EMEA 05

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EMEA

industry THE INDUSTRY MAGAZINE FOR EUROPE • MIDDLE EAST • AFRICA

ADVANTECH DOWNLOAD WHITEPAPER

KOLLMORGEN INTERCONNECTED ENGINEERING SERVICE INCREASES PRODUCTIVITY AND CREATES TANGIBLE ADDED VALUE

18 INDUSTRIAL CLOUD ROUTERS UNVEILED BY DELTA ELECTRONICS AT SPS ITALIA 2016

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THREE SUSPENDED CRANES AND SIX VERLINDE HOISTS IN THE INJECTION MOULD MAINTENANCE WORKSHOP AT PARKER HANNIFIN

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THE INDUSTRY MAGAZINE FOR EUROPE • MIDDLE EAST • AFRICA

TYCO GAS & FLAME DETECTION

FISCHER CONNECTORS

BALLUFF

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8 FLUKE PROCESS INSTRUMENTS

DELTA

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BRADY

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KENNAMETAL

SICK

KOLLMORGEN

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FLUKE PROCESS INSTRUMENTS

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NSK

SWISSLOG

VERLINDE

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VERLINDE

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ARC INFORMATIQUE

ADVERTISERS: ADVANTECH 3 - MEPAX 4 - ASCO SIRAI 7

www.industryemea.com

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OPTIMIZE YOUR INTERNATIONAL PR AND ADVERTISING FOR THE INDUSTRIAL MARKETÂ !

Outstanding results

Optimized process

80 employees in 35 different countries, ensuring a strong relationship with main local media. Mepax distinguishes itself through its extensive media knowledge and ability to select the best international online/print advertising options. PR can be translated into 35 languages.

25,000 published articles in 2014: EMEA: 45% - Asia: 35% - Americas: 20%. Most of the articles are published in the top 1000 media worldwide.

With a proven process set for more than 70 active customers, we can adapt to all specific client needs with the highest reliability.

We have developed in house the most advanced PR dedicated ERP, enabling transparency and real-time full online reporting. International media management is then made easy, fast, and efficient for optimal results.

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International capability

www.mepax.com info@mepax.com

THE MOST INNOVATIVE PR AGENCY 05 | Industry EMEA | July 2016

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@mepaxIntPR

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NEW MX 32 GAS DETECTION CONTROLLER NOW AVAILABLE

Tyco Gas & Flame Detection is pleased to announce that the new MX 32 alarm and control system is now available.

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esigned to meet SIL1 requirements, the new MX 32 is a compact, low-profile controller that continuously monitors gas detection. It uses the same platform as the MX 43 that has already proven to be a very high performing and reliable controller.

For more information visit www.TycoGFD.com

The new MX 32 manages both digital lines and analog channels and covers all needs for a wide variety of gas monitoring applications. Its digital technology allows up to 8 detectors to be distributed on two lines for increased savings. The unit allows two inputs for Wheatstone bridge sensors.

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LEAN SOLUTION FOR TRACK-AND-TRACE

All-in-One RFID Reader BIS M-4008.

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he BIS M-4008 from Balluff is an All-in-One RFID Reader with integrated processor. The 13.56 MHz reader with IP67 protection and a rugged die-cast zinc housing features a Profinet interface, needs no additional processor and can communicate directly with the control level.

The reader is an ideal choice wherever a lean solution is needed for detecting data carriers on workpieces and workpiece carriers at individual stations. Typical applications include material flow control in production facilities, conveying systems and assembly lines.

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The device is the only all-in-one reader on the market with an integrated 2-port Ethernet switch for constructing simple line- and ring topologies. An integrated webserver provides conven-ient status monitoring from a distance. Highly visible LEDs di-rectly on the device also indicate status.

The new reader supports data carriers conforming with RFID standard ISO 15693. Anyone needing faster data transmission can simply choose Balluff high-speed data

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carriers with a transmission rate of up to 8x faster than the standard and extra-large memory capacities of up to 128 kB. The BIS M-4008 saves the user much time and money in as-sembly and installation. The die-case zinc housing can be in-stalled directly on metal in a variety of ways. Direct connection to Profinet also represents reduced wiring expense and effort. Yet another benefit is the use of costeffective 4-pin, M12 standard cable for the power and Profinet connection.

Device master data are available as a GSDML file for typespecific parameterization. Ready-made function blocks provide for simple S7 programming. www.balluff.co.in

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SOLENOID VALVES

You get the peace of mind that comes with purchasing from a long established supplier with the backing of one of the largest global technology companies.

You get the support that you need throughout the whole purchasing cycle thanks to an extensive local and international network of sales staff and distributors.

You also get a product that optimises the performance you need from your machine or process, without paying for functionality or performance that you don’t need.

Simply what you need

1946 2016

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Sirai - Bussero (MI) Italy - Tel. +39 02950371 - sirai.com TM

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FISCHER RUGGED FLASH DRIVE NOW FIVE TIMES FASTER WITH USB 3.0

Fischer Connectors, the worldwide innovator in push-pull circular connectors and cable assembly solutions, today launched the USB 3.0 version of its ultra-portable, miniature, lightweight and extremely tough Fischer Rugged Flash Drive. This memory stick has been specially designed for the safe transportation and storage of sensitive data in harsh environments.

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he USB 3.0 Fischer Rugged Flash Drive is even faster, smaller and more user-friendly than the USB 2.0 product introduced to the market in 2011. The read speed is now up to five times faster; standard memory sizes are 32, 64 or 128 GB; the body is shorter; and, in order to guarantee secure access, it is now available not only with the Fischer UltiMateTM Series interface, but also with the Fischer MiniMaxTM Series interface. The activity LED is a further feature of the new product to improve usability.

Miniature – the size of a key ring – and lightweight, the Fischer Rugged Flash Drive has proven to be the durable solution for people on the go who need to download and securely transfer confidential data, images or videos from devices used in extreme environmental conditions or in hard-to-reach areas. It is perfectly adapted for applications where data security and confidentiality are critical, such as the defense and security, financial, medical, industrial, energy, underwater, motor and extreme sport sectors, e.g. for civil or military UAVs, ROVs, test & measure equipment or rugged computers.

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Main technical specifications • IP68 sealed even unmated • Unique Fischer UltiMate (size 07) and MiniMax (size 08) interfaces • Up to 100 MB/s read speed • 6High speed USB 3.0 • Memory sizes: 32, 64, 128 GB • R esists corrosion, vibration, shock and extreme temperatures 05 | Industry EMEA | July 2016

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The Fischer Rugged Flash Drive USB 2.0 on UltiMate size 08 and new versions UltiMate size 07 and MiniMax size 08 with USB 3.0.

Safe AND secure The Fischer Rugged Flash Drive is both safe and secure. Its rugged casing provides full protection against extreme environmental conditions. The flash drive is waterproof down to 120 meters and is resistant to extreme operating temperatures (-40°C to +85°C). Thanks to the unique proprietary Fischer Connectors’ circular connector interface combined with a durable encapsulation technique, it guarantees data security in case of loss or theft.

booth no. G 497, Hall 6. The Fischer Rugged Flash Drive will be commercially available in July.

More information: • Web page: http://www.fischerconnectors.com/global/en/fischerrugged-flash-drive-usb-3 • How to contact us: http://www.fischerconnectors.com/global/en/contact-us

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“Performance and flexibility” “At times when privacy and confidentiality are of paramount importance, you need the right product to protect your critical information against the elements and the potential risk of loss or theft,” explains Wim Vanheertum, Product Manager at Fischer Connectors. “Technology moves fast, and both performance and flexibility are required when designing high-speed applications using video. The new Rugged Flash Drive increases data transfer speed by five, and its flexible modular design, which includes a large selection of body styles, sizes, contact configurations and memory capacities, offers high customization.”

Showcased as world premiere at Eurosatory tradeshow The new Fischer Rugged Flash Drive is showcased for the first time, along with the company’s new electrical and optical connectivity solutions, at the Eurosatory tradeshow in Paris from 13 to 17 June 2016, at Fischer Connectors’ 05 | Industry EMEA | July 2016

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NEWS

INDUSTRIAL CLOUD ROUTERS UNVEILED BY DELTA ELECTRONICS AT SPS ITALIA 2016

Delta Electronics has recently launched its innovative 3G Cloud Router DX-2100 series and Industrial Ethernet Cloud Router DX-2300 series, both to be displayed at the major industrial show SPS Italia 2016, in Parma from May 24 to 26. These state-of-the-art routers enable a built-in secure tunnel between the DIACloud cloud service and a set of industrial devices such as PLCs, HMIs, AC motor drives, AC servo systems, sensors and more. Users can connect to DIACloud through Apps, web browsers or PC Windows platforms. The new DIACloud service offers simple and efficient control of automated facilities.

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esigned to support fast and reliable two-way data collection, DX-2100 is a rugged wireless router that establishes a secure ‘tunnel’ between the user and the remote networked devices or PC (via the cloud server) without the need for VPN servers. This makes it possible to perform remote configuration, remote firmware upgrades, scheduled tasks and remote management operations.

The device is targeted at a host of remote connectivity applications that include industrial automation, smart homes, smart buildings, smart grids, surveillance and transportation monitoring.

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Superior performance based on quick, strong and secure connectivity is viable with these advanced new devices.

Able to support Modbus TCP and RTU protocols, the DX2100 is downward compatible with GSM/GPRS/EDGE 2G networks. Both the DX-2100 and the DX-2300 offer HSPA+ data transmission rates of up to 21.6 Mbps (downlink) and 5.76 Mbps (uplink). Before purchasing any router, users are advised to determine how fast it transmits data.

For the Industrial 3G Cloud Router, further benefits include automatic APN parameter matching and connection redial, therefore minimising offline time in the event of internet drop-out. In addition, there are various peripheral interfaces that include RS-485, RS-232 and Ethernet ports to meet all user device connectivity requirements, while an integral RTC

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(Real-Time Clock) also features along with support for NTP (Network Time Protocol) synchronisation over a network.

From a security perspective, the firewall offers many advanced functions, including SPI (Stateful Packet Inspection) and the prevention of DoS (Denial of Service) attacks. What’s more, the firewall also provides NAT (Network Address Translation), port triggering and port mapping functionality, along with IP address, MAC address and URL filtering. All of this helps to make Delta’s DX-2100 and DX2300 some of the market’s most secure industrial cloud routers.

Additional user advantages include networking failure diagnostics, device and PLC interlocking, and custom alarm conditions with email alerts. www.delta-emea.com

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TURNKEY TEMPERATURE MONITORING SYSTEM FOR WALLBOARD PRODUCTION

Noncontact measurement technology from Fluke Process Instruments helps optimize wallboard dryer settings and increase yield.

Noncontact quality assurance and 100% traceability.

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luke Process Instruments launches a new, complete turnkey solution for real-time temperature monitoring and documentation of wallboard manufacturing processes. The TIP900 system is an efficient quality control tool designed to help manufacturers quickly set up their line and improve yield. The infrared temperature measurement system creates highly detailed thermal images of the boards as they leave the dryer.

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Analyzing these, the system software detects moisture and density variations and identifies any faults, such as clumps or voids in the plaster core, paper blows, edge burns, or overlapping boards. The thermal images and any flaws are instantly displayed on a touchscreen, allowing the line operator to adjust the dryer for maximum board quality.

Tolerances for rejects, alarm settings, and report generation are user-configurable.

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The dust-proof and Ethernet-enabled TIP900 system allows for remote access to all thermal images and graphs of all processed boards. The LogViewer database stores all recorded data. It can be searched with customized filters, enabling trend analyses and long-term traceability. www.flukeprocessinstruments.com

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SPILL PALLETS WITH LOAD CAPACITY UP TO 3000 KG

Brady offers a new range of durable plastic spill pallets and decks to store drums or IBC’s on.

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ny business that stores some or even a great many drums or IBC’s will find the new spill control solutions very practical to contain leaks from drums or IBC’s and to avoid undesired contact with the environment or between substances.

Increased safety Spill pallets and decks can stop drum or IBC leaks from spreading on the work floor. In businesses that store several fluids in drums or IBC’s, they can help avoid undesired and potentially dangerous contact between fluids in the event of a leak. Spill pallets and decks also help avoid employee absence from work due to slips and falls, a major cause for workplace injuries.

Easy to handle Brady’s new spill control pallets and decks are very practical.

They can easily be lifted from all sides by a forklift, are easy to handle, durable and can carry up to two heavy drums. They offer 650 kg to 2700 kg load capacity for drums, and up to 3000 kg for IBC’s, and are designed for frequent professional use.

For more information, contact Brady at emea_request@ bradycorp.com www.brady.co.uk

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A range of solutions A complete range of spill control pallets and decks is available to meet various needs. Brady offers a spill control pallet that can hold a EURO-pallet on top, an IBC-storage compliant spill pallet, spill pallets that together form an entire spill deck and a heavy-duty spill pallet to carry extreme weight.

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Stellar Precision owner discusses tooling on the shop floor with production manager Ed Frieze.

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STELLAR SUCCESS

The mix of machine tools on Stellar’s shop floor is one of continuous improvement and adoption of new technology.

This solid ceramic endmill might feel like plastic in your hand, but its cutting performance in nickel-based alloys is often twenty times that of carbide tools.

Solid ceramic endmills from Kennametal help this aerospace job shop meet a critical delivery date.

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ost shops evaluate new cutting tools in an effort to reduce machining time, increase tool life, or improve part quality, and sometimes all three.

Stellar Precision Components Ltd., a Tier II aerospace supplier in Jeanette, Pennsylvania, did it for an entirely different reason. “We’d just taken an order for some Inconel parts,” says production manager Edward Frieze. “None of us were really worried at that point about tool life or making a profit on the job—our only concern then was how the heck could we get them shipped in eight weeks.”

“We started out doing a lot of overload work from other larger shops in the area, but that evolved into direct support of several nuclear programs because of my father’s experience in this area,” says daughter Lori Albright, now owner and president of Stellar Precision. “We’ve since become a key supplier to a number of prime aerospace and defense contractors including Boeing, Lockheed, and Raytheon, as well as various nuclear and medical customers, and have over 70 employees and sales revenues of nearly ten million dollars US.”

Opening Doors Four decades earlier, Mike Vucish Sr. was working for a manufacturer of naval nuclear components when he saw an opportunity to go into business for himself. He bought some equipment, invited a few students from the technical school where he taught shop class at night, and opened the doors of Stellar Precision in 1978. He continued to work at his day job until his fledgling company was firmly established, but in the meantime brought some family members on board to help out.

Stellar prides itself on continual updates to its equipment list, and has an eclectic mix of CNC machine tools from Haas Automation and Okuma, although that balance is steadily tipping in Haas’ favor as the shop’s older machines go into retirement. Albright says not only is the Haas equipment less expensive than its foreign-built competition, but that “Made in America” resonates with many of Stellar’s customers. “This approach also lets us replace our equipment on a more regular basis, which in turn keeps us current on technology.”

Key equipment includes an Okuma LB-45 lathe able to turn 36 in. diameter parts up to 120 in. long (91 mm x 305 cm), and a Haas VF-11 5-axis machining center with 10 ft.

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NEWS Hot stuff. Kennametal’s full ceramic end mills operate at spindle speeds up to 10 times faster than carbide and provide far greater tool life.

of X-axis travel (305 cm) and a table load capacity 4000 lb.

(1814 kg). Stellar also has several wire EDMs, a dozen or so 3, 4, and 5-axis machining centers and mill-turn lathes, and offers value-added services such as non-destructive testing, welding, heat treating, and Teflon coating.

Not Too Tough Stellar is used to meeting demanding requirements. Recent projects include components for RAM Block II anti-ship missiles, the CCtCap crew transport vehicle, 155mm Long Range Land Attack Projectile (LRLAP) advanced gun system, rocket motor cases for the Atlas Five launch vehicle, and others. Their newest project, however, would be one to test the mettle of machinists and management alike.

Nor was tolerance an issue. Frieze points to one recent titanium part that called out a 0.005 in. (0.127 mm) profile tolerance over its 12 in. length (304 mm), the equivalent of holding “a couple tenths” in parts that cost over $5000

Seminar Payoff Earlier that year, Frieze and several of his coworkers had attended a learning event sponsored by a local chapter of the National Tooling and Machining Association (NTMA), and hosted at the Kennametal technical center in the nearby town of Latrobe. There he met product manager Matthieu Guillon, who introduced him to a cutting tool that Frieze was initially skeptical of. “It looked and felt like a plastic toy end mill,” he laughs.

That tool was Kennametal’s series of 4 and 6-flute high performance full ceramic end mills. Constructed of SiAlON KYS40 grade ceramic and designed specifically for roughing in nickel-based high-temperature alloys, these end mills often out-produce carbide by up to 20 times. Says Guillon, “We recommend a starting speed of 825 SFM up to 3300 SFM (250 to 1000 m/min) and feedrates starting at around 0.001 IPT (0.03 mm) depending on the tool diameter and other conditions. Despite the far higher cutting speeds,

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Frieze explains that Stellar had just received a purchase order for a handful of Inconel 625 prototypes. The raw material blanks for the job measured 18 in. square x 3 in. thick (457 x 457 x 76 mm), and weighed nearly 300 lb. each (134 kg). The project team suffered little indigestion over the tough material’s poor machinability; Stellar routinely cuts Inconel and other nickel-based superalloys, as well as tungsten, maraging steels, 60 Rc 4340 (300M), and tool steel.

apiece before machining. Meeting the relatively wide open tolerances on the Inconel part was not a concern.

The problem was one of raw material removal: when finished, the Inconel plates weighed in at a svelte 30 lb. (13.6 kg), 90-percent lighter than their starting weight. Frieze knew there weren’t enough hours in the day to remove that much material using conventional carbide tooling, not if he were to meet the deadline. He needed a better solution.

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Lori Albright in an early morning strategy discussion with Kennametal product manager Matthieu Guillon.

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“The tools aren’t inexpensive,” he says. “At one point, Lori had around $20,000 worth of end mills sitting in her office and we were starting to question the investment. But once you calculated in the machine costs and reduced cycle time, we figured it was three to four times more cost-effective to go this route. Each end mill gave us one half hour of cut time, at which time we replaced it whether it was worn or not. The process was so predictable we were able to run lights out. It was a drastic savings.”

Young people and fresh ideas are two of Stellar’s biggest assets, says owner Lori Albright.

we have some customers who have reported 2 to 3 times greater tool life than carbide.”

>>> Stellar didn’t have any immediate use for the ceramic tools, but after making some quick feed and speed calculations, Frieze knew they would be an effective solution given the right application. Several months later, that application arrived with the Inconel plates. He called Guillon to say he might have a good use for those ceramic cutters they were talking about, and wondered how soon he could get some.

Skeptic to the Last Frieze remained skeptical. He’d tried indexable ceramic cutting tools on both milling and turning jobs in the past and had mediocre results. In this case, however, he was willing to try anything if it meant meeting the customer’s deadline. When Guillon arrived a few days later with the ceramic end mills, Frieze followed Kennametal’s feed and speed recommendations to the letter, crossed his fingers, and pushed cycle start.

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“We weren’t certain what would happen so started out with a block of test material,” he says. “You don’t use cutting fluid with ceramic—only an air blast—and everyone in the shop was crowded around the machine saying, ‘Wow, look at that!’

There was fire shooting everywhere. It was something we’d never seen before. But within the first hour, we knew it was going to work.”

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Enjoying the Heat Best of all, Stellar delivered the parts on time with zero scrap, and is now quoting a second, even larger order. Owner Lori Albright was quite pleased with the outcome. “This type of situation is the nature of our business. We have to react to our customers’ needs and employ the best technology available to do so. That’s one of the reasons why Kennametal is so welcome here. We work together as a team to solve challenges.”

Looking forward, Albright anticipates continued growth.

Having expanded Stellar’s existing facility six times, she figures it might be time to put up an entirely new building on nearby property. She also looks forward to bringing additional young people to the machining trade. “We have apprenticeship programs with several of the area schools, one of which my father used to teach at,” she says. “I find that it’s often our younger people that drive our innovation. It's too easy to keep doing things the old way and not invest in tooling and equipment, or pursue new technology. The days of high volume, round-the-clock fender clip manufacturing are gone, and it’s only by continually improving their manufacturing processes that companies can succeed and grow. For us, Kennametal is part of that success.” www.kennametal.com

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INTELLIGENT SENSORS PAVE THE WAY FOR THE INDUSTRY OF THE FUTURE

SICK presented innovative sensor solutions for forward-looking applications at the Hannover Messe trade fair. The exhibit on human-robot collaboration at the SICK stand in Hanover proved to be a major draw.

Success for SICK at the Hannover Messe 2016.

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t the Hannover Messe (HM) trade fair, SICK AG presented innovative sensor solutions for forwardlooking applications under the slogan “Industry 4.0

ready”.

As a technology supplier in the field of industrial sensors, SICK's presentation explained how intelligent sensor data can be used: from highly aggregated, complex web services in the cloud and shop-floor systems for logistics transparency to autonomous robot control.

In particular, the exhibit on human-robot collaboration proved to be a major draw, featuring a robot arm which took a glass cup from a visitor. The robot used the RFID tag affixed to the cup to read the individual print job and performed the task by itself. As the station was protected

Meanwhile, the trade fair also featured a first in the field of track and trace technology in the form of the RFU65x RFID read/write device, which creates transparent paths within the factory.

The device is the first to be able to measure the movement direction of an RFID tag bearer when read. This means that, in the future, it will be possible to record not only the position, but also the transport path of workpieces with minimal effort. In this way, the current location of a part will always be evident in real time.

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From its stand at Hannover Messe – the world's largest industrial fair, featuring 3,342 exhibitors – SICK demonstrated the importance of its role as a technology driver in the field of Industry 4.0. Alongside the company's own intelligent systems and sensors, SICK also presented various examples of its collaborations with research and industry partners.

These joint exhibits featured integrated solutions typical of Industry 4.0, which were a big hit with visitors.

with microScan3 laser scanners, the robot was able to work without partition screens in this application. As soon as anyone came within a certain distance of the robot during operation, its movement slowed down. If someone came even closer, the robot stopped completely.

The eventful week saw a constant stream of visitors to SICK's stand in Hall 8. Employers from the US subsidiary SICK, Inc. were also present in order to honor the close collaboration with the USA as a trade fair partner. www.sick.de 05 | Industry EMEA | July 2016

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HIGH IMPACT CUSTOMIZED SOLUTIONS INTERCONNECTED ENGINEERING SERVICE INCREASES PRODUCTIVITY AND CREATES TANGIBLE ADDED VALUE

The linear axis can be positioned exactly using an AKD & AKM one-cable package (incl. control unit).

MEquadrat AG is a start-up that has been providing highly specialized solutions for four years as a mechatronics service provider, particularly in the laboratory and medical areas.Interdisciplinary thinking plays a fundamental role in this company’s product development activities. Original ideas related to implementation, efficient development and customized support also characterize the collaboration they had with drive specialist Kollmorgen on their new production module for the medical sector. Kollmorgen’s backlash-free direct drive solution allows exact synchronicity and concentricity with maximum precision up to 2 µm, and is more cost-effective.

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ne of the founding concepts of the service company MEquadrat AG, situated in the municipality of Root in Lucerne, is networked thinking and the creation of new machines and systems that meet its customers’ needs through consistency in the software used, the sophisticated mechanical and electronic components, and the associated increase in the degree of automation.

One thing is clear for Stefan Nyffenegger, a member of the executive management team at MEquadrat AG: “The interlock between the mechanics, electronics, and software is the key to innovative products and higher productivity. We also break new ground with our unconventional approach, as can be seen with the current project for a machine module that is designed for processing thin-walled material in the medical sector”.

A difficult objective: Precise clamping despite high levels of rotation The two-sided and torsion-free clamping of highly sensitive glass and aluminum tubes is a particular challenge for the production module developed and constructed in Root. The product diameter ranges from between around

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Stefan Nyffenegger and Martin Zimmermann in front of the machine module.

Nyffenegger emphasizes: “With the KBM kit motor solution from Kollmorgen we have found the perfect solution for us, and the overall drive concept really was customized to our needs.”

Zimmermann: “The team from MEquadrat knew exactly what they wanted. We were able to make concrete proposals based on their input in order to get there. This allowed us to develop the best solution together.”

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Detailed view of Kollmorgen’s KBM Kit Motor. The delicate product can be guided through the drive in a fluid process as a result of the large hollow shaft. Absolute precise synchronization up to 2 µm is central to this.

one millimeter to 20 mm, with very thin wall thicknesses of around one-tenth of a millimeter. Cutting and joining processes are carried out on the sensitive hollow rod material. The high speed for the material clamped on both sides in the process requires absolute precision in terms of the synchronicity.

Developing the overall module in such a compact manner in accordance with the customer’s strict specifications required a highly meticulous and extremely precise drive system for the spindles in the workpiece feeder mechanism and for the relevant process steps with the clamped product. Stefan Nyffenegger highlights: “With the KBM kit motor solution from Kollmorgen we have found the perfect solution for our needs, as the product can be guided through the drive in a fluid process thanks to the large hollow shaft.”

But tt became apparent that a rotor and a stator with the full functionality of a servo drive should be used as a result of the compact packing density and complexity of this assembly. In the end, the company decided the best

Aside from the time pressure and the extreme requirements related to precision in the functional specifications, there was another additional crucial challenge related to the medical technology: “The drive solution must be free from abrasion and lubricant, and we weren’t able to carry out any experiments at the implementation and commissioning stages for the mechanics and software”, says Nyffenegger.

All of the components provided in this machine module therefore had to be tested and shown to be absolutely reliable.

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Collaboration on an equal footing for unconventional solutions The engineers at MEquadrat already had the idea of selecting a direct drive as they were designing the drive system. heir intention was to use an existing modular design in order to meet the precision requirements and to guarantee implementation on a time and cost-efficient basis.

solution was from Kollmorgen. The experts at the drive manufacturer were ready for any special requests.Decisions at the implementation stage for this project were made very quickly, as the experts from both companies collaborated witheach other on an equal footing. The synchronicity however remained a problem. But a few ideas were developed for this and the product selection was narrowed down during some initial telephone discussions. The Key Account Manager at Kollmorgen, Martin Zimmermann, and his colleagues providd their full support: “When MEquadrat only requested the rotor and the stator for the feeder unit in this project, we knew that a mechatronics engineer would need to focus on the motor in greater detail. You have to have confidence when trying new things like in this project, which requires mutual and absolute trust”.

The interaction of the direct drive with AKD Drives and the controllers from National Instruments (NI) enables 05 | Industry EMEA | July 2016

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The linear axis can be positioned exactly using an AKD & AKM one-cable package (incl. control unit). The KBM Kit motor which is responsible for synchronization of the tubes fed through sits on top of this.

extremely precise positioning. The cycle times in the current regulator are around 670 ns, and are just 62.5 µs in the speed regulator. Nyffenegger stresses: “This allows us to achieve optimum synchronicity in line with these high dynamic requirements. As such this drive combination represents the optimum price-performance ratio.”

Precise positioning with plug-and-play solutions The crucial thing here that the two synchronized axes achieve extremely precise concentricity of 2 µm. Nyffenegger adds: “We’re talking about accuracy ranges that are otherwise only seen in spindle axes in large production plants.” The high speed was another of the major challenges in this project. There are systems on the market that “can indeed clamp sensitive products such as these at the required level of accuracy, but they often lose their clamping force from 500 rotations per minute. I haven’t seen any comparable product on the market that maintains its full clamping force at 3000 rpm!”, highlights Nyffenegger.

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The “AKM” drive with single-cable solution and SFD feedback were selected for the linear axis in the machine design.

The components now just needed to be put together and everything fitted perfectly.

The resolver method as a single-cable solution is one of the drive expert’s specialties aimed at making optimum use of the robustness of the resolver. Nyffenegger stresses: “The wiring required in the AKM motor is also minimal here as a 05 | Industry EMEA | July 2016

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The direct drive permits extremely precise positioning. The cycle time for the current regulator is 670 ns, while for the speed regulator it is 62.5 µs.

result. Highly compact cable carriers can also be used which really are sensational for tight spaces.”

Summary: Achieving the objective using collaboration based on trust The AKD one-cable package (controller & servo motor) is used for the components in the liner drive for the feeder mechanism. The major benefit with this is that the system comes from one source. Nyffenegger emphasizes: “This way I don’t need to worry about any screw fittings or pins that do not fit. We just had to plug it in and get started, which also made the implementation time very short.” Integration of the precise drive technology in the precise mechanics was therefore the central element in the very close and focused collaboration for this project. Keeping an eye on the costs – despite the required level of speed accuracy, the bearing and form tolerances for the mechanics and the fact that everything fits right from the word go, required a lot of mutual trust for both sides. Martin Zimmermann adds: “Our specific part in the project related in particular to our comprehensive recommendation as to how the customer can achieve its objective in an optimized and most costeffective manner .”

One thing is clear for Stefan Nyffenegger: “We were also able to discuss ideas directly with the Kollmorgen product developers, and put forward our requests related to the shaft and hub connections. Sitting down at a table and discussing in order to find solutions, or discussing the design details on the phone, provided us with the assurance that everything

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The AKD servo amplifiers are fast, flexible, are suitable for a wide range of functions with Ethernet-based communication, and can therefore be integrated quickly and easily into any application.

would work correctly with the drive, and that we would be able to get things right the first time on this project.” The design phase alone for the machine took just three months, which is extremely efficient. “The Kollmorgen part such as the installation of the axes and connection of the motor with full configuration and testing was completed within two days. This drive concept which was really customized to our needs worked out brilliantly for us. It fulfilled its objective, worked straight away, and met all of the requirements that we set ourselves for our customer.”

AKM standard synchronous servo motors with permanent magnets. The powerful synchronous servo motors from the AKM series, which includes more than 500,000 standard models, are available in different fastening, connection, speed, and feedback versions and with lots of additional options.

KBM frameless kit motors (modified by the customer in order to fit into the module). KBM frameless kit motors for rotary direct drive applications. The wide selection of frameless fit motors in the KBM series is the latest direct drive technology. They meet all of the requirements from machine constructors in terms of flexibility, power density, dynamics, lifespan, and simple installation.

AKD & AKM one-cable package for easy integration. AKD servo controllers and AKM servo motors can be used in any application and are particularly cost-efficient one-cable solutions. The AKD servo amplifiers are fast, flexible, are suitable for a wide range of functions with Ethernet-based communication, and can therefore be integrated quickly and easily into any application. AKD enables plug-and-play commissioning and interfaces with all parts of the machine without barriers.

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Benefits of Use: • High flexibility of the coordinated components • Integrated hollow shaft for special application predestines integration of a clamping system which maintains its clamping force even at 3000 rpm • Direct drive without any play or redundant mechanical parts allows exact synchronization and concentricity with the utmost precision up to 2 µm and is thereby hardwearing • EtherCAT on board for simple implementation and integration (hardware and software) – also in LabVIEW • Excellent, comprehensive support from Kollmorgen from design through execution to commissioning • Easy conversion to different diameters • High process stability when increasing the degree of automation, achieving higher productivity levels, leading in turn to increased profitability

Products used: The following Kollmorgen motors (with a 1-cable system) and drives are used in the project:

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NSK UNVEILS AIP+ ADDED VALUE PROGRAMME

NSK can provide a range of induction heaters in different sizes based on weight and power requirements.

To help ensure the optimised and profitable operation of machinery and equipment, NSK has introduced its AIP+ Added Value Programme. Designed to deliver a complete bearing care package, AIP+ uses a quartet of innovative maintenance and service tools – condition monitoring, mounting tools, laser alignment and lubrication solutions – which have been carefully developed to help maximise machine performance and operating life.

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SK’s Condition Monitoring Service (CMS) is a comprehensive health check for operational machinery. Offering a consistent process of application, CMS comprises an initial assessment to check both the suitability of CMS and define its monitoring route.

This is followed by data collection using NSK vibration, temperature and speed measuring equipment, along with data analysis to check the health of the machine, and full reporting including recommended actions.

Any unwanted forces, such as those resulting from outof-alignment or out-of-balance conditions, will be easily identified following application of the NSK condition monitoring equipment, which can measure vibration, for example, in three axes simultaneously. The monitoring equipment will also pick up any issues relating to lack of lubrication or the potential for early fatigue. NSK already has a fully trained team of CMS experts in place that is able to respond to requests across Europe.

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With regard to NSK’s selection of bearing mounting tools, these have been designed to ensure that all bearings are handled and fitted correctly, without damage. To obtain optimum performance, bearings must be fitted correctly, both on to a shaft and into a housing. Due to the fact that one ring of the bearing will have an interference fit, installation requires special tools so that the necessary force is applied evenly to the fitted ring. Alternatively, heat can be applied to achieve assembly, again using NSK tools supplied as part of AIP+.

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NSK’s selection of mounting tools have been designed to ensure that all bearings are handled and fitted correctly.

NSK’s Condition Monitoring Service (CMS) is a comprehensive health check for operational machinery.

For those who rely on NSK bearings, it is imperative to use NSK tools as this is the only way to ensure correct assembly and disassembly. All NSK mounting tools are now in stock ready for dispatch. If required, a package can be offered that includes training in how to achieve best practice fitting and removal.

Another powerful tool in NSK’s AIP+ portfolio is laser alignment. NSK’s alignment tools are designed to minimise losses and ensure the machine gives optimum performance with the lowest energy. Industry research suggests that a staggering 50% of machines run out of alignment, which leads to higher loading and lower overall performance.

Finally, NSK can also offer lubrication solutions as part of its new AIP+ Added Value Programme, a proven maintenance practice that is essential for extended bearing and machinery lifetime.

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In an era where typical maintenance budgets can range from 15 to 40% of annual turnover, any savings that can be generated are certain to deliver a highly positive effect on profitability. NSK’s AIP+ has been developed to help plant engineers achieve these savings as part of a structured and proven process. www.nskeurope.com

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SWISSLOG ENHANCES ITS PALLET STORAGE AND RETRIEVAL OFFERINGS WITH ACQUISITION OF POWER AUTOMATION SYSTEMS (PAS)

Swisslog Warehouse and Distribution Solutions, leading provider of best-in-class intralogistics solutions, announces the acquisition of Power Automation Systems (PAS), the world-wide market leader in pallet shuttle automated storage and retrieval systems (ASRS). Now with offerings ranging from advanced robotics to fast case shuttles and pallet shuttles, together with KUKA Swisslog continues building the Automation Powerhouse chain offering clients compelling solutions.

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hristian Baur, Swisslog CEO of Warehouse and Distribution Solutions, stated “The acquisition of PAS allows Swisslog to expand our product portfolio and offerings with focus to the North American and APAC markets. As the leader in logistics automation, our goal was to offer our clients a new dimension of speed and storage density for pallet warehouses that handle a confined number of SKU’s with high volume, not only in the green field, but also for existing buildings.”

Winning situation for PAS and Swisslog customers PAS and Swisslog customers will remain top priority throughout the acquisition and leadership change. “The combination of Swisslog and PAS will deliver benefits to our customers greater than the sum of our parts,” said Markus Schmidt, Senior Vice President, Swisslog Warehouse and Distribution Solutions Americas. Continued Schmidt, “Furthermore, Swisslog offers its world class service with our customer support team consisting of 24/7 help desk, remote system monitoring, on-site support, spare parts and system retrofit expansions, and modernizations, which will be of great benefit to PAS’s existing customers.”

Growing opportunity for Swisslog and PAS Headquartered in Lathrop, CA, the PAS office will immediately serve as the Swisslog Americas West Coast location. In addition, the acquisition is designed to further develop and expand Swisslog’s reach in North America, South America, Asia, and Australia toward end of production line ASRS

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applications for fast moving goods with a maximum degree of customer satisfaction. “Swisslog and PAS have partnered in the past to provide top notch automation solutions for clients such as Coca-Cola and Sutter Home (Trinchero Family Estates). I am proud that we have attracted Swisslog, a company with a great reputation and global size, so that the PAS solutions can grow to their full potential and expand on the leadership we’ve created,” said Pat Mitchell, inventor, founder, and previous owner of PAS. Michael Felbinger has been appointed as General Manager of the PAS business line and will ensure seamless integration into Swisslog. Said Felbinger, “I am looking forward to working with the innovative PAS team to deliver firstclass products and solutions that create high value to our customers worldwide.” Felbinger has 20 years of material handling experience in Europe and the United States and serves as a Vice President within Swisslog Americas.

For more information on Swisslog, visit www.swisslog.com MORE INFORMATION 05 | Industry EMEA | July 2016

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THREE SUSPENDED CRANES AND SIX VERLINDE HOISTS IN THE INJECTION MOULD MAINTENANCE WORKSHOP AT PARKER HANNIFIN

The mould routine maintenance workshop.

PARKER HANNIFIN with its global turnover of €11.5bn is a world leader in movement and control technologies. The company designs, manufactures and markets a wide range of hydraulic, pneumatic and electromechanical components.

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he Muzillac factory in Brittany employing 130, located 25 km from Vannes, is a plastics injection specialist for products of the FSCE division and for the automatic assembly of instant fittings The factory is ISO 9001, ISO 14001 and ISO TS certified and the injection mould maintenance workshop very recently installed three EUROPONT overhead cranes on each one of which is fitted two VERLINDE hoists.

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The moulding workshop The moulding workshop is the core production activity at the Muzillac plant. Twenty-two Engel, Fanuc or Ferromatik injection presses are served by a suspended crane fitted with a 3-tonne VERLINDE EUROBLOC VT hoist for mould changing operations. These presses are used for the moulding of connectors for small pneumatic hoses and for compressed air system couplings in industrial buildings. For the car industry, five presses are dedicated to the production of motor fuel distribution circuits integrated by Parker Autolive in its manufacturing facilities. Mickael Le Pon, injection facility production manager, explains.”We carry out between 300 and 350 parts series changes per month involving just as many injection mould changes. To ensure the moulding workshop works at full capacity it is first of all vital that the moulds are in perfect condition and as their 05 | Industry EMEA | July 2016

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manipulation can only be carried out with the suspended crane, the latter must be totally available and reliable.”

Mould routine maintenance, a decisive production factor Mickael Lepon: “Even if our activity is complex, it has to be understood that it is based in the main on two basic equipment units – plastic injection presses and moulds. To ensure production quantity and quality in phase with our targets, we have to ensure without fail regular inspections and routine maintenance of the moulds because we depend to a large extent on them to guarantee the productivity and the manufacturing quality of our products.”

A special workshop for mould routine maintenance The 500 m² workshop dedicated to mould routine maintenance consists of three successive square 10 m x 10 m work stations. After a certain number of duty cycles, the mould is removed, cleaned ultrasonically and the toolmaker is sometimes required to recondition the spindles by electroerosion or replace possible faulty parts.

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VERLINDE EUROBLOC VT hoists ready to be operated on the suspended cranes.

Installation of suspended cranes and VERLINDE MONOBLOC VT hoists Before the EUROPONT suspended cranes were installed, a single jib crane served the three work stations. As the manipulation of metallic moulds whose weight varies between 50 and 1500 kg necessitates taking numerous precautions, the toolmakers frequently had their work interrupted while awaiting the availability of the jib crane.

It was therefore decided to make each station autonomous with its own suspended crane fitted with two VERLINDE hoists of a lifting capacity of 1.6 tonnes. The three EUROPONT cranes travel on the same metallic structure and to avoid accidental collisions, limit switches guarantee travel safety.

Following this new work organization making each work station autonomous, the productivity of the mould routine maintenance shop has risen by 25%. As moulds are made of two parts whose sizes and weights vary, each crane is fitted with two VERLINDE EUROBLOC VT hoists in order to facilitate their manipulation in complete safety.

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The selected VERLINDE EUROBLOC VT hoists are fitted with 2-speed motors for lifting and a variable speed motor for horizontal travel. In this way the load is totally controlled horizontally and vertically without any rocking effect. The daisy-chain type power supply is conventional and the control boxes are wired. This solution was in fact preferred to a wireless system for reasons of safety, in order to avoid any possible confusion between the control boxes of the three work stations.

Lifting hook with safety latch.

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The two parts of a mould raised by VERLINDE hoists.

The three suspended cranes. Each EUROPONT suspended crane is fitted with two VERLINDE hoists.

VERLINDE, a long-time partner of PARKER HANNIFIN at Muzillac Mickael Lepon: “We have enjoyed a relationship of trust with SERE Maintenance for decades and so quite naturally we called upon them to re-organize our mould routine maintenance workshop. They delivered and installed the cranes and hoists and together we inspected the equipment at reception before testing the strength of the metallic structure under load. Our experience with a varied range of Verlinde equipment led us to install EUROBLOC VT hoists whose reliability meet our requirements with a high level of cost effectiveness.

To this can be added the fact that SERE Maintenance is located not far from us making their preventive maintenance service very convenient. In the mid/long term, we envisage installing a second suspended crane in the moulding workshop to be accompanied by a further Verlinde hoist.”

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Sere Maintenance, managed by Ludovic Mathis, is a partner of Verlinde and has been a member of the EUROPONT overhead crane manufacturers’ network for more than forty years. A workforce of fifteen ensures the smooth running of the company’s different activities: lifting operations representing 80% of the company’s turnover, together with an activity involving the cathodic protection of metals, mainly for water, gas and compressed air circuits for industry.

A whole range of services are also available to customers, such as lifting and handling equipment maintenance.

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www.verlinde.com

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HIGH-TEMPERATURE PYROMETERS FIT FOR HARSH ENVIRONS

Easy operation, superior precision, and longevity combined in one rugged infrared thermometer.

Fluke Process Instruments introduces the Endurance series of high-temperature infrared thermometers.

Featuring a stainless steel IP65 housing and galvanically insulated I/Os, these units enable continuous process monitoring of the most demanding industrial applications, including primary and secondary metals manufacturing, carbon processing, and silicon production.

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roviding a measurement resolution of 0.1 °C, they also meet the requirements of the semiconductor industry.

Two models cover wide measured temperature ranges of +550 °C to +1,800 °C and +1,000 °C to +3,200 °C, respectively. They can be operated in one- or two-color (ratio pyrometer) mode. An optical resolution of up to 150:1 allows measurements of smaller objects from a distance.

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The series is designed for comfortable configuration and operation. The sensors feature an intuitive rear-panel user interface and a built-in web server for data archiving, traceability, and process troubleshooting. The PC-based Endurance setup and monitoring software includes time-saving tools such as the new match function which automatically detects the correct emissivity of the measured surface. What is more, Fluke Process Instruments has further extended the range of sighting options and now offers a high-resolution on-board video camera for remote monitoring of the application and sensor alignment via Industrial Ethernet. In addition to laser sighting, which marks the position or size of the measurement spot, LED sighting

projecting the actual spot size on the target is also available now. Endurance series pyrometers provide a robust solution for manufacturers seeking to improve product quality and uniformity, reduce reject rates, maximize throughput, and minimize energy costs. Periodic lens cleaning checks are unnecessary, since a dirty lens alarm tells users when it is really time to clean. Accessories include an air-purge collar. The rugged sensors operate reliably at ambient temperatures up to +65 °C or up to +315 °C using cooling accessories. The manufacturer provides a best-in-class fouryear warranty. The sensors use either Power over Ethernet (PoE) or DC power (18 to 48 VDC, 500 mA). They are available with Industrial Ethernet, RS-485, or Profinet interfaces as required. www.flukeprocessinstruments.com

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VERLINDE ELECTRIC WIRE ROPE HOIST FITTED TO 360° POWER SLEWING JIB CRANE

A EUROBLOC VT2 electric wire rope hoist from VERLINDE has been integrated with a new 360° power slewing jib crane at Yarmouth Harbour on the Isle of Wight, UK. Designed, manufactured and installed by UK distributor, PELLOBY, the crane/hoist offers a safe working load of 5 tonne.

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s a vital tool for a busy dock, the new crane provides dockside access for the various boats using the harbour on a daily basis. Thanks to its 360° rotation, 7 metre height and use of a VERLINDE EUROBLOC VT electric wire rope hoist, the crane can be used for loading and unloading goods and equipment, or for lifting vessels out of the water for maintenance purposes.

An EUROBLOC VT2 04115 CRP4 hoist was specified. This short headroom trolley version offers 9 metres height of lift, 8 + 1.3 m/min hoisting speed, 3-20 m/min travel speed and M5 duty classification. Deemed ideal for the 838 x 292 x 176 kg universal beam, the hoist will be expected to perform with complete reliability in this exposed, salt-rich marine environment.

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Pelloby prides itself on being the UK’s leading jib crane manufacturer and was therefore able to produce a fast and accurate quotation for this rotating jib crane, while tailoring every aspect of it – from the power slewing operating system to the choice of hoist and paint colour – precisely to the client’s requirements. The company was also able to provide detailed renderings and drawings of how the finished system would look during both the quotation and design phases.

The EUROBLOC VT electric wire rope hoist earnt its selection for the project due to a host of end user benefits. For instance, it is the only hoisting unit with wire rope and a 05 | Industry EMEA | July 2016

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hook that offers in its standard version the market’s smallest hook approach ‘C’ dimensions and ‘F’ approach distance.

In addition, the pulley block minimises lateral shift during hoisting, while EUROBLOC VT hoists also offer users the possibility of adjusting speed while travelling. Further attributes include enhanced safety, ergonomic and easeof-maintenance features.

Pelloby oversaw all stages of the project at Yarmouth Harbour, from manufacturing the various parts of the system at its production plant in Telford and delivering the crane to the Isle of Wight via a trusted logistics partner, through to installation and final commissioning to guarantee its safety and suitability for use. It is operated via an easy-to-use handheld radio control system which governs the jib arm rotation, the longitudinal travelling motion, and the movement of the VERLINDE EUROBLOC VT hoist and carriage. www.pelloby.com

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PCVUE INTRODUCES PROXIMITY-BASED CONTEXTUAL MOBILITY FOR SCADA

PcVue® is ARC Informatique’s core product, the company is an independent provider in HMI/SCADA software. It has been contributing to the evolution of the automation industry for 30 years by providing a flexible solution for supervising building management systems, industrial processes, utilities, and infrastructure. The BTL listed PcVue Solutions are now entering an uncharted market to provide an innovative mobile offering for SCADA in intelligent buildings.

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roximity-based services enabled by micro-geolocation for Indoor Positioning Systems (IPS) are growing quickly. The IPS technology market alone is estimated to reach $5 billion in revenues by 2017 and to represent over 200,000 installations of infrastructure equipment, including Wi-Fi hotspots, Bluetooth antennas, and more than 800 million branded applications downloads.

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This technology has made possible the practical deployment of contextual Human Machine Interfaces (HMI). Contextual HMI creates the opportunity for new more efficient work processes for those who rely on Supervisory Control and Data Acquisition (SCADA) and Building Management Systems (BMS) to perform their job.

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Remote access to supervisory systems have typically been accomplished by using internet browsers on laptops. With the increasing adoption of smart mobile devices, technology such as Microsoft Remote Desktop Services (RDS) has been adopted as an alternative for mobile HMI. Navigating an HMI designed for a workstation while using a much smaller mobile device can prove difficult given the reduced screen size and mechanism for managing the mouse. A mobility infrastructure eliminates this problem via the presentation of information and controls in the context of role and place. It provides a dynamic HMI that changes as the worker moves through workplace zones automatically adjusting for job responsibility. In a plant scenario, such a system is aware which floor a worker is on and automatically sends the status and controls of equipment in that worker’s proximity. It is a very pro-active approach that is recognized to improve the efficiency of commissioning, operation and maintenance of automation systems.

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For safety, it is critical that the Mobility Server knows the current location of workers. With the ready availability of geolocation signals, IPS indoors and GPS outdoors, it is possible to track location by simply archiving the device’s position over time. Safety and dispatch tracking are natural functions of the Mobility Server which relies on position in order to create contextual HMI. PcVue Solutions are reinventing mobility architectures with smart mobile devices using proximity services in innovative ways to benefit SCADA and Intelligent Building projects throughout the world. www.pcvuesolutions.com

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