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Industry

Asia Pacific THE INDUSTRY MAGAZINE FOR ASIA

NORD RISING TO THE OCCASION: CUSTOMIZED SOLUTION FOR CRANE DRIVE SYNCHRONIZATION

22 MAYR HIGH PERFORMANCE IN A COMPACT DESIGN BACKLASH-FREE ROBA® -DS SERVO COUPLINGS WITH SPLIT CLAMPING HUBS

38 WIDIA INTRODUCING NOVO™: DIGITAL WIDIA KNOWLEDGE THAT DELIVERS EXTREME RESULTS

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SECO THE MULTIPLE CHALLENGES OF MACHINING ISO P WORKPIECE MATERIALS

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THE INDUSTRY MAGAZINE FOR ASIA

EPLAN

BAUMER

SECO

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8 PEPPERL +FUCHS

BALLUFF

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HMS

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STAHL

HMS

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PEPPERL +FUCHS

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NORD

WIDIA

ELMO

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EPLAN

KENNAMETAL

WIDIA

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HURON

MAYR

KENNAMETAL

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http://industry-asia-pacific.com


SECO

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BUREAU VERITAS

ARC INFORMATIQUE

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STRATEGIC PARTNERS: MITSUBISHI ELECTRIC EUROPE AND EPLAN

“The project quality and data consistency increase through the integration with GX Works2 and at the same time, cost and development time of our mutual customer will be reduced.” says Hartmut Pütz, President of Mitsubishi Electric’s Factory Automation – European Business Group.

More integration for electrical engineering and PLC programming

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ransferring data from electrical engineering directly into PLC programming – this is now state-of-the-art technology with the integration of Eplan Electric P8 and GX Works2. Yet Mitsubishi Electric Europe and Eplan continue striving for more as partners in the e-F@ ctory Alliance to further increase project quality and data consistency for users.

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The development departments at Mitsubishi Electric and Eplan are working closely together in order to realise the optimal integration of electrical engineering and PLC programming. The Eplan Platform and GX Works2 – Mitsubishi Electric’s programming software for their PLCs of the MELSEC Series – are now linked via a new interface. This enables reductions in development costs of more than 50 per cent for joint customers. Here is one specific use scenario: an electrical engineer creates a wiring diagram and, with a click of the mouse, sends the information for the I/O addresses and function texts (as examples) to the PLC programmer, who is programming GX Works2 controls. This automatic data exchange prevents time-consuming and costly inquiries. 08 | Industry Asia Pacific | January 2015

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This, in turn, leads to considerable reductions in development and commissioning times for plants and systems. As part of this platform, Eplan Electric P8 combines the data for the electrical hardware planning and control technology as well as the associated comprehensive documentation. “The project quality and data consistency increase through the integration with GX Works2 and at the same time, cost and development time of our mutual customer will be reduced.” says Hartmut Pütz, President of Mitsubishi Electric’s Factory Automation – European Business Group.“ Maximilian Brandl, President of Eplan, adds, “We are pleased to be a member of Mitsubishi Electric’s partner network. Our global customers benefit from the E-CAD and PLC interface, and the high component availability at the Eplan Data Portal. Furthermore, this cooperation with Mitsubishi Electric Europe will strengthen our new market presence in Japan.” The central Eplan Platform includes all data from preliminary planning through to detail engineering. This information can be used as the basis for subsequent project phases in the PLC-oriented automation technology. Furthermore, macros (libraries) and CAD product data from Mitsubishi Electric can be integrated in order to accelerate component


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Maximilian Brandl, President of Eplan: “Our global customers benefit from the E-CAD and PLC interface, and the high component availability at the Eplan Data Portal.�

selection, configuration and schematic designs. Once electrical engineering has been completed, all of the data stored in Eplan can be directly imported into GX Works2, which enables quick and simple system configuration and programming. Projects saved in libraries can also be used for future applications; a function, programme or system structure that has been designed, tested and approved is then available to be integrated into a new system in just a few minutes, which considerably simplifies the creation of future designs. Engineers benefit from these innovative engineering solutions across disciplines and beyond project phases and development processes. www.eplan.fr

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Can your CAD do this? Automate the most time-consuming tasks of electrical engineering like wire-numbering, device-tagging, cross-referencing, and errorchecking, even prevent you from making errors?

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With EPLAN Electric P8, the leader in electrical design automation, you can accomplish in a day what takes a week or more using CAD tools. Request your 30-day free trial at eplanusa.com


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BOURDON BY BAUMER: COMEBACK RELAUNCH IN SOUTHEAST ASIA

The convention at Baumer Singapore was the venue for the “Bourdon Relaunch” in South East Asia.

Baumer revives the “Original Bourdon” in Southeast Asia. Mechanical pressure gauges using cutting-edge Baumer technology are making a comeback in Singapore, Thailand, Vietnam, Malaysia, Indonesia and the Philippines which are historically important markets for the “ Bourdon tube ”.

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ven today, the pressure gauge developed by Eugène Bourdon in 1849 and named after him, remains the most common method of mechanical pressure measurement in industries such as oil and gas. After the acquisition in 2005, f the Bourdon-Haenni company became a member of the Baumer Group who today is the owner of the only “Original Bourdon” label.

More information at: www.baumer.com/bourdon

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Baumer Singapore and distributors from adjacent countries have now given the starting signal for their offensive “Bourdon campaign”. “In Southeast Asia, Bourdon is one of the most important and well-known brands among mechanical process instruments. With the "Original Bourdon" from Baumer we continue this tradition in the region”, said Marut Jaturonrusami from Kanit Engineering in Thailand. “Our tight-meshed partner network enables us to respond optimally to customer wishes”, adds Kenny Ng, Managing Director of Baumer Singapore.

Traceability System” (BTrace), a new order fulfillment method with a fully documented and traceable process. Combined with the lean philosophy, it creates measurable added value for customers in terms of cost efficiency, reliability and traceability.

The proven Bourdon principle in mechanical pressure gauges is enhanced by Baumer state-of-the-art quality methods that offer significant benefits in demanding oil and gas industry applications. This includes the “Baumer 08 | Industry Asia Pacific | January 2015

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A BASIC APPROACH TO MACHINE TOOL UTILISATION

HQ ILL Machine Tool Utilisation

Achieving maximum productivity and profitability in machining operations results from optimisation of the entire metalcutting process. The foundation of that effort is intelligent application of cutting tool parameters in combination with full utilisation of machine tool capabilities.

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here are two main components of effective machine tool utilisation. The first involves finding ways to maximise the amount of time the machine is available to cut metal, and the second includes tactics to make the most productive, reliable, and profitable use of that time.

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Maximising available time Full utilisation of a machine tool must begin with maximising the time it is available to cut metal. Even though a machine is on the shop floor 365 days a year, its productive availability is much less. In the case of five-day, single shift workweeks, and counting time lost to holidays and other interruptions, there are approximately 1,300 or 1,400 machine hours per year available for production. Even so, the machine is not cutting metal during every one of those hours. Programming and setup consume a certain amount of time. To make that non-productive period as short as possible, manufacturers employ strategies that include offline programming and modular setup methods. Tool magazines and automatic tool changers expedite tool handing, another time-consuming 08 | Industry Asia Pacific | January 2015

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necessity. Robotic work handling and pallet changers help reduce the time required to load raw workpieces and unload finished parts. Every hour saved via improved programming speed, faster setup methods, and streamlined tool handling and work handling is another hour that is available to machine parts. Using time efficiently After implementing strategies to maximise the amount of time available to cut metal, manufacturers are challenged to use that time efficiently and produce as many parts as possible at the lowest cost. The key is to fully utilise the capabilities of the machine tool while the cutting edge is in contact with the workpiece material. Recognition of the machine tool’s limitations plays a role as well. When planning to best use the time available, it is clear that some elements of the machining process cannot be changed. The end application of the machined part


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HQ ILL Average Time Spendings On A Machine Tool

determines the choice of workpiece material, and the material’s machinability dictates initial cutting parameters. For example, the poor thermal conductivity of titanium alloys demands use of low cutting speeds and feed rates to minimise buildup of heat. Machine tool capabilities are also a given, because changing the machine is not usually an immediate option. Manufacturers recognise these factors when estimating production costs. However, significant differences between estimated and actual costs can result from inaccurate evaluation of machine tool characteristics and application of cutting conditions that cannot be sustained. There are common requirements when establishing initial cutting parameters for any machining operation. Depth of cut and feed rates must be chosen to avoid tool breakage, assure formation of desirable chips and limit generation of heat. Cutting speeds that are too high will cause tools to wear out too quickly, and speeds that are too low will not allow tools to function productively.

In addition, the choice of cutting conditions depends not only on the characteristics of the cutting tools but also, in a large number of cases, on the capabilities of the machine tool. Different machine tools have differing limits of power, torque, rpm, and stability. The clearest limitation is power. Power ratings alone do not determine a machine’s capability for a specific application. A 60-kW machine tool would appear to offer more than adequate power, but if the intended manufacturing operation is, for example, producing 12 m-long, 3 m-diameter forging rolls, 60 kW is not as impressive. The power required to cut a specific workpiece depends on the workpiece material and size, the depth of cut, feed rate and cutting speed. Power demand rises as cutting forces are multiplied by higher cutting speeds. Accordingly, high cutting speeds may require power beyond a machine’s power rating.

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Cutting faster generally will produce a workpiece in less time. But while the machining time is shorter, tool life also is shorter and tool costs will increase. More tools will be required to do the job and worn cutting edges must be indexed or replaced. The downtime resulting from tool changes boosts the costs of the operation overall. In effect, there is a tradeoff between faster and more expensive machining and slower and less costly operation. Consistent

productivity and process stability lie in between the two approaches: insufficiently aggressive cutting parameters reduce costs until the tool no longer functions efficiently and productivity is lost, while increasingly higher parameters raise productivity until the tool wears too rapidly or breaks.

Additionally, extreme cutting parameters may have effects that exceed other machine tool capabilities. Excessively high depths of cut can create forces that are beyond a machine’s structural rigidity and vibration may degrade part quality. Similarly, overly high feed rates can produce large volumes 08 | Industry Asia Pacific | January 2015

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HQ ILL Machine Tool Accuracy

of chips that may interfere with the cutting process or clog chip evacuation systems. To maximise the utilisation of a machine tool within the limits of its capabilities requires an intelligent, balanced approach in the development of cutting parameters. Generally, that involves reducing cutting speeds while proportionally increasing the feed rate and depth of cut. Utilising the largest depth of cut possible (recognising its effects on machine stability) reduces the number of cutting passes required and thereby reduces machining time. Depth of cut generally has little impact on tool life, but the effect of cutting speed is significant. Feed rate should be maximised as well, although extreme feeds rates can have negative effects on workpiece surface finish.

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When a manufacturer achieves a reliable combination of feed rate and depth of cut, cutting speeds can be used for final calibration of the operation. The goal is to utilise cutting conditions that offer both productive metal removal rates and process stability. The best combination of machine capabilities and cutting parameters provides a balance of tool costs, process reliability and productivity.

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Future strategies While recognising that machine tool capabilities can impose limitations on the machining process, changing the machine is not a simple, fast or inexpensive solution. It is quicker and easier to manipulate cutting tool application parameters to achieve optimum performance with the existing machine. And even if investment in a new machine tool is feasible, the relatively long operating lifetime of the equipment is an important consideration. A company may buy a machine tool with capabilities that match or exceed its present needs, but factors such as part workpiece material, size and volume can and will change significantly over the five, 10 or more years that the machine will be in operation. To cope with the changes it will be necessary to alter cutting conditions, but that must be done in an intelligent way. After finding ways to maximise the amount of time a machine tool is available to cut metal, the preferred path is to select tools with substrate material, coatings, and cutting edge geometries that are best for the workpiece materials and operations involved. The next step is to apply the minimum cutting speeds at which the tools will work well. Then, feed rates and depths of cut should be as high as possible, while recognising the power and stability characteristics of the machine tool. Mathematical formulas have been developed that can help determine the best match between machining parameters and machine capabilities. If possible, a shop may prefer to run practical tests to get similar results. Fairly


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HQ ILL Machine Tool Settings

often, the formulas only confirm reality. Probably more than 90 percent of time a simple, pragmatic approach of lower cutting speeds, with maximised feed rates and depth of cuts, accompanied by manipulation of cutting speeds as a calibration tool is most effective. That approach will be successful in providing reliable and productive machining as well as full utilisation of the capabilities of the machine tool at hand. By: Patrick de Vos, Corporate Technical Education Manager, Seco Tools For more information on how Seco’s innovative products and expert services bring success to manufacturers across all industry segments, please visit: www.secotools.com

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BALLUFF MICROMOTE速 SENSORS

Small but powerful!

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he miniaturized MICROmote速 photoelectric sensors from Balluff with separate electronic processor unit provide a large amount of optical performance in a tiny amount of space thanks to the miniaturized LEDs, photodiodes and phototransistors. Balluff specially developed a new, patented manufacturing process for its production. This provides the micro-optical components with high optical precision. The MICROmote速 sensors are ideal in small installation spaces and on moving machine parts and robot grippers, where low weight is necessary.

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The robust sensors integrated into the metal housing are operated with a separate amplifier, which can be positioned outside of the action area. Highly flexible electrical cables provide secure transmission of the sensor signals between the sensor head and the amplifier. In this way, the sensors are also a technical alternative to fiber optics. An additional plus: The amplifier features ergonomic indicators and operating elements. The photoelectric sensor heads with dimensions of just a few millimeters not only have impressive technical characteristic values, but also numerous other unique selling points. 08 | Industry Asia Pacific | January 2015

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Thanks to a sophisticated modular system, users can find the ideal solution quickly and cost-effectively. It does not matter if the application involves position detection of small parts, identification and counting of objects or detecting the filling levels of foaming liquids. Available products include, diffuse sensors, throughbeam sensors, high-vacuum sensors, fork sensors, but also precision hose sensors used, for example, in the detection of liquids and bubbles. www.balluff.fr


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INTELLIGENCE INSIDE: THE NEW FIELDCONNEX速 FIELDBARRIER

The FieldBarrier with twelve outputs and a compact design.

Intelligent Fieldbus from Pepperl+Fuchs is synonymous with a generation of components that brings diagnostic capabilities into the field. The new FieldConnex速 FieldBarrier is the perfect addition to this concept of uncompromising availability. It includes twelve outputs with diagnostics and monitoring. The FieldBarrier comes with innovative technical features that offer reliable protection against typical fault scenarios to ensure maximum reliability.

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n intelligent component is an ideal component: FieldConnex速 FieldBarriers can detect the special dynamics of faults, such as loose contacts or contact bounces. As a result, faults can be identified and isolated both quickly and reliably.

Author: Andreas Hennecke, Product Marketing Manager, Process Automation division www.pepperl-fuchs.com MORE INFORMATION

The new component is the first to allow monitoring of the physical layer at each FieldBarrier output. This enables gradual changes in the installation and faults in the control room to be reported. This monitoring function ensures an even higher degree of transparency and covers a significant gap in the monitoring process as it proactively identifies maintenance requirements. Another feature is the sophisticated load management. The twelve outputs start sequentially, reducing the load on the power supply from the inrush current. What's more, if the segment current reaches critical levels, automatic load-shedding of less critical nodes is activated in order to safeguard against failure of the entire segment.

This package of integrated intelligence is completed by the FieldBarrier self-monitoring function, which can transmit alarm signals to the control room. These innovative features do not require any engineering. The FieldConnex FieldBarrier is the perfect addition to diagnostics-enabled intelligent fieldbus components and is another key step toward achieving the goal of 100 % availability.

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ONE ETHERNET HARDWARE – ANY INDUSTRIAL ETHERNET NETWORK

New Ethernet solution from HMS Industrial Networks makes it possible for device manufacturers to download the industrial Ethernet protocol of choice to standardized Ethernet hardware from HMS.

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MS Industrial Networks now releases “Anybus CompactCom for Common Ethernet” – a communication solution which includes an Ethernet hardware that is loadable with PROFINET, EtherCAT, EtherNet/IP or Ethernet POWERLINK. This brings full flexibility to device manufacturers, who can simply download the desired industrial Ethernet protocol to a CompactCom chip, brick or module before delivery to the customer.

Comes in three different form factors Launched as part of the Anybus CompactCom 40-series, the Common Ethernet solution is available in three different form factors depending on the required level of integration to the host device: Chip, brick or module, all loadable in the same standardized way. “As the industrial network market moves towards industrial Ethernet, the CompactCom Common Ethernet solution instantly becomes a key component in our offering. It makes life easier for device manufacturers, since they do not have to stock finalized CompactCom products for different industrial Ethernet networks – instead they can simply download the network protocol that corresponds to customer orders to our standardized Common Ethernet hardware,” comments Leif Malmberg, Product Line Manager, for embedded products at HMS. “Since the module is built on proven Anybus CompactCom technology powered by the Anybus NP40 network processor, customers will also get instant access to the entire CompactCom family with one implementation project. This means access to any fieldbus and industrial Ethernet network by simply plugging in another Anybus module.”

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Supports IT functions The Common Ethernet concept supports IT functions by default, meaning that it can be used as an Ethernet TCP/ IP solution if the user wants to develop connectivity to a proprietary Ethernet network.

implementing Anybus CompactCom, device manufacturers can achieve instant connectivity to 20 industrial networks by simply plugging in the corresponding Anybus product. This opens new business opportunities for the device manufacturers and widens their market considerably.

Firmware Manager included By using the accompanying Firmware Manager software, users can easily download firmware for their network of choice. It is also possible to use FTP or the application interface for downloading firmware.

www.anybus.com

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The Anybus CompactCom 40-series – for demanding applications Built on the award-winning NP40 network processor from HMS, the Anybus CompactCom 40-series is designed to meet the demands of high-performance industrial Ethernet applications and therefore enables fast communication between the host device and the chosen network – 1500 bytes of process data in each direction. The 40-series comes in chip, brick and module formats which enables customers to select the right level if integration without the need for customization. What is Anybus CompactCom? Anybus CompactCom is a series of industrial network interfaces which are integrated into an industrial device to offer connectivity to different industrial networks. CompactCom comes in chip, brick or module format, allowing the user to choose level of integration. By 08 | Industry Asia Pacific | January 2015

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ENERGY-SAVING LIGHTS FOR HAZARDOUS AREAS

Thanks to extraordinary light efficiency, the LED-based tubular light fittings from the new 6036 series save considerable operating costs.

Compact, innovative LED design.

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. STAHL now offers compact LED-based tubular light fittings for use in Ex zones 1/21 and 2/22 that provide users with an alternative to typical linear luminaires. With a diameter of merely 55 mm, the new lights take up less than half the space required by conventional linear luminaires, and reach less than half their weight.

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What is most striking, however, is the design that makes the new 6036 series extraordinarily light-efficient: 30 fourfoot long LED-based tubular light fittings, for instance, ensure an illuminance of approximately 500 lx, which would usually require 35 linear luminaires with two 36 W fluorescent tubes each – or alternatively 48 conventional

box-type units retrofitted with LEDs. However, R. STAHL’s new lights consume only about half as much power and the specific power consumption per 100 lx is merely 1.5 W/m². This ensures enormous savings regarding operating costs – depending on the comparative solution and the time frame, just under 20% to more than 50% savings are realistic in practice. The tubular light fittings can be operated in a very wide temperature range from -40 to +60 °C. The maintenancefree units are suitable for general lighting purposes or for use as machine lamps. Due to their slim design, they can be installed in hard-to-access locations. Even at an ambient temperature of +60 °C, they reach a lifetime of 80,000 hours. The vibration-proof units are IP66/IP67-protected by default, resulting in excellent suitability for maritime applications. In addition to ATEX and IECEx certificates, they also feature certificates for many major markets (GOST, Gazpromnadzor, UL do Brasil, GL). www.r-stahl.com/home.html

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LIGHTER, BRIGHTER, LONGER-LIVED: EXLUX 6001

The explosion-protected EXLUX 6001 luminaires are more compact, lighter, robust and versatile than their predecessors and many competing products.

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. STAHL’s new line of light fittings for use in Ex zone 1/21 and 2/22 hazardous areas achieves better energy efficiency than comparable devices and provides approximately 10% more luminous intensity. EXLUX 6001 luminaires also feature a design that is considerably more compact, stable, and torsion-resistant than their EXLUX 6000 predecessors. While more than one million of the longproven EXLUX 6000 lights have been deployed worldwide over the last twenty-odd years, the new generation now meets increasing user demand for a similarly economic, yet enhanced product with improved technical features reflecting the most current state of the art.

In addition, R. STAHL provides especially cost-efficient standard models with a power consumption of 18 W, 36 W, or 58 W that are available at short notice. Featuring 4 mm² cage clamp terminals, 5-core through-wiring, and a full-phase safety shutdown, these models are adequately equipped for the majority of all typical applications. The new series fully complies with the requirements of all current industry standards. Notably, the new silicone-based foamed gasket has been optimised for maximum durability, as stipulated by IEC 60079. This sealing solution, which is resistant to various chemicals as well as UV radiation, the fitting’s hinge, and a newly designed central lock reliably ensure IP67 protection over many years.

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Depending on their performance class, the 6001 luminaires are a quarter to a third lighter than their predecessor models and many competing products. Users now also benefit from the extremely robust design of these slimmer, narrower units: unlike most lights, the new devices can be operated at extremely low ambient temperatures (as low as -30 °C). In many cases, this amounts to a decisive extension of the application range that saves costs by making extra specifications unnecessary. In order to facilitate a step-bystep exchange of existing EXLUX pendants, the installation

of the new units remains fully compatible to the predecessor series. Moreover, swiftly removable replacement parts ensure quick and easy maintenance. Like before, the new lights are available with customer-specific modifications on request.

www.r-stahl.com/home.html

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HMS EXPANDS NETBITER REMOTE MANAGEMENT OFFERING

The Netbiter EC310 communication gateway sends data from the customer’s device to Netbiter Argos.

HMS Industrial Networks now expands the Netbiter Remote Management offering to include three different services catering for different user needs. The dedicated services enable both quick connection to a single remote machine, as well as advanced projects including multiple installations and users.

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MS also presents a new Netbiter EasyConnect gateway (EC310) which communicates via Ethernet only.

Three different services Netbiter is a cloud-based solution for remote management of equipment such as power generators, PLCs, sensors, tanks etc. Users connect a Netbiter gateway to their equipment and log in to the online data center Netbiter Argos (www. netbiter.net), where they can access their devices online. Netbiter now includes three different services:

• Remote Access – Free and included with a Netbiter gateway Opens up a secure tunnel to a PLC or machine. This enables configuration, programming or debugging of almost any industrial device from any location. Users utilize their regular configuration software just as they would if they were on site. • View and Control – Free and included with a Netbiter gateway Allows users to manage a single installation remotely. Online dashboards, alarms and trend graphs provide full insight from any location.

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• Manage and Analyze – Subscription-based service For large-scale, multiple installations with several users. Users can customize the Netbiter Argos interface and integrate data into their own system with the Netbiter Argos API.

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Control a single device or a whole site online.

Realizing the Internet of Things “With this new service offering, we take another step in making it easier for our customers to access their field equipment online,” says Henrik Arleving, Product Line Manager at HMS Industrial Networks. “We can now offer a quick and easy solution for monitoring a single installation online as well as powerful multi-site management with multiple users for larger installations. Netbiter can now meet even more demands for putting field equipment online, realizing the Internet of Things.”

Learn more about the new Netbiter services at the new website www.netbiter.com

New gateway HMS also offers a new gateway, the Netbiter EC310, which sends data from the remote site via Ethernet only. This is a complement to the EC350 which communicates both via the mobile phone network (3G/GPRS) and via Ethernet. What is Netbiter? Netbiter is a remote management solution for monitoring and controlling industrial equipment online.

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A Netbiter gateway connects to the remote equipment in the field and sends data to the Netbiter Argos data center. This cloud-based server collects and stores the data from the field equipment and enables users to get statistics and reports on the performance of their devices. At www. netbiter.net users can see the status of their devices and can monitor and control equipment in a graphical dashboard.

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OPC 120: CODE READERS WITH AN INNOVATIVE POLARIZATION FILTER THAT READS EVEN ON REFLECTIVE SURFACE

OPC120P – reliable reading on reflective surfaces.

Vision Sensors today can be highly sophisticated systems, as illustrated by the new OPC 120 Series code reader for 1-D and 2-D codes. In addition to its functionality, compact design, and high speed, the special features of this device include a polarization filter for reading high-gloss materials and a PROFINET connection.

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ith the OPC120 Series code readers, Pepperl+Fuchs offers stationary readers for detecting and decoding 1-D and 2-D codes, such as barcodes and Data Matrix codes. The housing may be only 70 mm wide, 70 mm high, and 54 mm deep, but contains a CMOS imager, an LED flash, and a control interface. The code reader is capable of reading the majority of code symbologies that are currently in use and is available in two versions. The OPC120W design comes at an attractive price and can be used in many standard tasks that have normal reading speed requirements. By contrast, the OPC120P is the “ highend ” design, reaching high reading speeds of 100 readings/s or tape speeds of up to 10 m/s.

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Innovative Polarization Filter Technology Eliminates Reflections A typical weakness of optical sensors is the fact that they are affected by unfavorable reflections that may be caused by external light or the camera's own light. Under normal circumstances, it is rarely possible to completely prevent reflections as they are dependent on multiple factors, including the reading angle of the code reader, the angle of the light source, and the orientation and structure of the surface on which the code to be detected is located. Codes on rounded, curved, or cylindrical objects made from reflective materials – such as ball bearings or metal tubing – are particularly difficult to assess, as various reading angles can occur during a single reading. Developers at Pepperl+Fuchs have equipped the OPC120P with unique polarization filter technology that prevents faulty readings in these and similar scenarios. This technology eliminates harmful reflections and enables more reliable readings to be taken, even if codes are located on highly reflective surfaces such as metals, plastics, and printed circuit boards, or on film.


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Read up to four codes in a single image capture.

No More Refocusing or Parameter Changes Required The exceptionally large reading distance range of 70 to 180 mm makes a significant contribution to the efficiency and flexibility of the Vision Sensor. The OPC120P is capable of reading codes on reflective surfaces and at different distances without mechanical refocusing or parameter changes being required. There is no need for auxiliary side lighting or adjustable lenses, as are commonly required when using other readers in challenging situations. As well as detecting 1-D and 2-D codes, the code readers are able to check for the presence of variable textures and static graphics. The presence detection function ensures that variable structures – such as use-by dates and dates of manufacture – really are located at a pre-defined point, e.g. on food packaging. Logo detection allows non-variable features – such as company logos – to be detected and checked. The reader is able to read long codes by means of multiple image capture if it is confronted with codes that do not fit in one image. The device automatically combines up to six consecutive images so that it can easily decode extremely long codes or those on round objects.

Reliable reading on printed circuit boards.

PROFINET Connection with Integrated Switch The OPC120 is available with all major interface variants, making it easy to integrate into systems and machinery. These interfaces include RS232, digital inputs/outputs, a connectivity option for a rotary encoder or trigger sensor, Ethernet TCP/IP, and the latest addition: “ PROFINET.” Industrial Ethernet supports a transfer rate of 100 Mbit/s and meets the real-time requirements of PROFINET IO Real-Time Conformance Class A. The developers have simultaneously integrated a two-port switch as an ideal solution enabling a direct connection to the next PROFINET device. This enables networks to be implemented in a linear topology without the need for additional coupling or switches. All configuration settings for the Vision Sensor can be accessed via PROFINET, while the Vision Configurator Windows software serves as a front end for parameterization purposes. Additional options offered by the code reader include access to the fault pattern memory, output of the code quality, and manipulation and formatting of the result strings. www.pepperl-fuchs.com MORE INFORMATION

It is often the case that multiple codes need to be read in one application. The OPC120 allows up to four codes to be read in a single image capture. The device can not only read codes but also process up to four tasks, such as presence and logo detection, in a single image capture.

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RISING TO THE OCCASION: CUSTOMIZED SOLUTION FOR CRANE DRIVE SYNCHRONIZATION

The end-user, a manufacturer of heavy truck trailers, required an additional crane for the handling of new, larger trailer models.

What to do when the crane of your choice is no longer available? An Australian provider of overhead cranes fulfills all customer needs, even when the parameters are very particular.

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or this application, the challenge was to synchronize a new bridge crane with two existing ones. The German manufacturer NORD DRIVESYSTEMS configured the drives keeping in mind the end-users budgetary requirements.

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Melbourne-based Modular Cranes Pty Ltd is one of Australia’s leading overhead crane suppliers, offering modular packages for payloads up to 100 tons. The cranes are individually adapted to suit the particular factory layout or application. The family-run business, established more than 30 years ago, supplies quality material handling products to clients all over the country. Modular Cranes works with top crane technology manufacturers such as Advanced Radiotech Corporation, Donati, and Street. The company also services cranes throughout Victoria as well as New South Wales, South Australia, and Tasmania.

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Emulating specifications of a discontinued crane model A manufacturer of heavy truck trailers approached Modular Cranes with an unusual problem. The company had been successfully using two 22 meter wide overhead cranes in its factory. The cranes, traditional single-girder bridge designs rated at 12.5 tons each, were installed on the same set of support beams spanning the entire length of the factory. They were identical in their specifications and synchronized for two speeds as well as for ramp-up and ramp-down times. A wireless handheld remote control pendant simultaneously actuated the pair of cranes as required. Changes in the production process now necessitated the installation of a third identical crane on the same set of support beams, allowing for very long and heavy trailers to be moved through the factory with the load shared between two of the cranes at any one time. However, the specific crane used in this application was no longer in production. After many years of reliable service, the existing cranes had not nearly reached the end of their lifespan, and therefore it was neither economical nor environmentally sustainable to replace them. Modular Cranes needed to find a practical and economic alternative design solution to match the performance and synchronization characteristics of the existing onsite cranes.


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The 22 m wide overhead cranes run on beams that span the entire length of the factory, all three are synchronized for speed and ramp times.

Resilient gearbox NORD configured the gear units using its UNICASE helical inline gearbox series which, providing a wide torque range from 10 to 26.000 Nm and ratios from 1.35:1 to 14,340.31:1, enables unique flexibility in the configuration of the optimal

drive train for any task and mechanical setup. The UNICASE housing design – with its one-piece machined construction including integrated flange and bearing sets – provides long and trouble-free operation and allows for a highly robust solution that can withstand extreme loads. NORD is the unrivalled leader in this field and the only manufacturer worldwide to produce very large industrial gear units with 242,000 Nm output torques in a single-piece cast-iron housing. Adaptable electronics To solve the synchronization problem, NORD recommended a motor-mounted frequency inverter for straightforward installation that makes shielded cables unnecessary. The manufacturer has a comprehensive drive electronics program with graded performance and functional range options that allow users to choose suitable compact solutions with the exact features they require for any given task, thereby optimizing budget and resource use. The SK 205E inverter selected for this application realizes drive functions such as ramp-up: the inverter ensures the motor starts slowly with high torque, thereby protecting the mechanics from the extreme loads that are effective when the heavy overhead crane is started from standstill. An external brake resistor accommodates the regenerative current when the crane is decelerated. The inverter is also equipped with an integral 24 VDC power supply to provide the internal control voltage – therefore requiring only a power connection and no separate control cable.

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Customized drive configuration For the new overhead crane’s two bridge drives, Modular Cranes sought the expertise of German drive manufacturer NORD DRIVESYSTEMS. Annie McDiarmid, Operations Manager at Modular Cranes, says, “We were faced with the problem that our new crane needed to travel exactly in synch with the existing onsite cranes. NORD DRIVESYSTEMS offered us a solution that met our customer’s budgetary requirements and assured us that we could match acceleration, deceleration, braking, and traversing speeds with the existing non-inverter driven cranes.” NORD proposed an integrated solution consisting of an efficient helical gear unit, a standard fourpole electric motor with a 10 Nm electromagnetic brake, and a motor-mounted frequency inverter with an external brake resistor. The two bridge drives were configured to synchronize and match the existing cranes using a simple parameter set-up procedure and were flange-mounted on the crane girder. Operation is comfortably carried out with the same remote control pendant, no additional configuration is required. The precision of the NORD helical gear set and the flexibility of the decentralized frequency inverter software permitted this new crane to be synchronized with the existing cranes without rotary encoders.

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NEWS The bridge drives for the new crane were custom-tailored by German drive technology manufacturer NORD DRIVESYSTEMS.

The economic solution consists of two flangemounted NORDBLOC.1 geared brake motors, each fitted with an SK 205E frequency inverter and an external brake resistor.

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Global presence ensures local support Operations Manager Annie McDiarmid highlights the quality of NORD’s customer support, “Throughout the process, NORD offered us abundant amounts of support from trained professionals and worked with us to achieve the best possible outcome.” Her conclusion after the completion of this customization project: “No problem is too big for NORD!” To achieve this high level of support globally, the NORD DRIVESYSTEMS Group has established a large network of subsidiaries and service centers. The manufacturer has been represented on the Australian continent since the mid1990s. NORD’s Australian subsidiary, NORD DRIVESYSTEMS Pty Ltd, began operations in 2010 with the construction of an assembly facility in the Melbourne suburb of Derrimut. The plant boasts a state-of-the-art geared motor manufacturing capability with production and quality assurance processes that comply with the standards of the German parent company. NORD maintains sales branches in two further port cities, Sydney and Brisbane. Regional sales managers serve all States and Territories in Australia as well as New Zealand. NORD supplies motors conforming to the relevant Australian energy efficiency specification MEPS High Efficiency and frequency inverters with C-Tick certification. www.nord.com

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NEWS

TAKEN TO NEW HEIGHTS: INDUSTRIAL GEAR UNITS FROM NORD COMPLETE HEAVY WORKLOAD AT A RESERVOIR PROJECT

Over the course of three years, industrial geared motors from NORD transported one million tons of material. Now they are being prepared for their next assignment.

Swiss energy supplier Axpo is close to finishing the demanding large-scale “Linthal 2015” construction project: Switzerland’s largest hydroelectric undertaking will increase the overall output of the existing Linth-Limmern power plants from 480 MW to 1,480 MW.

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After the completion of the conveying tasks, the NORD industrial gear units were disassembled by plant manufacturer Marti Technik AG, and are now awaiting their next assignment. Ernst Kuster, head of conveyor maintenance at Marti Technik, says: “In compliance with the instruction manual, we changed the oil once, but that was the only maintenance measure we had to take over the course of three years. The NORD gear units performed brilliantly.” The industrial gear units qualified for this massive construction project thanks to the tried-and-tested UNICASE design: this one-piece housing block integrates all bearing seats. UNICASE housings are manufactured on state-of-the-art CNC machines in a single setting. The concept ensures high precision, rigidity, and strength, with no joints between the output side and the gearcase which are subject to radial forces or torque. Moreover, the overlapping bearing offset allows for more compact gearcases and larger roller bearings that allow for a long operating life.

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new underground pumping station was created to pump water from the Limmernboden reservoir at an altitude of 1,860 m above sea level into the Muttsee lake about 600 m higher up. This elevation difference will be used to produce hydroelectric power on demand. The heart of the project in particular – the underground center for the new pumped storage hydroelectric power station – required gigantic efforts. At an extreme incline of 45 degrees and a height difference of approximately 180 m, conveyor systems in a sub-station transported 500 t of excavated material per hour, around the clock. On a second conveyor belt, the crushed material was transported up to the gravel plant where it was stored or processed for further use. For a total of three years, these conveyors were driven by NORD industrial gear units and transported approximately one million tons of material.

www.nord.com

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NEWS

INTRODUCING NOVO™: DIGITAL WIDIA KNOWLEDGE THAT DELIVERS EXTREME RESULTS

Getting the right tools with the right fit in the right situation is automatic with NOVO™ from WIDIA.

NOVO™ digitizes tool, rules, and application knowledge and remakes estimating, planning, production, inventory and more.

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IDIA has a saying: “Extreme Challenges – Extreme Results.” Over the years, this has come to mean metalworking productivity breakthroughs for numerous shops from such well-known WIDIA names as VariMill™, VariTap™, WIDIA Victory™, and numerous others. In the future of what some have coined Industry 4.0 extreme opportunities exist in the digital integration of tooling data and knowledge to the shop floor. Extreme results are possible through integrating accurate, complete tool data, rules, and application knowledge digitally to dramatically rethink and shorten process planning, adding real value to CAD/CAM, CNC machine control, presetting, inventory management, and more. This is what WIDIA envisions with their launch of their new NOVO™ desktop and tablet application – on demand cutting edge delivery of cutting tool data and expertise for reduced product development and manufacturing lead times. “NOVO™ data represents real WIDIA tools and how they fit, function, and perform over a variety of machining scenarios,” says Bernie McConnell, vice president, WIDIA Products Group and Services. “Importing NOVO™ makes CAD/CAM programs more functional and valuable because the tools fit and move

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as designed. Implementing NOVO™ makes estimating and process planning a breeze because it supplies entire assemblies and spare parts lists with “best fit” functionality that otherwise takes hours of time finding in catalogs and product literature. NOVO™ empowers inventory management, purchasing and other vital shop processes because it is real expertise based on decades of development experience. It truly empowers shops to take on extreme challenges with extreme results.” Thinking Like a Process Planner “NOVO™ thinks like a process planner,” explains Thomas Long, head of the newly formed Virtual Machining RDE department at WIDIA. “It works from the feature back to the tooling strategy. In addition, each order number is tied to application data gleaned from hundreds of subject matter experts and decades of WIDIA experience. Request a part number and you also get pictures, assemblies, spare parts lists, as well as inserts that fit. Not only does it accomplish in minutes what formerly took hours, it yields an optimized solution, backed by WIDIA expertise, every time.” According to Long, NOVO™ assists shop personnel in a number of intuitive ways, from “I need to make a ½'' hole x


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NOVO™ delivers 3D solid models along with complete parts lists for all components. Nothing is overlooked.

More than a catalog alone, NOVO™ provides process knowledge, giving users a range of strategies to best improve shop production.

1 ½'' deep in ANSI 4140” to “I need a ½'' by 5xD solid-carbide drill.” In the first case, NOVO™ helps users define machining features, drilling a blind hole in this case, and then immediately reduces the product set to those that can do the job, taking into account constraint requirements such as material, tolerance, and machining sequence for both single tools and multi-tools. NOVO™ then ranks the results – based on knowledge-based rules – to best meet the challenges of the application as defined by the customer’s operating environment and user preferences, providing far more useful process knowledge than any online catalog alone, all obtained in a fraction of the time.

Seamless Connectivity, E-Commerce, and Tool Management Customers expect continuous fast development of technology platforms to deliver more value. Since the 2013 launch of the NOVO™’s original Tool Selector, Tool Configurator, Tool Advisor, and Job functions, NOVO™ has added connectivity to E-commerce, easy ISO 13399 exports, and seamless integration to the ToolBOSS™ tool management system via the Machining Cloud™.

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In the second case, when a customer already has preferred tool and grade in mind, NOVO™ smart-attribute filters not only quickly select the products available to do the job, NOVO™ also gives the options on what cutting item and adaptive item fits and also works with the selected solution. NOVO™ smart filters take the task of selecting ALL cutting tool components from hours to minutes, while providing a comprehensive and accurate list of solutions based on customer input.

In both cases, NOVO™’s Tool Configurator then provides all CAD files and graphic support for all tool components and their assembly – a major time savings for customers. Even further, NOVO™’s Job Functionality option is a cloudbased repository linked to a user by a unique ID where tool lists can be stored for future use, editing, copying, and sharing. These can be easily downloaded into standard report formats and include tooling commercial and dimensional data and weights, speeds and feeds, and photo or CAD model images.

Specifically, NOVO™ users can request a price quote from their local WIDIA Distribution Partners by transferring their 08 | Industry Asia Pacific | January 2015

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NEWS NOVO™ tools and process knowledge can be integrated into cloud-based jobs lists for easy organization.

NOVO™ is accessible on tablets and mobile devices, bringing complete tool lists and decades of tool knowledge to the table quickly.

shopping cart list to them via the “Request Quote” button. The distributor will receive a notification with complete detail of the items and requestor information to respond. A new pop-up also makes it easy to add spares and other individual items to existing shopping carts. Spare parts are clearly identified as “included” or “non-included” on bills of material.

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ToolBOSS™ users on the cloud with the latest software version can now use NOVO™ to see if an item proposed for a process plan is already available in their ToolBOSS™ inventory, making both plans and budgets more efficient. Customer part numbers are automatically populated in NOVO™ Tool Advisor results and Tool Availability pop-ups via the ToolBOSS™ database. “By adding ToolBOSS™ credentials to their user profile, customers easily check the inventory in their local ToolBOSS™ units with their developing process plans,” says Chris Merlin, Marketing Manager for the Virtual Machining initiative at Widia. “They’re better able to visualize items already in their shop.”

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Mobility Users can leverage NOVO™ via the tablet of their choice. “Mobility is no longer a luxury. With Android and Windows Tablet versions of NOVO™ now available, it brings an element of added mobility and access to your tool list no matter which device you log onto,” Merlin adds. “This also makes it easy for people working on the shop floor with tablets to collaborate with the process planners in other departments.” For more information, visit: www.widia.com


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NEW RELEASE – ELMO’S MOTION CONTROL EXPERIENCE: A FREE ONLINE REMOTE PRACTICE SYSTEM (RPS)

A new free online system that provides any user with the ability to build and practice advance servo control, multi-axis solutions and EtherCat networking.

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lmo Motion Control, a leading provider of comprehensive motion control solutions, is now offering a free remote login access via the Internet for its unique EASII Experience – Remote Practice System (EASIIRPS), enabling anyone from anywhere around the globe to experience from first-hand the advanced motion tools provided by Elmo’s EASII software environment. The new EASII Experience RPS is an exclusive and advanced simple-to-use Motion Control system.

The RPS is a true educational system for any engineer that is involved in automation and motion. For beginners it is a very efficient and comprehensive introduction to advance

It is Elmo’s modest contribution to improve the awareness to today’s very advance level of automation and motion control” said Haim Monhait, CEO of Elmo Motion Control. Elmo is offering login access to its unique EASII Experience RPS for anyone to explore the motor and the drives in action, configure the EtherCAT network, perform complex multi axis synchronized motions, develop IEC-61131-3 programs, motor automatic simplified and advanced tuning, advanced system analysis in the frequency and time domains, filter scheduling, motion sequencing, drive programing and data recording and much more. Setting up a machine has never before been so simple. MORE INFORMATION

The RPS comprise of servo motors, feedbacks, servo drives, multi-axis controller, Ethercat network Master controller, and Application Studio (EASII). This allows building up a complete application online with no need to purchase or install any hardware or operating system. “We are launching a free online Motion Control Experiencing tool that allows learning and exercising advanced motion control, high performance servo technology and Ethercat networking.

motion control, for skilled engineers, it demonstrates the most updated and state of art servo tuning, complex multi axis capabilities and real time Ethercat networking.

We invite you to log-on and experience our RPS directly from your browser at: www.elmomc.com/support/elmo-rps.html For more details, visit our website www.elmomc.com or contact Elmo representative.

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NEWS

(RE)LAUNCH: NEW EPLAN DATA PORTAL 470,000 part data including schematic macros, geometric dimensions and documents can be imported to engineering automatically using the Eplan Data Portal.

An integrated 3D viewer, a new user interface with manufacturer logos in fast and easy grid layout, additional manufacturers and updated component catalogues. The new version of the Eplan Data Portal provides users with significant functional advantages and, since it now contains 470,000 components, also features 20% more device data.

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sers will benefit from enormous time savings and increased project quality. The current 470,000 part data, including schematic macros, geometric dimensions and documents, can be imported to engineering automatically. This is made easier, thanks to the innovative functions such as a newly integrated 3D viewer, which enables users to view and assess components quickly and easily.

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It is possible to access several different views such as front, page or isometric views very easily with just a click of the mouse. Free rotation and zooming functions allow individual detailed views to be generated in a very flexible manner. The advantages for the user are obvious: For example, when placing a part in the project, the user will receive reliable decision support as to whether the component is suitable for the proposed control cabinet.

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Innovative operation with feedback function The interface of the Eplan Data Portal has also been optimized with the design functionality of the Data Portal App. Now the view of the 66 manufacturers that are currently involved have adapted this look and feel by displaying the manufacturer logos in a grid view that speeds up navigation. The feedback function has also been expanded with the new interface. Users can directly submit requests to manufacturers in the application. For example, if the user wants to send information about missing components, it can be done directly from the Data Portal. This means that the quality of the data is constantly increasing. The manufacturers involved also reap the rewards: the feedback function provides a direct line to the customer. The manufacturer knows what is required in concrete terms and can fulfil the user's requests in an optimal manner. The improved search function is another new addition to the portal. Search requests for article or type numbers are directly displayed as the first search results – this means the right component can be found faster.


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66 manufacturers with more than 470,000 records The Eplan Data Portal has not only made a major leap forward in terms of functionality, but also in regard to the manufacturer catalogues. Since the last update, in the beginning of July, five new product catalogues have been added. A further ten product catalogues have been expanded and updated. The number of devices has increased by more than 20%, which means that there are now more than 470,000 parts available.

Rockwell Automation has added more than 1500 parts from their MicroLogix product line, Micro850 product line and molded case circuit breakers. SMC Pneumatic has updated and expanded its product spectrum. Fluid users now have a variety of cylinders, valves and tubes at their disposal since there are now more than 15,000 records to choose from. ABB, General Electric, Icotek, Helukabel, Numatics, Rockwell Automation, Sick and Wieland have also updated their product ranges in the Eplan Data Portal.

The renowned Italian manufacturing company, Finder, is now represented with almost 700 records. Another new addition in the field of sensors and evaluation systems is ifm electronic with almost 500 records to support their customers. The new integration of the Vega configurator is also an interesting addition to the Data Portal. This means that the user is not only provided with standard components for process measurement technology from Vega Grieshaber KG, but also has the option of individually selecting and configuring components according to project demands.

Conclusion: Users benefit from a constantly increasing amount of device data – combined with an innovative technology that supports efficient design. More information: www.eplanusa.com/edp

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Updated and expanded data Manufacturers that were already integrated into the Data Portal have also amended and/or expanded their product portfolios. For example, Siemens has set up more than 2,100 records from the 3VA series, as well as the commercial data and the switch symbols for Eplan and documents, and 3D data including production information is also now available.

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DIFFERENT THINKING AND BETTER DATA ENABLE REAL PROCESS AND PRODUCTIVITY IMPROVEMENT – INTRODUCING NOVOSPHERE™ Real tool data is ranked on best fits with the user’s cutting parameters, providing a range of choices for increased efficiencies.

NOVO™ from Kennametal: a fundamental change in improving how work gets done.

Powerful cloud-enabled digital tooling data and intelligence seamlessly interfaces with production, inventory, e-commerce, and more to optimize shop productivity. NOVOsphere™ empowers shops hungry for real process improvement.

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rom better data, better thinking and better decisions. Since its groundbreaking launch in 2013, Kennametal’s NOVO™ digital process planning application has continued growing by supplying complete tool data (milling, turning, holemaking, tools, toolholders, spare parts, speeds and feeds, and much more) digitally, saving process planners, parts estimators, and manufacturing engineers hours of catalog lookups and process guesswork. Now with seamless connectivity via the Machining Cloud™, that same intelligence is driving new efficiencies in part design in CAD/ CAM, cutting simulations, presetting, actual machining, inventory management, and e-commerce.

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Another major step forward is to feed all these real and potential process improvements back into your shop based on actual data gathered from your own equipment and start seeing where capacities change and efficiencies improve. This intelligence and connectivity has led to NOVOsphere™, a fundamental step forward in how work gets done. “It seems that most technology suppliers are rushing to provide some form of digital access to information, but digital access is just the entry ticket,” says John Jacko, vice president and chief 08 | Industry Asia Pacific | January 2015

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marketing officer, Kennametal. “Where Kennametal differs is in its unshakeable focus on how customers can leverage better cutting tool data and information to improve their entire business. NOVOsphere™ is based on an open architecture to deliver just that. NOVOsphere™ is an amazing vision on how far things can go to deliver productivity to our customers.” Manufacturing process experts have described the current spectrum of digital processing claims as a “feeding frenzy of connectivity and data.”This is driven by a number of things – manufacturing businesses see opportunities for enhanced productivity and reduced time from design to production. More informed businesses add opportunities for providing services and products to better-informed customers – all at much greater speed. Others see value in offering informed analysis capabilities to convert this “firehose” stream of data to a manageable set of results and metrics. “Our vision for NOVOsphere™ from the beginning is to provide an open-source system that interacts seamlessly with shop systems needing to leverage cutting tool data and machining knowledge for productivity improvement,” Jacko explains. “NOVOsphere™ is built around the shop needs, from quotation


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Seamless integration with e-commerce and ToolBOSS™ tool management improves tool availability.

More than a tool catalog, NOVO™ includes tool advisor knowledge for a range of machining strategies.

to inspection. NOVOsphere™ has six essential application to help our customers be more productive: - Select and Advise: This is the stage where users evaluate machining strategies based upon machine, material, part features, and specs. What is the best approach? How long will it take? How much will it cost? Which tools do I need? - Simulate: This is the stage where users simulate the entire process from end to end with the use of software such as CAM. Are there any dimensional issues? Possible collisions, too many forces? - Inquire and Purchase: This is the stage where users find out what they already have that can do the job and if it’s available in real time to purchase when they need it. - Optimize: This is the stage where users would like to know how the plan is working. Are we within planned cycle time, costs? Do I use this tool/process consistently across machines/plants?

Specifically, NOVO™ users can request a price quote from their local Kennametal Distribution Partners by transferring their shopping cart list to them via the “Request Quote” button. The distributor will receive a notification with complete detail of the items and requestor information to respond. A new pop-up also makes it easy to add spares and other individual items to existing shopping carts. Spare parts are clearly identified as “included” or “non-included” on bills of material.

Data is key to productivity. With its open architecture, NOVOsphere™ possibilities are limitless. NOVOsphere™ is further evidence that “Different Thinking is Better Thinking.” From Design Through Purchasing What is amazing is the many areas of a production business where better tool data improves processes. DP Technology (Camarillo, CA) imports NOVO™ (now part of NOVOsphere™) tooling data into its latest version of ESPRIT cloud-enabled CAM software. This not only saves part programmers hours of time as opposed to manual tool creation, the part programs are better because the data is based on real tools that can be selected based on part features, work material, surface finish requirements, or whatever aspects of the job are most critical.

ToolBOSS™ users on the cloud with the latest software version can now use NOVO™ to see if an item proposed for a process plan is already available in their ToolBOSS inventory, making both plans and budgets more efficient. Customer part numbers are automatically populated in NOVO™ Tool Advisor results and Tool Availability pop-ups via the ToolBOSS™ database. “By adding ToolBOSS™ credentials to their user profile, customers easily check the inventory in their local ToolBOSS™ units with their developing process plans,” says Chris Merlin, Marketing Manager for the Virtual Machining initiative at Kennametal. “They’re better able to visualize items already in their shop.” Users can leverage NOVO™ via the tablet of their choice. “Mobility is no longer a luxury. With Android, Apple and Windows Tablet versions of NOVO™ now available, it brings an element of added mobility and access to your tool list no matter which device you log onto,” Merlin adds. “This also makes it easy for people working on the shop floor with tablets to collaborate with the process planners in other departments.”

Since the 2013 launch of the NOVO™ original Tool Selector, Tool Configurator, Tool Advisor, and Job functions, NOVO™ has added connectivity to E-commerce, easy ISO 13399 exports, and seamless integration to the ToolBOSS™ tool management system via the Machining Cloud.

Every shop sits on a rich mine of data that it can collect for its own continued improvement, but a significant drawback is efficiently gathering the data from different makes and models of machines and tools. All NOVO™ Optimize data and process knowledge complies with the MTConnect

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The value of NOVO™ data is not limited to the programming or process planning department. On the shop floor, presetting tools and tool assemblies is a valuable time-saver. ZOLLER (Ann Arbor, MI), a leader in automated presetting and balancing machines, knows customers can import NOVO™ data from the Machining Cloud and know they have precise and reliable tool dimensions, offsets, and other critical data to make presetting reliable and valuable.

All Optimized for Your Shop Delivering real tool data and process knowledge is one thing – where NOVOsphere™ delivers a knockout punch is optimizing process savings based on performance data drawn directly from your shop floor equipment. “NOVO™ Optimize is the newest manufacturing intelligence application in NOVOsphere™,” says Colin Tilzey, director of Kennametal’s Innovation Ventures Group. “It collects real-time data on how your cutting tools and machines are performing and also provides analysis of where process efficiencies or capacity improvements are available.”

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NOVO™ Optimize fundamentally changes how manufacturing can increase manufacturing efficiency and productivity. Learning from tool usage directly from the user’s own machine tools, the system automatically recommends process improvements as well as tracking machine tool usage and identifying areas to focus on which to focus continuous improvement.

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NOVO™ Optimize from Kennametal: a fundamental change in improving productivity.

open, extensible, royalty-free communications protocol designed specifically for the shop-floor environment. This means NOVO™ Optimize can draw data from machine tools, cutting tools, presetters or any piece of shop equipment or data source. And because it’s connected to NOVO™, it can automatically recommend process knowledge changes (speeds and feeds) or identify better-performing tools based on your specific needs – get the job done faster or optimize a specific machine or cell based on shop workload. “Each shop using NOVO™ Optimize has improvement opportunities unique to them based on operator feedback and shop conditions,” Tilzey says. “Identifying sources of machine downtime combined with powerful knowledge-based recommendations means the possibility for real, significant process improvement is just waiting to happen.”

SIDEBAR 1 – How It Works NOVO™ can be used in a number of intuitive ways, from “I need to make a ½'' hole x 1 ½'' deep in ANSI 4140” to “I need a ½'' by 5xD solid-carbide drill in grade KC7315.” In the first case, NOVO™ helps users define machining features, drilling a blind hole in this case, and then immediately reduces the product set to those that can do the job, taking into account constraint requirements such as material, tolerance, and machining sequence for both single tools and multi-tools. NOVO™ then ranks the results – based on knowledge-based rules – to best meet the challenges of the application as defined by the customer’s operating environment and user preferences, providing far more useful process knowledge than any online catalog alone, all obtained in a fraction of the time.

Such empowered shops better plan, process, and optimize their operations for significant productivity gains. The NOVO™ Optimize application is a subscription-based system developed in conjunction with Berkeley, CA – based System Insights Inc allowing customers to optimize a specific machine or an entire shop.

In the second case, when a customer already has preferred tool and grade in mind, NOVO™ smart-attribute filters not only quickly select the products available to do the job, NOVO™ also gives the options on what cutting item and adaptive item fits and also works with the selected solution. NOVO™ smart filters take the task of selecting ALL cutting tool components from hours to minutes, while users get a comprehensive and correct list based on their input.

For more information, visit www.kennametal.com/novo

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In both cases, NOVO™’s Tool Configurator then provides all CAD files and graphic support for all tool components and their assembly – a major time savings for customers.


NEWS Identification of part cycle time and cost savings from NOVO™ Optimize recommendations.

Machine tool efficiency identification and optimization by NOVO™ Optimize.

“NOVO™ thinks like a process planner,” explains Thomas Long, head of the newly formed Virtual Machining RDE department at Kennametal. “It works from the feature back to the tooling strategy. In addition, each order number is tied to application data gleaned from hundreds of subject matter experts and decades of Kennametal experience. Request a part number and you also get pictures, assemblies, spare parts lists, as well as inserts that fit. Not only does it accomplish in minutes what formerly took hours, it yields an optimized solution, backed by Kennametal expertise, every time” Even further, NOVO™’s Job Functionality option is a cloudbased repository linked to a user by a unique ID where tool lists can be stored for future use, editing, copying, and sharing. These can be easily downloaded into standard report formats and include tooling commercial and dimensional data and weights, speeds and feeds, and photo or CAD model images.

significantly widening skills gap as older workers retire and new workers fail to engage in manufacturing careers. “To effectively meet the skills gap for our customers, we need a better way to distribute the collected knowledge of Kennametal,” states Francois Gau, VP of Strategic Marketing and New Business Development. “More than a catalog, NOVO™ brings users into a community – all our ongoing expertise delivered in a digital means of accessing process knowledge quickly. The result empowers users by providing the right solutions specifically tailored to their operations. It solves problems instead of managing data.”

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SIDEBAR 2 – Addressing the Skills Gap Manufacturing is experiencing a global renaissance in developed and emerging economies around the world as major industries such as aerospace, automotive, energy and others consistently demand new and better products. Manufacturing technology providers have responded with computer-driven machine tools, digital-based computeraided design and manufacturing software (CAD/CAM), and significant advances in tooling. Yet behind this positive outlook lies a major barrier threatening this scenario: a 08 | Industry Asia Pacific | January 2015

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WIDIA HYDROFORCE™HT: UNIVERSAL HYDRAULIC CHUCK REDUCES INVENTORY, MAXIMIZES PERFORMANCE

Ultimate high-torque chuck for all rotating applications.

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xtreme challenges require the right tools, and the highest-performing tools require the best components. WIDIA, the world’s leading provider of wear-resistant products and applications engineering, recognizes the foundation for successful machining is built on rock-solid reliability and performance, which is why the company is proudly introducing HydroForce™ a new high-performance, high-torque universal hydraulic chuck. “The right chuck maximizes tool life, workpiece surface quality, and production flexibility, and this is the most advanced hydraulic chuck available – a first-choice solution for all rotating applications,” says Doug Ewald, global product manager at WIDIA.

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With a more compact and stable design, featuring a 40% thicker front wall cross-section, HydroForce HT provides the increased rigidity necessary for improved cutting parameters and better results. Clamping force is up to three times better than regular hydraulic chucks, and with improved vibration dampening, runout is three microns at 2X diameter overhang. Balance quality of G2.5 is achieved at speeds up to 25,000 rpm. 08 | Industry Asia Pacific | January 2015

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“All this robust performance is available in a high-torque chuck requiring only two sizes for all your rotating tooling tasks,” Ewald continues. “Direct clamping is available for 20 and 32 mm (0.75 and 1.5 in.) diameters and reducer sleeves are applied for all other diameters.” More cost-effective than expensive thermo shrinkfitting operations; up to four times more clamping force compared with collet chucks; and higher balancing quality performance than power milling chucks, HydroForce HT is a cost-effective universal chuck solution that simplifies inventory while maximizing tool life and machining results for milling, drilling, reaming, and other rotating applications. For more information, visit: www.widia.com


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MU TECH

MU TECH by Huron is an entry-level 3-axis milling machine that has the distinctive feature of being equipped as standard with an electrospindle. Versatile and multi-application, MU TECH can also operate in 3+2 axis mode.

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t offers high power at low speed for rough cutting of large parts since it can be used at service class S1 starting at 3000 rpm and at service class S6 for 40% of the time at 2200 rpm. Finishing operations can subsequently be performed in 5-axis mode at high speed. MU TECH 6, the first version available, features a dia. 600 mm table.

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MU TECH is equipped as standard with a high-speed electrospindle. It provides 23 kW of power with 75 Nm of torque and a maximum speed of 12,000 rpm. It can be used in continuous service (S1) starting at 3000 rpm and in continuous service with intermittent load (S6) for 40% of the time at 2200 rpm. The electrospindle is equipped with a rotary head (B-axis). The +30°/-120° rotation allows general mechanical components to be machined vertically and horizontally. Continuous head rotation is achieved by a play-free system that also allows all possible 5-axis shaping applications. Flawless machining stability is achieved through the design of the spindle and the use of high-performance bearings. MU TECH is also equipped with a special cooling system that maintains it at the correct temperature. Each axis is driven by large-diameter high-performance ball screws and all movements are controlled by encoders to ensure accuracy to within one

one-hundredth of a millimetre along the three axes. The maximum linear speed is 30 m/min. Like the other machines in the Huron range, the MU TECH's structural components are made of heavily ribbed cast iron to substantially dampen vibrations and ensure a high level of machining stability. Its symmetrical design guarantees very high geometric stability. MU TECH also features a highly ergonomic design. Its wide-opening doors afford easy access to the work area for removing the head and performing other tasks, such as loading the machine with an overhead crane. The frame accommodates all axes of movement and the 1000 × 600 mm table travels vertically at up to 560 mm. The 750-mmstroke transverse saddle is topped by a 560-mm-stroke ram. The j 600 mm rotary table (C-axis) is used for 5-face machining and, with its play-free drive, high-precision 5-axis machining of workpieces measuring up to j 800 × 550 mm. The standard automatic tool changer contains 24 tools and features a double arm and a drum-type tool magazine. MU TECH can be equipped with an optional rotary table integrated in the stationary table, other spindles, a 40 – or 60-station tool changer, through-tool coolant and workpiece and tool touch probes. www.huron.fr/Index.aspx 08 | Industry Asia Pacific | January 2015

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HIGH PERFORMANCE IN A COMPACT DESIGN BACKLASH-FREE ROBA®-DS SERVO COUPLINGS WITH SPLIT CLAMPING HUBS

Radial installation: The ROBA®-DS servo couplings with split clamping hubs guarantee easy and fast installation, even in difficult ambient conditions: They are suitable for large shaft distances and in all applications, in which the drive aggregates must not be moved any more.

The high-performance ROBA®-DS shaft couplings transmit the torque backlash-free and with high torsional rigidity. They compensate for shaft misalignment and are both wear – and maintenance-free. On the sizes up to 150 Newton meters, mayr® power transmission are going to extend its standard hubs for mounting the shafts by a radially divisible hub – for easy and fast installation, even in difficult ambient conditions.

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hort dimensions, little installation space requirements, reduced weight and low mass moments of inertia – the ROBA®-DS servo couplings win over customers due to their high performance density. They are able to transmit high torques even at comparably small diameter, which makes them the ideal shaft couplings for dynamic drive systems with high speeds. These couplings are made of steel and high-strength aluminum alloys, which forms the basis for the extremely compact design.

Backlash-free torque transmission The couplings compensate for radial, axial and angular shaft misalignments by means of the flexible disk packs. This way, they protect the bearings from unwanted wear and tear and prevent unnecessary downtimes and costs. In order to achieve backlash-free torque transmission, the disks in the fixing area are treated with a special blasting procedure. The ROBA®-DS disk pack couplings are robust and reliable. They are temperature-resistant, wear – and maintenancefree and transmit the torque with very high torsional rigidity. Therefore, they are especially suited for applications in extreme ambient conditions.

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Fast and easy installation The area of application for servo couplings is growing. Therefore, mayr® power transmission have extended the standard hubs for shaft attachment by a radially divisible hub, a so-called split clamping hub, also for sizes 3 to 15. At permitted speeds of 3000 rotations per minute, these sizes for shaft diameters of 45 to 79 millimeters cover torques from 35 to 150 Newton meters. The half-shells 08 | Industry Asia Pacific | January 2015

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High-performance ROBA速-DS servo couplings: They transmit high torques even at comparatively small volumes and are the ideal shaft couplings for dynamic drive systems with large speeds.

guarantee easy and fast coupling installation, even in difficult ambient conditions. Therefore, the hubs are used preferably in applications, in which the drive aggregates such as the motor and the gearbox must not be moved after the positioning and aligning for coupling installation. These hubs are also recommended for large shaft distances, for example for cardan shafts in linear actuators, as in these cases the coupling is installed last and therefore has to be easy to install. High performance density Installation is carried out radially: To do this, the coupling is brought to the shafts and pre-assembled with the axially moveable half-shells. Here, it is important that the markings on the half-shells and on the hub bodies overlap. Then, the cap screws must be tightened evenly and in several sequences to the required tightening torque. The ROBA速-DS servo couplings are available as doublejointed couplings with a connection plate or a variablelength sleeve. Their compact design, the short installation times and the high performance density make these couplings a particularly efficient and economic solution. MORE INFORMATION

www.mayr.com/en/

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DRIVING SUCCESS IN STAINLESS STEEL AND CAST IRON TURNING WITH NEW BEYOND DRIVE™ FROM KENNAMETAL

New grades and coating mean many more pieces per edge. New Beyond Drive inserts from Kennametal feature a bronze TiOCN top coating that increases wear resistance and functions as a wear indicator.

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anufacturing is experiencing a powerful resurgence worldwide, and along with that resurgence come tighter schedules and more competition, increasing the pressure on manufacturers to deliver more components faster and reliably to the plants that need them. The need for different and better thinking is more focused than ever. New Beyond Drive™ cutting tool inserts from Kennametal are helping component suppliers expand and thrive in this environment with enhanced performance and extended tool life that mean many more finished pieces per cutting edge.

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Specifically designed for cast irons, steels, and stainless steels that make up many critical components over a variety of industries, Kennametal’s new Beyond Drive inserts are a product of ongoing design leadership, engineering, materials science, and manufacturing directly targeted to the needs of component manufacturers.

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Like all of Kennametal’s Beyond™ line of products, Beyond Drive inserts feature a proprietary post-coat surface treatment that improves edge toughness, reliability, and depth-of-cut notch resistance, and a micro-polished surface to reduce friction and workpiece sticking (BUE). A fine-grained alumina layer allows for increases in cutting speed, improving productivity and reliability at high cutting temperatures. With Beyond Drive, adding a new titanium oxy-carbonitride outer coating (TiOCN) not only increases wear – and abrasion-resistance, its bronze color is also an effective wear indicator. Depending on the application, field tests are showing anywhere between 30 percent and 125 percent more parts per edge. All new Beyond inserts are CVD (chemical vapor deposition) coated, but whereas conventional CVD coatings are under tensile stress, Beyond inserts undergo a proprietary postcoat treatment on all surfaces to reduce this stress, which improves coating adhesion and reduces micro-chipping. More uniform and reliable wear of the cutting edge results in improved and more consistent tool life. “Together with


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the right geometry, we’ve seen big improvements in cutting performance and tool life in both internal and field tests,” says Manuel Sedan, senior product manager, turning products, at Kennametal. For example, in one test for a plant producing cast-iron transmission components, with no change in feed, spindle speed, or depth of cut, Beyond Drive completed 325 pieces per cutting edge compared to 200 pieces for the plant’s current inserts. Not only was this a phenomenal increase in parts per edge, projected machine hours freed per year totaled 125 while the number of inserts required per year dropped from 813 to 500.

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“A stronger supply chain that gets more parts to the market reliably is the foundation of a healthy and growing manufacturing industry,” Sedan adds. “Plus the days of one man-one machine are long in the past. With one operator running a cell or any number of machines, greater predictability and performance with tools is an increasingly crucial component for success. Beyond Drive is a truly exciting development that promises more pieces per shift, more efficient machine utilization, and long tool life.” Beyond Drive is available in eight grades and numerous insert styles, covering a complete range of applications for turning steel and cast iron components. For more information, visit www.kennametal.com 08 | Industry Asia Pacific | January 2015

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THE MULTIPLE CHALLENGES OF MACHINING ISO P WORKPIECE MATERIALS

The ISO P classification of workpiece materials includes the metals generally referred to as steels. While steels don’t present obvious machining challenges on the level of materials such as heat-resistant aerospace alloys used in aerospace applications, steel alloys and irons are the workpiece materials most widely applied across all industries.

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steels, including alloys hardened up to 400HB and stainless alloys with chromium content of 12 percent or less. Some long-chipping malleable irons are also part of the ISO P group.

ISO system The ISO metalworking workpiece material classification system is divided into six categories. The K group covers cast irons. Heat-resistant superalloys including nickel – and titanium-based alloys are in the S group. Materials in group H are characterised by their hardness and basically include steels hardened to 45-65 HRc. Stainless steels – alloys with chromium content greater than 12 percent – make up the M group. The N category covers nonferrous metals, mainly aluminium as well as copper and brass. Finally, the P classification includes unalloyed, low-alloy, and high-alloy

The classifications are based largely on the dominant physical properties of the different materials. Those properties essentially determine how the material reacts to being machined, and how in turn machining affects the cutting too. K group metals are characterised by abrasiveness, which accelerates tool wear. Heat-resistant superalloys in the S group generally have poor thermal conductivity, which results in heat concentration in the cutting zone that can deform a cutting tool. The hardness of the metals in group H creates great pressure on tools and generates heat as well. The M group is distinguished by strain hardening, in which the workpiece material becomes harder as it is deformed in the cutting process. The increased cutting pressure and heat generation can cause notch wear and other problems. Metals in the N category exhibit a tendency to adhere to the cutting tool, which leads to edge buildup, poor surface finish, and cutting tool fracture.

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uch wide use has spawned the development of a large selection of steel alloys with differing physical properties that generate a variety of metalcutting performance issues. Those issues, in addition to economic considerations born of high-volume production demands, make machining of ISO P steels a significant challenge for parts manufacturers as well as the makers of the tools used to machine them.

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NEWS Example of an insert designed for steel turning: WNMG080404-MF2,TP1500

Example of an insert designed for steel milling: LOEX080404TR-M08, F40M

Because each of the five ISO groups named above has a more or less dominant distinguishing physical property, cutting tools can be engineered, to a degree, to counteract the property’s negative effects on the cutting tool. Tools for cutting materials in the H group are biased toward strength, for example, while tools engineered to cut N category metals are sharp and designed to promote chip flow that minimises the occurrence of adhesion. Workpieces in the ISO P group, however, present more complex challenges. Steels in general and widely differing steel alloys in particular can exhibit more than one or even all of the properties that affect cutting tools, although usually not to an extreme degree. This poses a conundrum for tool development; in many cases, for example, a sharpedge tool engineered to counter the adhesion tendencies of a low-alloy steel may not be able to withstand the abrasive characteristics of another steel composition. In addition, development of specialised steel alloys continues unabated as manufacturers seek materials matched to the particular performance demands of their customers’ parts.

Different steels, different tools The effects of machining on steel workpieces vary with the composition of the steel alloy and the process by which it is manufactured. Unalloyed steels with carbon content less than 0.25 percent; for example, have been developed for applications such as automobile axles that require strength and resistance to impact and fracture. These rolled or forged alloys produce chips that are difficult to break and that rub

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Understanding metalcutting When machining steel alloys, finding a productive balance between tool performance properties is like dancing on a thin rope. Striking that balance requires an understanding of the nature of metalcutting and the interaction between the workpiece material and the cutting tool.

Metalcutting is not a splitting process comparable to the way that a knife cuts. The metalcutting process instead puts pressure on the workpiece material until it deforms and shears away in the form of a chip. Many collateral effects accompany the shearing action. The mechanical forces required to sufficiently deform the material generate a great deal of pressure as well as heat leading to temperatures on the order of 800-900 ËšC. Interrupted cuts or machining parts with hard inclusions subject the cutting tool to impact. Beyond mechanical considerations, the high levels of heat and pressure can catalyse chemical reactions between the cutting material and the workpiece material, producing chemical wear in the form of diffusion or cratering. And last but not least, metalcutting involves a high level of friction. As the chip is formed and rubs over the tool, it creates friction and what are known as tribological effects; tribology is the science that examines surfaces in contact with each other at certain temperatures and pressures and determines the degree to which the surfaces will modify each other. All these forces and interactions produce varying results; perhaps the most important one is that the tool wears out.

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the surface of a cutting tool and produce crater wear and even adhesion problems. For these compositions, cutting tools are designed with sharp edges to more efficiently shear the workpiece material, and also employ coatings to resist chemical wear and provide lubricity to the cutting surface. On the other hand, high alloyed steels with alloy content over 5 percent, including elements such as manganese, can be hardened for use in components that require wear resistance and rigidity, such as hydraulic components and machine tool parts. The chips produced generally are easily formed and broken, but the tools machining these alloys are subject to high pressure and high temperatures. If the unmachined workpiece was produced via casting or forging, a rough surface and possible inclusions from the mould require cutting tools with both toughness and resistance to abrasive wear.

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Economic considerations The traditional goal of machining operations is to produce more parts faster, and therefore requires application of the most aggressive cutting parameters possible. Other issues, however, modify that simple goal. Economic considerations can play a large role in the selection of cutting parameters. Parts such as aerospace components produced from exotic alloys most often are made in relatively low volumes. Manufacturers machine the parts at a pace aimed to maximise process reliability and preserve the expensive 08 | Industry Asia Pacific | January 2015

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workpiece materials and costly manufacturing time already invested. As a result, speeds and feeds employed with advanced workpiece materials usually are productive but conservative. The approach to machining of steel components often is different. Many steel parts are manufactured in high volumes and as quickly as possible to maximise economic return on relatively simple parts machined from less-expensive workpiece material. Higher cutting speeds, the typical path to higher productivity, require cutting tool substrates with the ability to retain strength at high cutting temperatures. In light of the growing selection of steel alloys, it can become necessary for manufacturers or machine shops to consult with cutting tool manufacturers to find the tool grade and geometry best suited to a particular application. Ongoing tool development is aimed at creating tools that can cope with the multiple issues presented by steel alloys. Manufacturers seek tools that are sharper yet stronger, with coatings and geometries designed to overcome the heat, pressure, chemical and adhesion mechanisms of wear. Environmental consciousness A relatively new consideration also influences the choice of machining parameters for steel materials. Many manufacturers are now pursuing environmentally conscious or “green� machining initiatives. These include reducing energy consumption and minimising the waste generated during the machining process. Although technological


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machining challenges remain of primary concern when processing exotic metals, environmental concerns are rising in importance when machining steels. One way to reduce energy consumption is to reduce cutting speeds. In many cases, manufacturers can maintain productivity by proportionally increasing feed rate and depth of cut. In addition to saving energy, such strategies also result in longer tool life. That in turn reduces the waste stream from the machining operation in that fewer cutting edges and “throwaway� inserts are consumed to produce the same number of parts. Use of lower cutting speeds also generates less heat, which can reduce demands for metalworking coolant, itself an undesirable waste product of the metalworking process.

For more information on how Seco’s innovative products and expert services bring success to manufacturers across all industry segments, please visit: www.secotools.com

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Conclusion Because ISO P steels are perceived as being overly familiar and widely applied on routine parts, machining operations involving the alloys usually are not subject to intense interest and analysis. However, when manufacturers understand that steels present multiple machining challenges that can be overcome with careful tool selection, high part volumes can make even small improvements in machining productivity significant contributors to profitability and even environmental preservation.

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BUREAU VERITAS PARTNERS WITH THE GREEN BUILDING CERTIFICATION INSTITUTE (GBCI) & REINFORCES ITS PRESENCE IN THE GREEN BUILDING CERTIFICATION MARKET

The Green Building Certification Institute, the certification body for the U.S. Green Building Council’s LEED green building program, and Bureau Veritas have signed a Memorandum of Understanding to facilitate the LEED program. LEED is the world’s foremost program for the certification of design, construction, maintenance and operations of green buildings.

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s part of the agreement, Bureau Veritas shall perform certification review for LEED projects internationally on behalf of GBCI. The partnership furthers the GBCI’s commitment to a transparent, independent and professional certification process and shall leverage the global presence of Bureau Veritas.

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The green building market is expected to grow by 780% reaching 5.3bn sqm of certified space worldwide by 2020. This massive trend is driven by growing expectations for improved performance of buildings worldwide and the health and well-being of building occupants. Buildings and infrastructure represent approximately 40% of global energy consumption and the green building movement has the potential to significantly reduce this environmental impact. Green buildings are quickly becoming the norm with massive growth expected in the world’s leading construction markets such as China, India and Brazil.

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Studies have shown that LEED buildings offer occupants a better working environment leading to an increase in overall productivity. Other benefits include higher asset value, better energy performance and lower operating costs. “Partnering with the GBCI and USGBC, places Bureau Veritas at the forefront of this growing market”, specifies Didier MichaudDaniel, CEO Bureau Veritas. “Our teams are dedicated to helping our clients improve people’s daily lives the world over through the implementation of the LEED standard”. “Entering into an agreement with Bureau Veritas will enable USGBC to provide consistent quality of service globally,” said Rick Fedrizzi, President, CEO & Founding Chair, USGBC. “Our new strategic partnership will enable both parties to address the expanding green building market with the high levels of quality the market demands.”


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The Agreement was signed between the two parties on 24th July and will go into effect immediately with a global reach. The first buildings to be certified by Bureau Veritas within this partnership are due to be delivered later in 2015. www.bureauveritas.com

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SCADA MODERNIZATION OF THE INDUSTRIAL AQUEDUCT OF LAKE COMO

Lake Como, in northern Italy, is served by nearly 40 miles (60 KM) of aqueducts. The aqueduct draws its water directly from the lake and pumps it to storage tanks. The water flows from the tanks via aqueducts serving businesses around the lake. The waterworks reliability is paramount as water disruption leads to lost production for manufacturers of Como. After 30 years of service, the SCADA system was in need of modernization.

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nergy costs in the region have risen significantly during the last 30 years. The geography of the lake set in mountainous terrain, is particularly challenging to water management. The modernization of the SCADA created the opportunity to not only take advantage of technology advances, but also to review concepts of water management and to introduce the concept of energy profile management.

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Pumping is the greatest percentage of energy consumed. Energy profile management involves analyzing daily consumption and comparing to lake levels which allows projection of storage required. The set-points for the pumps are managed such that the tanks are filled at night when electricity is less expensive. Operating the pumps during the day is possible, but minimized to reduce costs. The SCADA collects other relevant operational data of the system including continuous recording of pressure, level, flow rates and volumetric meter readings. In the future, 08 | Industry Asia Pacific | January 2015

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further optimization of energy costs may be possible. Telecommunications was evaluated in the early phases of the project. The decision was made to move to an Ethernet based network. Existing telephone land-lines interconnect the PLCs and the SCADA host. HDSL provides the Ethernet network over the telephone system. The Ethernet-based network provides multiple advantages to a field bus architecture including the potential for future revenue sources. For example, other Lake Como utilities may lease bandwidth for their own industrial protocols or other applications such as surveillance and telephony may be hosted. The design also made the telecommunications independent of PLC and SCADA vendors for the project. Two critical aspects of the communication reliability had to be addressed were network security and availability. Standard IT practices for security are used. Firewalls and VPN’s ensure that the appropriate policy is deployed, allowing only access to recognized users of the system.


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Secondly, cellular modems are connected to each PLC. In the case of a failure of the land-line network, system operators can reach the PLC directly using mobile devices. A client-server architecture was chosen for the SCADA. The simplified design is based on commercially available hardware with a modular open architecture for maintainability. PcVue, from ARC Informatique, was chosen for versatility and ease of maintenance. The graphics provides a very lean display, thanks to modern symbols for visualization and animation. The variables (tags) in PcVue, using a branching structure, minimize the number of screens to be developed. The client stations deployment is essentially automatic. Clients are enabled by simply sharing the project file. Any modification for the project can be made on the server and copied to the clients.

A critical aspect was coming on-line with minimal disruption. It was not easy to manually operate the system and only possible for short times during emergencies. To replace the SCADA, a total halt of the waterworks was required. Well organized and coordinated teams worked simultaneously on all sites, such that installation and commissioning was minimized. The selected system integrator, T.S.A., provided a careful analysis of the state of the art in existing similar systems. T.S.A, formed a partnership with Borghi, who had previously been responsible for the design and installation of new electrical switchgear and control. The synergy between the two partners (TSA-Borghi) allowed for a competitive proposal with a substantial savings in cost. More importantly, the team had all the necessary areas of expertise to be able to execute all stages from design to commissioning without depending on third party subcontractors.

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The system has about a thousand alarms, which are divided into priority levels. All of the alarms are stored and are available in both textual forms and with graphic animations. When alarms are raised, the SCADA uses contextual logic to determine the appropriate course of action. For high priority alarms, SMS text messages are sent to the operator based on the concept that the operator can connect to the network and acknowledge the alarm. If the operator does not respond within a designated time, the system will resend the SMS message until the alarm is acknowledged.

Even the choice of the contractor was strategic. Only qualified system integrators capable of design and implementation of the entire system with full autonomy on the project were considered.

www.pcvuesolutions.com

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