NORD configures complete drive systems for various application areas (IP55/IP66, ATEX zone 22/3D). Integrated process and PI controller functions enable the fully automated control of process variables and compensation of disturbances – in stand-alone and mobile applications as well as in complex setups with several drives. Thanks to two analog inputs, the inverters can directly process sensor data such as pressure or flow rate. Optional signal and power plug connectors facilitate handling and ensure compatibility. A programmable energy-saving function automatically reacts to partial load

operation – increasing efficiency and significantly reducing running costs. Operation is straightforward and flexible via control terminals, bus, or via an optional potentiometer that enables adjustments directly at the inverter. Up to four operation modes can be stored, saving setup time; for instance during cleaning cycles or media changes. The customized parameters can be quickly exported to other units via a pluggable storage module, the system bus, or Ethernet interfaces. With control cabinets no longer required, the decentralized option minimizes cabling effort for users, and since the inverter is supplied pre-assembled the electrotechnical effort during installation is minimal.


NEWS

ProSoft Technology’s new Industrial Cellular Gateway offers secure connections to remote devices.

OPC120P—the code reader for highly reflective surfaces

T

he ICX30-HWC allows remote site access and communication to PLCs, RTUs, and other Ethernet and serial devices. ProSoft Technology®, a leading industrial communication company, has released the ICX30-HWC Industrial Cellular Gateway, which allows for remote monitoring of devices where WiFi may not be available.

including 3G GSM, WCDMA and HSPA+ Networks, among others. For more information about the Industrial Cellular Gateway, visit http://psft.com/icx30hwclapr

The industrial cellular gateway provides secure wireless Ethernet and serial connectivity to remote devices and equipment over 3G cellular service. These include PLCs, RTUs, DCS systems, instruments, electronic billboards and communication towers. The industrial cellular gateway is ideal for programming and maintenance, remote data collection, location-based monitoring and SCADA applications. Remote devices are accessed using secure VPN tunnels over Internet connections. In addition, the EtherNet/IP™ Class 3 Server allows diagnostic data to be sent to a Rockwell Automation ControlLogix® or CompactLogix system. The ICX30-HWC supports cellular networks worldwide,

More Information 06| Industry Asia-Pacific | MAY 2014

33


Asia Pacific May 14  

Industry Asia Pacific is the portal for Aisa technical engineers.