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THE INDUSTRY MAGAZINE FOR MIDDLE EAST

MAYR A PERMANENT OVERVIEW OF THE BRAKE OPERATING CONDITIONS INNOVATIVE MONITORING SOLUTIONS FOR SAFETY BRAKES

4 HMS THE ROAD TO WIRELESS – WHICH WIRELESS STANDARD SUITS YOU BEST?

8 THE NEW “MINIS”: NOW COMPATIBLE WITH THE HAINBUCH MODULAR SYSTEM

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BALLUFF ABSOLUTE FEEDBACK SYSTEMS FOR EFFICIENT DRIVES

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01 | Industry Middle East | September 2015

THE INDUSTRY MAGAZINE FOR MIDDLE EAST

MAYR

KENNAMETAL

NORD

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HMS

HAINBUCH

BONFIGLIOLI

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HAINBUCH

BALLUFF

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www.industrymiddleeast.com

ARC INFOMATIQUE

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NEWS

A PERMANENT OVERVIEW OF THE BRAKE OPERATING CONDITIONS INNOVATIVE MONITORING SOLUTIONS FOR SAFETY BRAKES

The module ROBA®-brake-checker not only energises brakes, but also monitors them without the use of sensors. This opens up new possibilities for the monitoring of safety brakes.

The monitoring of electromagnetic safety brakes is an increasingly important topic. mayr® power transmission is therefore setting new standards with the new, intelligent brake control module ROBA®brake-checker. This module is not only able to energise brakes, but can also monitor them without the use of sensors. It is flexible and easy to integrate into existing systems.

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s the amount of networking between people, processes and machines increases, the requirements on the individual components of a drive line also rise. mayr® power transmission has therefore risen to the current challenges set by the Industry 4.0. and has already incorporated into its range intelligent products which can communicate with the superordinate controls.

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The latest developments include an intelligent brake control module, the ROBA®-brake-checker, which is not only able to energise safety brakes, but also to monitor them without the use of sensors. It recognizes the switching condition of the actuator and the wear on the brake linings, and thus detects safety-critical conditions prior to their occurrence.

Any changes in the braking torque can thus be instantly detected and countermeasures initiated – for maximum functional and operational safety.

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Higher performance, less inconvenience The new module ROBA®-brake-checker serves to operate safety brakes at reduced power while simultaneously monitoring their switching condition. It is designed for an input voltage of 24V or 48V DC, and can control brakes with a coil nominal current of 10A or 5A. In comparison to the previous fast acting rectifiers, the new module is characterised by its higher performance and also by a larger input voltage range of 18-30 VDC or 42-54 VDC and a controlled output voltage at reduction.

In addition, a higher cycle frequency is possible. The module ROBA®-brake-checker reliably detects when the brake condition changes; i.e. whether the armature disk has been attracted or released. The module emits the respective switching condition of the brake via a signal output. With the ROBA®-brake-checker, the switching condition of safety brakes can therefore be recorded in machines and systems even without the usual microswitches or proximity sensors.

The module functions highly reliably without mechanical contacts and is wear-free, independent of the cycle

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The targeted braking torque control is carried out using the new module ROBA®-torqcontrol. The device can be operated with 24V or 48V DC voltage, and is able to control brakes with the coil nominal voltage of 10A or 5A.

Using the new, intelligent module ROBA®-torqcontrol, mayr® power transmission provides an economically attractive possibility to generate a variable braking torque on ROBA®-stop safety brakes.

frequency and count. The additional wiring and possible sealing of switches and sensors is therefore no longer required.

In addition, it is possible with the sensorless condition monitoring to adapt the overexcitation time automatically if required. Here an integrated automatic system regulates the voltage to the set lowering voltage after a brake-specific overexcitation time. Using a DIP switch, the automatic system can be switched off, after which it is possible to set certain, specified values manually.

ROBA®-torqcontrol. It features the properties of the ROBA®brake-checker, and is additionally able to change the level of braking torque during operation through the targeted influencing of current and voltage. In this way, devices and machines can be evenly and gently decelerated. The module ROBA®-torqcontrol allows control circuits to be constructed and movements to be braked intelligently – ideal prerequisites for use in smart, networked machines. www.mayr.de

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Detect errors before they occur Through the comparison of tightening current and holding current, the module ROBA®-brake-checker is able to detect a possible wear reserve or line breakage, or, if applicable, to detect unpermitted heat-up. In this way it can reveal safetycritical conditions and errors prior to their occurrence, and thus guarantee maximum operational safety for machines and systems. The new monitoring module can be used for a wide range of ROBA-stop® brakes, and can be easily, quickly and inexpensively integrated, also into existing systems.

With its compact dimensions of 30 mm in height, 69 mm in width and 73.6 mm in length, it can easily be integrated into control cabinets.

Braking movements with intelligent systems For applications which require braking torque control in addition to condition monitoring, mayr® power transmission provides the braking torque control module 01 | Industry Middle East | September 2015

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NEWS

KENNAMETAL RECOGNIZED WITH BOSCH GLOBAL SUPPLIER AWARD

Kennametal Inc. (NYSE: KMT) announced today that it has been awarded the Bosch Global Supplier Award 2015 from Robert Bosch GmbH (“Bosch”), a leading global supplier of technology and services.

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he biannual award recognizes outstanding performance in the manufacture and supply of products or services – notably in the areas of quality, costs, logistics and innovations.

“It is an honor to be recognized by Bosch as the only tooling manufacturer to receive their Global Supplier Award,” said Don Nolan, Kennametal president and CEO. “This award acknowledges Kennametal’s global team who is working relentlessly to deliver innovative products, superior quality and outstanding performance to the customer every day.”

Kennametal was among 58 suppliers out of 35,000 that Bosch presented with this esteemed award. To be eligible, suppliers must deliver best-in-class services, quality and total cost of ownership as well as guarantee global footprint and significant sales in the purchasing category.

“The Bosch Global Supplier Award honors our top suppliers, who play such a key role in Bosch’s success,” said Dr. Volkmar Denner, chairman of the Bosch board of management.

“Our suppliers are important partners in helping us shape the connected world. We want to work with them to develop beneficial solutions for our customers.”

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www.kennametal.com

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NEWS

BRAND-NEW BRIGHT MINDS FOR NORD DRIVE CONTROLLERS

Highly intelligent family: NORD frequency inverters integrate PLC functions.

Integrated basic PLC capability due to faster CPU and firmware upgrades.

Featuring an integrated PLC, frequency inverters from NORD DRIVESYSTEMS combined with geared motors become a full-fledged intelligent system solution. All distributed SK 180E and SK 200E controllers and the cabinet inverters SK 520E and above now offer an integrated PLC. The PLC enables straightforward free programming of drive-related functions according to IEC 61131-3 in “Structured Text” and “Instruction List” using the free-of-charge NORD CON programming and parameterization tool.

In addition to their outstanding functional versatility including position control, the distributed SK 200E units also provide exceptional overload tolerance and are available for a wider power range than usual in this product class – up to 22 kW. The highly compact control cabinet inverters from the SK 500E line will be available up to size 11, with 160 kW rating, later this year. www.nord.com

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The intelligent inverters can thereby manage sophisticated tasks such as autonomous process monitoring or dynamic operation without an external controller. This allows for very economically priced solutions. Moreover, these newgeneration inverters control a wider range of motors: support for IE4 synchronous motors is currently being tested in the field.

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NEWS

THE ROAD TO WIRELESS – WHICH WIRELESS STANDARD SUITS YOU BEST?

WiFi, Bluetooth or Zigbee? Tom McKinney of HMS Industrial Networks offers a review of the available short range wireless standards for industrial applications.

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ecently the buzz around Industrial IoT has grown to a deafening roar. The market for IIoT devices is projected to grow exponentially over the next several years as businesses start to capture more data regarding their operations. That data will be used to monitor and optimize processes, and as companies learn to use the data they capture to improve processes, the result will be increased productivity. Beyond internal productivity, this data may lead to improved company-to-company operations benefiting both the producer and the customer.

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Multiple technology advancements have converged to make large-scale Industrial IIoT deployments possible.

These advancements include reduced cost of data storage, lower power RF solutions and higher levels of network accessibility. Another important enabler for Industrial IoT is wireless standardization.

Wireless is nothing new Wireless networks have been used for over 30 years in the industrial market. In the past, these networks were typically sub 1GHz proprietary systems. The solutions used simple modulation techniques like amplitude-shift keying (ASK) or frequency-shift keying (FSK). Radios that supported these types of modulation could be created easily with a handful of discrete parts. The drawback of these solutions were a complete lack of security and limited bandwidth.

Over the last twenty years, several standards have been developed to define robust radio solutions. The most recent standards are secure enough for broad deployment. In addition, several new free-to-use frequency bands where introduced in the 80s including the 2.4GHz and 5GHz bands.

Deploying a standardized radio solution today is a costeffective secure way to both monitor and control devices in the field or factory. Given the number of wireless standards to choose from, the question becomes which standard is the right standard to deploy.

So let’s take a look at the three most common wireless standards deployed in the 2.4GHz band: Bluetooth, WiFi and Zigbee.

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NEWS

Bluetooth Low Energy Bluetooth Low Energy (BLE) was introduced as an update to the Bluetooth standard. Leveraging some of the techniques used in 802.15.4, BLE was able to achieve even lower power points when compared to Zigbee and support many of the features originally created by the Zigbee standards effort.

About the author:Tom McKinney is Business Development Manager at HMS Labs – HMS Industrial Networks’ initiative for new innovation. Tom has many years of engineering management experience within wireless, VoIP and 1394 technology and is a frequent writer and lecturer on wireless technologies. tmc@hms-networks.com

WiFi WiFi or IEEE 802.11a/b/g/n is the widest deployed consumer and enterprise wireless TCP/IP network solution.

WiFi is short for Wireless Fidelity and is a standard used to identify Wireless Local Area Network (WLAN) devices.

The committee managing this standard is aims to create the best possible wired TCP/IP network replacement. The committee prioritizes security and speed over all other tradeoffs. As a result, 802.11n has the highest bandwidth of any short range wireless standard. The drawback is power consumption and processing power required to effectively manage the 802.11 stack. These drawbacks created a gap in the market and several standards have emerged to address the very low power wireless market.

Bluetooth Bluetooth and Zigbee were both introduced to address markets not serviced well by WiFi. The Bluetooth standard addressed the needs for a low power Personal Area Network (PAN). A PAN is defined as the network that surrounds a person or a smart device. The requirements include fast association, simple human-to-machine interfaces and low power. In a PAN, multiple transmitters can be placed very close together – Bluetooth includes timing to ensure device transmitters don’t overlap. Bluetooth was also designed under the assumption it would have to co-exist with WiFi and includes a frequency hopping algorithm to ensure Bluetooth messages can get through even when multiple WiFi channels are active. Finally, because Bluetooth uses a very low power transmitter, it is less sensitive to multi-path compared to WiFi. As a result, Bluetooth can be deployed successfully without extensive RF site reviews and planning.

The system is very resistant to noise and interference.

Although technology standards may vary, there is no doubt that more and more applications will be wirelessly connected in the near future. With the advent of Industrial IoT, billions of devices will need to hook up to the Internet, and many of these connections will undoubtedly be wireless.

Summary of the pros and cons of each standard: 1) WiFi a.

Pros i. Highest Bandwidth up to 600Mbits/s with 802.11n ii. Fixed 25 MHz or larger Channels iii. Support for 2.4 and 5GHz channels iv. Extensive security features b.

Cons i. Range is lower with higher data rates and 5GHz ii. Not a good match for battery powered sensors 2) Bluetooth/BLE a.

Pros i. Very low power ii. Massive deployed iii. Very good performance in congested or noisy wireless environments iv. Ease of use, no frequency planning or site map requirements b.

Cons i. Max data rate of 2Mbits/s ii. No automated roaming standard 3) Zigbee a.

Pros i. Very low power ii. Fixed channels between WiFi channels in 2.4 GHz band iii. Support for sub 1GHz bands b.

Cons i. Complicated mesh network ii. Max bandwidth of 250Kbits/s

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Zigbee Zigbee is based on IEEE 802.15.4 which is a general-purpose, low-power wireless radio standard that allows different protocols to be built on top of the standard radio. Zigbee set out to support low power sensor networks capable of covering a large area. Zigbee uses meshing networking and a very aggressive power profile to meet the needs of this niche market. Zigbee’s protocol is designed for quick turn-on and turn-off, thereby saving power. Several other protocols have been built on top of 802.15.4 including ISA100, WirelessHART and 6LoWPAN.

Selecting the standard for you So which standard is the right standard to deploy? That depends on the system requirements. In summary, WiFi has the highest bandwidth and most comprehensive stack but Bluetooth, BLE and Zigbee offer features ideal for particular applications. For example, if monitoring battery-powered sensors over a very large area, Zigbee would be the ideal standard. Bluetooth/BLE works well as a cable replacement point-to-point technology or for monitoring sensors over a smaller area. BLE has a huge installed base of tablets and phones making it an excellent choice for human-to-machine interfaces.

More on wireless solutions for industrial communication on www.anybus.com

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THE NEW “MINIS”: NOW COMPATIBLE WITH THE HAINBUCH MODULAR SYSTEM

Hainbuch Spanntop mini with adaptations.

The mini product series with Hainbuch’s tried and trusted modular system.

Set-up for any draw tube position with three versions of the Spanntop mini chuck.

Sometimes small things turn out to be a big success. And that’s true for the mini chucks.

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ut one thing they haven’t had until now was compatibility with the Hainbuch modular system.

That’s no longer the case, and of course this includes both series of chucks: the round Spanntop and the hexagonal profile Toplus. Because of its reduced interference contour, to be able to use the modular system the Spanntop mini chuck comes with an adapter ring.

The existing Mando Adapt mandrel and jaw module work perfectly with the new Spanntop mini. The Toplus version does not use an adapter ring, instead it has ring of attachment holes for fixing the jaw module, and next year it will get its own Mando Adapt series of adapters. And finally, as another piece of good news, Spanntop and Toplus minis both have full through-bore and are available in three standard lengths to suit all machines and drawtubes.

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Reduced clamping device interference contour and less mass These two factors play an ever more important role in any machining process. Tool accessibility and low energy consumption are key criteria for modern workholding making them ready for the challenges of the future.

Increasingly parts have smaller dimensions and higher tolerances than in the past, So the emphasis is no longer on 01 | Industry Middle East | September 2015

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the chuck size but rather on the complete process. Thanks to greater tool accessibility, the mini chucks can use shorter and therefore more stable tools on the main and counter spindles. This again has a direct influence on the surface finish. Not only is the mass reduced by over 38%, the chuck diameter and the total lengths have also been considerably reduced [by a third or a quarter]. So the “little” chucks make a “big” difference. The reduced interference contour makes it easier to choose the right tool and this helps with the issue of reduced space especially in counter spindle machines. The reduced mass is also results in lower energy consumption especially in mass production. Because spindle acceleration and deceleration are more dynamic this shortens the cycle times, and all this contributes to lowering the cost per workpiece.

Hainbuch at the EMO 2015 in Milan: Hall 4. Stand B06. www.hainbuch.com

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RPS ENDURANCE INVERTERS WITH NEW PARALLEL OPERATION FEATURE – AVAILABLE IN 20 FT “ICON ND” STATIONS UP TO 2.25 MWAC RPS Station ICON ND – The perfect home for RPS Endurance inverters

RPS Endurance is a robust, compact powerhouse with a rated power of up to 563 kWac for each inverter unit.

Electrical Schematic of RPS Station ICON ND with 2 x 2 units of RPS Endurance

Bonfiglioli’s RPS Endurance inverters are now ready to tango: With the introduction of the new tandem feature, two units operate seamlessly in parallel on a single medium-voltage transformer winding. This makes the performance and ease of handling of RPS Endurance inverters now fully available for megawattscale PV stations.

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hanks to the further extended power range of single RPS Endurance units of up to 563 kWac at 50°C ambient temperature, the new features allows the effortless realization of 1MW+ tandem configurations with a common ac connection, paired with the best-in-class 15 % permanent overload capacity (up to 648 kWac) at reduced ambient temperatures. Constructed with a record footprint and designed for maximum productivity even in the toughest conditions, these ratings make the RPS Endurance a truly compact powerhouse.

The new RPS Station ICON ND series integrate 2 x 2 units of RPS Endurance inverters into a compact 20 ft container design, achieving an excellent power rating of up to 2.25 MWac per station. This great compactness is paired with a proven and easy-to-maintain forced-air cooling system.

ICON ND stations are delivered ready to connect to an external three-winding medium-voltage transformer, helping customers to significantly reduce project execution times.

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A unique feature for indoor-rated PV inverters, the innovative two-zone ambient protection system distinguishes the RPS Endurance from other solutions and makes it a preferred choice wherever harsh conditions for plant installation and operation are present, such as in the “sun-belt” regions of the world. The intelligent encapsulation design maximizes uptime through a full IP54 ambient protection degree of active components. Thanks to advanced air cooling technology, the inverter design ensures outstanding reliability and serviceability. With numerous self-protection

functions and grid management options, the RPS Endurance is built to satisfy your power control requirements in the fast developing global PV market.

www.bonfiglioli.com

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HAINBUCH – DON´T TALK ABOUT IT, SOLVE THE PROBLEM!

The automation effort is small but the flexibility is enormous.

So switch to full automatic mode with the automatic clamping head [collet] change station!

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mall batch sizes, more and more part variants, competition growing bigger and bigger and always less time. A familiar problem! Hainbuch the workholding manufacturer knows all about these issues, they’ve come up with an automation solution that makes you more productive, more independent and more flexible.

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People who know Hainbuch know that no production process problem is unsolvable. So Hainbuch was looking for a smart, minimalist automation solution that would make work easier. This did not have to be a robot, it should be executed independently by the machine operator.

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The solution: A stocking and changing station placed on the workpiece feeder belt of a vertical lathe. To setup, the spindle passes with the chuck over the combination of clamping head and end-stop to be changed and it is swapped completely reliably within seconds by a pneumatic pulse. The workpiece to be clamped is then directly grabbed from the next changing station and clamped.

Because of this design, there is no need for extra automation.

However, the machine can become amazingly flexible.

Using a clamp check with air sensing the efficiency can be increased even further. This simple practical solution is suitable for a variety of machines because the changing station can be installed directly beside an industrial robot or gantry. A genuine high tech example that you would expect from Hainbuch and if you imagine that this is the only one available from think again, this was just one of several of their automation solutions.

NEWS The automation effort is small but the flexibility is enormous.

The clamping head and end-stop can be changed quickly and easily.

Smart solutions • Optimal set-up changing clamping parts [clamping heads and end-stops] • Ideal for lowering batch sizes or multiple part variants • Operator free production over 3 shifts • No expert set-up needed • Low upgrade cost • Low investment compared to conventional automation How it works • Clamping head and end-stop use a clever clutch mechanism • The changing station sets up the clamping head and endstop together using a pulse trigger • No special alignment, workholding is ready to use www.hainbuch.com HAINBUCH at the EMO 2015 in Milan: Hall 4 Stand B016 MORE INFORMATION 01 | Industry Middle East | September 2015

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ABSOLUTE FEEDBACK SYSTEMS FOR EFFICIENT DRIVES

The BML series from Balluff offers rugged, precise and quick absolute position and angle measurement systems, which are ideal for installation or direct integration into drive and positioning systems.

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he new, magnetically encoded absolute position and angle measurement systems with Permagnetﾂｮ nonius technology close a gap in the segment of compact, integrative, absolute measurement systems with IP 67 housing for external installation. As an open kit for full integration, they now have the option of being used in rotary applications as well. Using these systems, the formats, strokes and end positions of axes can be adjusted automatically, quickly and reliably.

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The new absolute encoder disk can be integrated easily into motors and actuators as a highly precise, absolute feedback solution. Because of this, it is an efficient alternative to conventional magnetic or optical solutions for accurate control of motors and drives. The low space requirement for the solution for rotary applications provides another eyecatching quality; it is just 12 - 20 mm in length and 30 mm in diameter depending on the design.

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A fully integrated, single窶田hip solution is the core of the magnetic scanning and signal generation process. The position data is generated in real time and made available in absolute form using interfaces typical in drive engineering, SSI or bidirectional BiSS C. Incremental SIN/COS analog signals and ABZ signals are also on hand for use.

The evaluation kit from Balluff is also brand new to the portfolio. It includes a perpendicularly magnetized Permagnetﾂｮ absolute angle measurement system with high system accuracy. Just like the encoder kit, it offers a variety of serial (absolute) and incremental interfaces for connection to many different closed-loop systems. It is easy to use. Once adapted to the drive, the user can run required system tests to derive a customized, optimized solution using the BiSSUSB adapter and provided evaluation software. http://www.balluff.co.in/

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ARC INFORMATIQUE AND UBIQUICOM JOIN FORCES TO BRING LOCATION AWARENESS AND SAFETY TO YOUR SCADA APPLICATION

ARC Informatique is an independent provider in HMI/SCADA software. With its core product, PcVueÂŽ, the company has been contributing to the evolution of the automation industry for 30 years. The PcVue Solutions range provides a flexible solution for supervising industrial processes, utilities and infrastructure.

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ased in Milan, Italy, Ubiquicom is an award-winning technology company specialized in the design and development of products and solutions for the positioning and tracking of people and assets in unconventional contexts and using unconventional technologies.

Easy to configure and performed via Web services, these new features allow the detection and tracking of people and assets directly displayed as PcVue markers (which can be symbols) in a geographical map. This detection and tracking is efficient whether indoors and outdoors regardless of the network’s type and available communications (GSM, WiFi, Bluetooth, BLE).

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The two companies at the forefront of technological innovations, chose to collaborate and combine their skills to offer a unique mobility solution. This partnership manifests a joint effort to instill mobility at the heart of supervisory systems. A deliberate move from ARC Informatique in order to step into the field of Internet of Things (IoT) by interfacing with established networks such as LoRa, Sigfox, etc.

New features for Indoor & Outdoor Positioning Services Based on the real-time monitoring of biometric and environmental parameters, Ubiquicom adds an upper layer application to the PcVue Geo Map Control with its Locator Suite.

Through this collaboration, ARC Informatique reaffirms its ambition to provide an innovative mobile offering for SCADA. www.pcvuesolutions.com

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