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Industry

Asia Pacific THE INDUSTRY MAGAZINE FOR ASIA

DE DIETRICH PROCESS SYSTEMS IS LAUNCHING A NEW EXTERNAL PROTECTION OF GLASS-LINED PARTS

6 KENNAMETAL STELLAR SUCCESS

20 FLUKE PROCESS INSTRUMENTS ALL-NEW 20-CHANNEL TEMPERATURE LOGGER

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PCVUE INTRODUCES PROXIMITY-BASED CONTEXTUAL MOBILITY FOR SCADA

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15 | Industry Asia Pacific | July 2016

THE INDUSTRY MAGAZINE FOR ASIA

HAIMER

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DE DIETRICH PROCESS SYSTEMS

TYCO GAS & FLAME DETECTION

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7 EMERSON INDUSTRIAL AUTOMATION

BALLUFF

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FISCHER CONNECTORS

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PORTESCAP

DORNER

SECO TOOLS

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FLUKE PROCESS INSTRUMENTS

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KENNAMETAL

SICK

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FLUKE PROCESS INSTRUMENTS

ELMO

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VERLINDE

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25 FLUKE PROCESS INSTRUMENTS

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VERLINDE

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www.industry-asia-pacific.com

ARC INFORMATIQUE

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NEWS

MAPAL RELIES ON THE SAFE-LOCK™ SYSTEM FROM HAIMER

Within a wide range of markets, such as the aerospace industry, cutting tools from MAPAL have successfully established themselves for high-performance machining operations liketrochoidal milling. In order to offer users even greater protection against tools being pulled out of the chuck during machining operations, and to prevent damaging single workpieces or the machine itself, MAPAL is going to rely on the Safe-Lock™ pull-out protection system from HAIMER. The two companies recently signed a corresponding licensing agreement.

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AIMER and MAPAL have reached a partnership and licensing agreement. The toolholding specialist from Igenhausen near Augsburg and the precision cutting tool manufacturer from Aalen are combining their strengths to form a new partnership. In the future, they will work strategically closer together on the progression and further development of technologies and their applications in the manufacturing market.

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The two companies have signed an agreement that has contractually solidified their partnership. “We are proud and happy to have a strong partner at our side in MAPAL that is one of the world's leading tool manufacturers,” emphasizes Claudia Haimer, managing partner of HAIMER. And the managing partner of MAPAL, Dr. Dieter Kress, is also looking forward to the future cooperation. “We value the high-level expertise of HAIMER whose innovative solutions in the 15 | Industry Asia Pacific | July 2016

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field of tool holders represent the perfect complement to our high-tech tools.” Through the agreement, MAPAL has acquired a license to HAIMER's Safe-Lock™ technology that is patented worldwide. “The Safe-Lock™ system has proven itself both in the market and during our in-house trials. Consequently we have decided to use this leading system,” Dr. Jochen Kress, Member of the MAPAL Senior Management, says. “It is very frequently used for modern machining strategies. With Safe-Lock™ the productivity and tool life can be significantly increased,” Andreas Haimer, Managing Director and President of the HAIMER Group,explains . When it comes to high-speed cutting, absolute safety is especially crucial. Considering the high value of the single workpiece or an unmanned production, scrap parts and machine downtime have to be avoided in order to guarantee process reliability.


NEWS

From left to right: Dr. Jochen Kress, member of the senior management of MAPAL, Dr. Dieter Kress, managing partner of MAPAL, Claudia Haimer, managing partner of HAIMER and Andreas Haimer, managing director of HAIMER.

Through special drive keys in the tool holder and grooves in the cutting tool shank, the Safe-Lock™ system from HAIMER ensures high accuracy frictional clamping with the security of a form fit between grooves on the cutting tool and the drive keys in the chuck. This prevents the cutting tool from turning or being pulled out of the chuck during machining. As a first step and starting in October, MAPAL will be offering selected cutting tools for high-performance machining with the Safe-Lock™ shank. As a second step, the MAPAL hydraulic chucks will follow and also be designed for this type of pull-out protection. www.haimer.com

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DE DIETRICH PROCESS SYSTEMS IS LAUNCHING A NEW EXTERNAL PROTECTION OF GLASS-LINED PARTS

To address the problems of its customers, particularly in pharmaceutical and fine chemicals, sensitive to the risk of contamination of their products by paint chips, De Dietrich Process Systems has developed a new exterior nickel coating for glass-lined parts.

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his coating is particularly suitable for glass-lined accessories such as manhole covers, protection rings and even some AE reactor covers, or process peripheral such as piping.

To address this risk, De Dietrich Process Systems has developed a nickel coating solution that provides corrosion protection comparable to painting, while eliminating the risk of chipping.

The external protection of process equipment (reactors, piping, etc.) in glass-lined steel is traditionally provided by the paint. These paints have excellent corrosion resistance but may in places be subject to high mechanical stress, and flake.

Indeed, nickel coating has outstanding properties: • Bonds perfectly with the base material • Impact resistant • Easy to clean thanks to a specific surface preparation • Makes it possible to apply homogenous surface coating to components with complex geometries

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The GMP (Good Manufacturing Practices) standards of the pharmaceutical industry prohibit the fact that a paint flake can contaminate the final product.

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www.dedietrich.com


NEWS

NEW MX 32 GAS DETECTION CONTROLLER NOW AVAILABLE

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

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

For more information visit www.TycoGFD.com

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

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NEWS

LEAN SOLUTION FOR TRACK-AND-TRACE

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

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he BIS M-4008 from Balluff is an All-in-One RFID Reader with integrated processor. The 13.56 MHz reader with IP67 protection and a rugged die-cast zinc housing features a Profinet interface, needs no additional processor and can communicate directly with the control level. The reader is an ideal choice wherever a lean solution is needed for detecting data carriers on workpieces and workpiece carriers at individual stations. Typical applications include material flow control in production facilities, conveying systems and assembly lines.

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The device is the only all-in-one reader on the market with an integrated 2-port Ethernet switch for constructing simple line- and ring topologies. An integrated webserver provides conven-ient status monitoring from a distance. Highly visible LEDs di-rectly on the device also indicate status. The new reader supports data carriers conforming with RFID standard ISO 15693. Anyone needing faster data transmission can simply choose Balluff high-speed data

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carriers with a transmission rate of up to 8x faster than the standard and extra-large memory capacities of up to 128 kB. The BIS M-4008 saves the user much time and money in as-sembly and installation. The die-case zinc housing can be in-stalled directly on metal in a variety of ways. Direct connection to Profinet also represents reduced wiring expense and effort. Yet another benefit is the use of costeffective 4-pin, M12 standard cable for the power and Profinet connection. Device master data are available as a GSDML file for typespecific parameterization. Ready-made function blocks provide for simple S7 programming. www.balluff.co.in


NEWS

CONTROL TECHNIQUES INTRODUCES NEW HIGH POWER MODULAR DRIVES

Control Techniques, an Emerson business, has extended its range of high power modular drives. Both its Unidrive M and Powerdrive F300 variable speed drive ranges are now available in the larger frame size 11, providing a flexible method of building compact, reliable high-power solutions.

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aralleled together, Unidrive M can control asynchronous and permanent magnet motors in systems up to 2.8 MW (4,200 hp). The new frame 11 is a 250 kW (400 hp) module that allows system builders to create high power solutions with the smallest number of components, keeping both footprint and costs to a minimum. Unidrive M differentiates itself on performance with extremely fast current control algorithms and high switching frequencies. Active Front End (AFE) solutions deliver unparalleled torque precision and power quality.

The Unidrive M modules can be paralleled into a wide range of flexible solutions to solve all system needs including Active Front End and multi-pulse rectifier configurations. They can be controlled by Control Techniques’ Unidrive M600, M700, M701 and M702 controllers. Control Techniques also offers a full range of high powered drive products tailor-made for fan, pump and compressor applications from 90 kW to 2.8 MW. The Powerdrive F300 series also features a modular design and can control permanent magnet or standard AC induction motors. This modular approach to building high power systems also provides the flow industry with flexibility while keeping complexity low.

MORE INFORMATION

www.EmersonIndustrial.com/Automation www.EmersonIndustrialAutomation.com www.Emerson.com

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NEWS

FISCHER RUGGED FLASH DRIVE NOW FIVE TIMES FASTER WITH USB 3.0

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

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

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

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Main technical specifications • IP68 sealed even unmated • Unique Fischer UltiMate (size 07) and MiniMax (size 08) interfaces • Up to 100 MB/s read speed • 6High speed USB 3.0 • Memory sizes: 32, 64, 128 GB • R esists corrosion, vibration, shock and extreme temperatures 15 | Industry Asia Pacific | July 2016

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

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

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

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

Showcased as world premiere at Eurosatory tradeshow The new Fischer Rugged Flash Drive is showcased for the first time, along with the company’s new electrical and optical connectivity solutions, at the Eurosatory tradeshow in Paris from 13 to 17 June 2016, at Fischer Connectors’ booth no. G 497, Hall 6. The Fischer Rugged Flash Drive will be commercially available in July. 15 | Industry Asia Pacific | July 2016

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NEWS

16MM ATHLONIX DC MINIATURE MOTOR FEATURES ENERGY EFFICIENT CORELESS DESIGN

Portescap introduces the next frame size in the DCP range of Athlonix™ high power density brush DC mini motors. Athlonix DCP motors offer an optimized price-to-performance solution ideal for a broad spectrum of applications. Available in a 16 mm diameter, the new 16DCP motor features an energy efficient coreless design with an optimized self-supporting coil and magnetic circuit, which ensures optimum price-toperformance is delivered.

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thlonix 16DCP motors are available in 2 variations, precious metal commutation and graphite commutation, both featuring an Alnico magnet inside. The unique constant force spring design for carbon brush ensures consistent performance. An REE (Restriction of Electro Erosion) coil is an available option, which ensures extended life of the motor and provides an environment of intrinsic safety especially at high speed conditions.

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With maximum continuous torque up to 2.63 mNm and higher stall torque than similar motors, Athlonix 16DCP motors are ideally suited for use in applications such as medical & industrial pumps, gas analyzers, security & access, power tools, mesotherapy guns and tattoo machines. “Athlonix motors are powered by a proprietary selfsupporting coil resulting into maximized magnetic flux and ampere-turns for a given diameter” says Sunil Kumar, Brush DC Product Line Manager at Portescap. “In contrast, typical self-supporting coils have inherent ampere-turns limitations 15 | Industry Asia Pacific | July 2016

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that affect the magnetic flux density in the magnetic circuit, which further limits power output and endurance of the motor,” he says. Component standardization and design modularity ensures quick customization capability for samples across various applications. “Due to lower motor regulation factor compared to comparable motors available in the market, our new 16DCP has higher load carrying capacity at minimum reduction in speed leading to more uniform power” says Sunil Kumar. Athlonix motors are available with encoders and gearheads of various sizes and ratios. They are manufactured in an ISO certified facility and are RoHS compliant. www.portescap.com


NEWS

DORNER ANNOUNCES ACQUISITION OF GEPPERT-BAND

Dorner Holding Corp., the parent company of Dorner Mfg. Corp., has announced the acquisition of Jülich, Germany-based Geppert-Band (http://www.geppert-band.de), a leading European manufacturer of belt and modular belt conveyors.

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orner Mfg. Corp. is an industry leader in the design, applications, manufacturing and integration of precision industrial and sanitary conveyor systems. The addition of Geppert-Band expands Dorner Holding Corp.’s geographic coverage and continues its strategy of international expansion. In late 2015, Dorner opened an office in Burlington, ON, Canada and acquired Penang, Malaysia-based, FlexMove; a manufacturer of flexible chain conveyors.

“As we continue to see growth internationally the addition of Geppert-Band allows us to better serve the European market,” said Terry Schadeberg, president and CEO, Dorner Mfg. Corp. “Its product offering and capabilities complement our existing strategy, and we’re pleased to welcome them to the Dorner family.” “We share a lot of similar core values, including a commitment to providing fast deliveries and quality customer service,” said Thomas Blesinger, president, Geppert-Band. “Dorner has a strong reputation in the conveyor market and we’re looking forward to providing our customers with an even wider variety of solutions.” www.dornerconveyors.com MORE INFORMATION 15 | Industry Asia Pacific | July 2016

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NEWS

EVOLUTION OF CHIP THICKNESS MODELS FOR MILLING

Multiple factors determine the results of metal cutting processes. Among the most important and the least understood factors is the ‘thickness of the chips’ cut by the cutting tool. Basically, ‘chip thickness’ is the measurement of the thickness of the non-deformed material at a right angle to the cutting edge. Chip thickness correlates e.g. closely with the forces that affect the tool and workpiece. Excessively large chip thickness result in chipping and breakage of the cutting edge, while insufficient chip thickness causes rapid edge wear.

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etermining and controlling chip thickness enables a manufacturer to maximise metal cutting productivity and efficiency, tailor cutting processes to specific workpiece materials and control costs. A lack of understanding of the importance of chip thickness leads many manufacturers to either overload or underutilise cutting tools, with negative effects on tool life and productivity.

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With that said, there exists mathematical models that aid in understanding the functional significance of chip thickness. Chip thickness models have evolved from simple equations describing chips generated in steady-state turning operations to complex formulas that take into account numerous variables in the interrupted cutting environment of milling.

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Chip thickness models for milling In a continuous turning operation, chip thickness does not change. In milling, however, chips continually vary in thickness as the cutting edge intermittently enters and leaves the workpiece. To simplify understanding of chip thickness in milling, approximately 40 years ago metal cutting researchers developed the concept of average chip thickness. The formula they produced mathematically creates a theoretical chip of a consistent average thickness. The average chip thickness model led to better understanding and control of the milling process. When determining the average chip thickness, one has to take into account the cutter’s radial engagement with the workpiece, along with the cutting edge geometry, cutting edge angle and feed rate. Adjusting the feed rate enables a machinist to manipulate chip thickness.


NEWS

The degree of radial engagement of the cutter in the workpiece may range from a small percentage of the cutter diameter up to 100 percent of the diameter in a slotting operation. Smaller radial engagement produces thinner chips. As the radial engagement grows, chip thickness reaches its maximum at 50 percent of cutter diameter. When radial engagement rises above 50 percent, chips begin to thin again.

The cutting edge angle has a direct effect on chip thickness. When the cutting edge angle is 90 degrees, as with a square shoulder cutter, chip thickness is 100 percent of the feed rate. But at a 45 degree cutting edge angle, chip thickness is 70 percent of the feed rate because the chip forms on a greater length of cutting edge. Reducing the cutting edge angle makes the chip thinner, and feed rate must be increased to maintain the desired chip thickness.

The preparation of the cutting edge also affects chip thickness. As a general rule, chip thickness must be at least as large as the radius of the cutting edge. For example, a 60 µm edge radius requires feed be adjusted to produce chip thickness of at least 60 µm. At a feed rate that is too low the edge will rub and fail to cut the workpiece material.

Application of the average chip thickness equation The average chip thickness equation takes into account the tool’s cutting edge angle and the radial engagement of the cutter. Figure 3 graphs the equation’s application in side milling in blue and central milling in red. On the main graph, the radial engagement of the cutter is compared to the cutter’s diameter, expressed as the Ae/Dc ratio. The smaller graph in the corner of the figure plots the effect of the cutting edge cutting edge angle. The figure illustrates a situation where the average chip thickness formula is not fully effective. When side milling with radial engagement that is very small compared to the diameter of the milling cutter, the formula does not function correctly (see dotted line). And in central milling, when 50 percent or more of the cutter is engaged in the cut, the red line shows continually increasing feed rate. That is contradictory to practical experience, where greater cutter engagement usually dictates feed rate reduction. Accordingly, the average chip thickness model is most

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Milling tool cutting edges usually feature preparations that increase the edge radius to provide protection from chipping and breakage. Such preparations include hones, chamfers and T-lands. These preparations permit more aggressive feed rates when milling difficult materials or rough surfaces. The goal is to form the chip behind the cutting edge and thereby avoid concentrating pressure and impact where they will accelerate edge wear or breakage. Adjusting the feed rate moves the location of chip formation and controls chip thickness. Increasing feed rate creates a thicker chip and decreasing feed produces chips that are thinner.

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NEWS

useful when radial engagement is greater than 20 to 25 percent of the cutter diameter and smaller than 50 to 75 percent of that amount. The average chip thickness model is based on geometric factors and simplifies a complex situation. Decades of application have shown that use of the average chip thickness model in tool life equations provides estimates that are accurate within plus or minus 15 percent. That level of accuracy is sufficient for power and torque calculations and for many operations in routine workpiece materials. Further, the time and effort for the calculations needed to manually solve the average chip thickness equation are reasonable. However, when applications require a higher degree of accuracy or when milling involves so-called difficult-tomachine materials, a model that includes additional factors is needed.

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Equivalent chip thickness Swedish researcher Sören Hägglund developed a more global model that provides a measurement called equivalent chip thickness, which can produce tool life predictions with accuracies of plus or minus two percent. In the model shown in figure 4, the yellow arc represents the varying thicknesses of the actual chip as produced by the milling cutter. The orange bar, which illustrates the average chip thickness approach, is an unfurled version of the yellow chip. The blue bar represents equivalent chip thickness. A key difference is that the equivalent chip thickness model factors in the time the tool edge spends in the cut. That is significant because as the amount of the cutter engaged in the workpiece varies, the cutting edge spends a different length of time in the cut 15 | Industry Asia Pacific | July 2016

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and the thickness of the chip that is generated changes as well. The equivalent chip thickness model also takes into account the influence of the tool’s nose radius on chip thickness. The model employs a concept originally developed for turning operations by Swedish engineer Ragnar Woxén in the early 1930s. Woxén’s formula calculates theoretical chip thickness along the tool nose, essentially straightening out the nose radius and enabling the chip area to be described with a rectangle. Chip thickness calculations help manufacturers avoid problems that arise when chips are thinner than a certain minimum or are thicker than a specific maximum level. When the radial engagement increases in relation to the cutter diameter, feed rate must be lowered to maintain the same chip thickness. This ensures that maximum chip thickness does not become excessive, a condition that will reduce tool life and eventually break the cutter. On the other hand, producing chips thicker than a certain minimum is especially important when machining strainhardening materials such as superalloys and titanium. A cutting edge producing chips that are too thin creates a work-hardened zone that is cut by subsequent cutting edges. Cutting the resulting layer of strain-hardened material accelerates tool wear and can shorten tool life by as much as a factor of three. Many shops machine strain-hardening materials the same way as hardened steels, employing lighter depths of cut and lower feed rates. As a result, milling cutters often run at parameters that produce insufficient chip thicknesses, with poor results. The choice of conventional or climb milling


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NEWS CHIP THICKNESS AND MILLING TECHNIQUE A partner to the equivalent chip thickness concept is consideration of the manner in which the chips are formed. Milling chip formation occurs in two different ways, depending on the rotation of the cutter in relation to the movement of the workpiece. The two methods are conventional (up) or climb (down) milling. In conventional milling, the cutter rotates against the direction of the workpiece feed. In climb milling, the cutter rotates in the same direction as the workpiece feed. In conventional milling, the cutting edge enters the workpiece at zero depth of cut. The chip begins to form at minimum thickness and finishes at maximum thickness. Conversely, the chip generated in climb milling begins at maximum thickness and tapers to its minimum. When milling with the conventional approach, the cutting edge rubs the workpiece before it cuts, and the thin chip absorbs heat poorly. Both conditions contribute to strain hardening of the workpiece surface and reduction of tool life. Chips fall in front of the cutter where they can be recut and degrade surface finish. In horizontal milling, upward cutting forces may lift the workpiece, necessitating use of complex workholding fixtures.

techniques (see sidebar) also affects chip thickness and the machining of strain-hardening materials. Conclusion Control of chip thickness is a key factor in successful milling operations. Taking full advantage of chip thickness concepts involves first calculating equivalent chip thickness, then determining minimum and maximum chip thickness limits. Because the complex equivalent chip thickness model includes a collection of variables, the calculations required to solve the equation consume a much greater amount of time and effort than the simplified model for average chip thickness. Manually making the calculations in a production environment is neither cost nor time efficient. However, the availability of computer software programs for calculating machining parameters, such as those available from Seco, enables users to enter data and solve the equations in seconds. The result is optimised milling processes that boost productivity and profitability. www.secotools.com

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By: Patrick de Vos, Corporate Technical Education Manager, Seco Tools

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Climb milling is preferred for a number of reasons. It eliminates rubbing of the cutting edge as it enters the cut, maximising tool life and reducing heat generation. Less machine power is required, and chips fall behind the cutter to minimise recutting and improve surface finish as well as tool life. The cutting action generates downward force, which helps stabilise the workpiece and simplify fixturing. The initial thickness of the chip enables it to carry away heat and minimise strain hardening of the workpiece surface when machining materials such as superalloys, stainless steels, and titaniums. However, the downward forces created in climb milling can cause backlash of the machine table, especially on older and/ or manual milling equipment. Backlash hinders accuracy and increases the chipload on the cutter to the point that it may break. As a result, the conventional milling approach may be required in situations involving less stable machines and workpieces. Conventional milling may also be preferable when milling castings, forgings and case-hardened material. That is because the conventional cut begins under the hardened or rough surface of the material, while the entry of the tool into the part at full chip thickness in climb milling may cause chipping of the cutting edge as it encounters the material’s hardened zone.


NEWS

RAYTEK, IRCON, AND DATAPAQ JOIN FORCES TO CREATE FLUKE PROCESS INSTRUMENTS

Fluke Corp. is integrating its Raytek, Ircon, and Datapaq product lines into a new brand: Fluke Process Instruments. All three companies have been part of the Fluke Corporation portfolio for some time.

Fluke Process Instruments combines more than 125 years of experience in pioneering new technologies into one integrated company,” said Fluke Process Instruments General Manager Ankush Malhotra. “By joining the three companies under a single brand, we can improve our communications and accelerate our product innovation. We are proud of the legacy these brands bring and will continue to grow them as Fluke Process Instruments.”

www.flukeprocessinstruments.com

Raytek, Ircon, and Datapaq branded products include a complete line of rugged and dependable infrared sensors, line scanners, thermal imagers, and temperature profiling systems for use in harsh, high-temperature industrial manufacturing environments.

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The company has launched a new website, www. flukeprocessinstruments.com, and will operate all related global activities under the new corporate name.

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

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STELLAR SUCCESS

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

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

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

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ost shops evaluate new cutting tools in an effort to reduce machining time, increase tool life, or improve part quality, and sometimes all three. Stellar Precision Components Ltd., a Tier II aerospace supplier in Jeanette, Pennsylvania, did it for an entirely different reason. “We’d just taken an order for some Inconel parts,” says production manager Edward Frieze. “None of us were really worried at that point about tool life or making a profit on the job—our only concern then was how the heck could we get them shipped in eight weeks.”

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

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

Stellar prides itself on continual updates to its equipment list, and has an eclectic mix of CNC machine tools from Haas Automation and Okuma, although that balance is steadily tipping in Haas’ favor as the shop’s older machines go into retirement. Albright says not only is the Haas equipment less expensive than its foreign-built competition, but that “Made in America” resonates with many of Stellar’s customers. “This approach also lets us replace our equipment on a more regular basis, which in turn keeps us current on technology.” Key equipment includes an Okuma LB-45 lathe able to turn 36 in. diameter parts up to 120 in. long (91 mm x 305 cm), and a Haas VF-11 5-axis machining center with 10 ft.

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

of X-axis travel (305 cm) and a table load capacity 4000 lb. (1814 kg). Stellar also has several wire EDMs, a dozen or so 3, 4, and 5-axis machining centers and mill-turn lathes, and offers value-added services such as non-destructive testing, welding, heat treating, and Teflon coating. Not Too Tough Stellar is used to meeting demanding requirements. Recent projects include components for RAM Block II anti-ship missiles, the CCtCap crew transport vehicle, 155mm Long Range Land Attack Projectile (LRLAP) advanced gun system, rocket motor cases for the Atlas Five launch vehicle, and others. Their newest project, however, would be one to test the mettle of machinists and management alike.

Nor was tolerance an issue. Frieze points to one recent titanium part that called out a 0.005 in. (0.127 mm) profile tolerance over its 12 in. length (304 mm), the equivalent of holding “a couple tenths” in parts that cost over $5000 apiece before machining. Meeting the relatively wide open tolerances on the Inconel part was not a concern.

Seminar Payoff Earlier that year, Frieze and several of his coworkers had attended a learning event sponsored by a local chapter of the National Tooling and Machining Association (NTMA), and hosted at the Kennametal technical center in the nearby town of Latrobe. There he met product manager Matthieu Guillon, who introduced him to a cutting tool that Frieze was initially skeptical of. “It looked and felt like a plastic toy end mill,” he laughs. That tool was Kennametal’s series of 4 and 6-flute high performance full ceramic end mills. Constructed of SiAlON KYS40 grade ceramic and designed specifically for roughing in nickel-based high-temperature alloys, these end mills often out-produce carbide by up to 20 times. Says Guillon, “We recommend a starting speed of 825 SFM up to 3300 SFM (250 to 1000 m/min) and feedrates starting at around 0.001 IPT (0.03 mm) depending on the tool diameter and other conditions. Despite the far higher cutting speeds, we have some customers who have reported 2 to 3 times greater tool life than carbide.”  >>>

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

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

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

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

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

Stellar didn’t have any immediate use for the ceramic tools, but after making some quick feed and speed calculations, Frieze knew they would be an effective solution given the right application. Several months later, that application arrived with the Inconel plates. He called Guillon to say he might have a good use for those ceramic cutters they were talking about, and wondered how soon he could get some. Skeptic to the Last Frieze remained skeptical. He’d tried indexable ceramic cutting tools on both milling and turning jobs in the past and had mediocre results. In this case, however, he was willing to try anything if it meant meeting the customer’s deadline. When Guillon arrived a few days later with the ceramic end mills, Frieze followed Kennametal’s feed and speed recommendations to the letter, crossed his fingers, and pushed cycle start.

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“We weren’t certain what would happen so started out with a block of test material,” he says. “You don’t use cutting fluid with ceramic—only an air blast—and everyone in the shop was crowded around the machine saying, ‘Wow, look at that!’ There was fire shooting everywhere. It was something we’d never seen before. But within the first hour, we knew it was going to work.”

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Enjoying the Heat Best of all, Stellar delivered the parts on time with zero scrap, and is now quoting a second, even larger order. Owner Lori Albright was quite pleased with the outcome. “This type of situation is the nature of our business. We have to react to our customers’ needs and employ the best technology available to do so. That’s one of the reasons why Kennametal is so welcome here. We work together as a team to solve challenges.” Looking forward, Albright anticipates continued growth. Having expanded Stellar’s existing facility six times, she figures it might be time to put up an entirely new building on nearby property. She also looks forward to bringing additional young people to the machining trade. “We have apprenticeship programs with several of the area schools, one of which my father used to teach at,” she says. “I find that it’s often our younger people that drive our innovation. It's too easy to keep doing things the old way and not invest in tooling and equipment, or pursue new technology. The days of high volume, round-the-clock fender clip manufacturing are gone, and it’s only by continually improving their manufacturing processes that companies can succeed and grow. For us, Kennametal is part of that success.” www.kennametal.com


NEWS

INTELLIGENT SENSORS PAVE THE WAY FOR THE INDUSTRY OF THE FUTURE

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

Success for SICK at the Hannover Messe 2016.

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

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

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

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

ready”.

In particular, the exhibit on human-robot collaboration proved to be a major draw, featuring a robot arm which took a glass cup from a visitor. The robot used the RFID tag affixed to the cup to read the individual print job and performed the task by itself. As the station was protected with microScan3 laser scanners, the robot was able to work

The device is the first to be able to measure the movement direction of an RFID tag bearer when read. This means that, in the future, it will be possible to record not only the position, but also the transport path of workpieces with minimal effort. In this way, the current location of a part will always be evident in real time. The eventful week saw a constant stream of visitors to SICK's stand in Hall 8. Employers from the US subsidiary SICK, Inc. were also present in order to honor the close collaboration with the USA as a trade fair partner.

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

www.sick.de

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NEWS

MOTION CONTROL SOLUTIONS FOR ANY MISSION, FOR ANY ENVIRONMENT

Ultra-High Current, Ultra Rugged, Ultra Small Servo Drives.

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leading provider of advanced and cost-effective motion control solutions, will introduce its new world-class motion controller and exhibit a variety of servo drives with advanced networking and high intelligence suited for manufacturing automation and robotics at XPONENTIAL 2016.

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Xponential 2016 will be Elmo Motion Control’s 10th year of exhibiting our latest Motion Control Technology to this ever expanding market of unmanned vehicle systems. From propulsion, navigations and communication of autonomous vehicles in either commercial or industrial and military environments, Elmo Motion Control has been the proven choice of companies in this industry. The solutions we offer range from 10w to 65Kw in power, the broadest offering available today supporting CANopen and EtherCAT Communication Protocols.

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This year, Elmo Motion Control will be highlighting 3 main products, The Gold Bee ,Gold Eagle500 and the Gold Lion. The Gold Bee is our smallest servo drive with the highest power density, 4000w. The Gold Eagle 500 is our newest product being shown which can offer up to 36kw in power (500 amps continuous at 85vdc). Last but not least is the Gold Lion, our multi Axis Motion Controller that provides simple Point-To-Point to complete multi-axis coordinated / synchronized motion with the use of CANopen or EtherCAT communications and uses C, C++, Microsoft .NET, IEC 611313 (PLCopen) to program through our EAS2 programming software tool. www.elmomc.com


NEWS

ALL-NEW 20-CHANNEL TEMPERATURE LOGGER

DATAPAQ TP3 20-channel loggers provide more detailed and higher-quality data to help users save time and boost productivity.

DATAPAQ TP3 for heat treatment, paint-curing, and ceramics processes.

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he new DATAPAQ TP3 data logger provides more measurement channels, connectivity options, and ease of use for profiling and surveying in hightemperature heat treatment applications. With a ±0.3 °C (0.5 °F) accuracy, the all-new logger surpasses the most stringent requirements. “We have worked towards this exciting launch for two years,”states Elie El Choueiry, Furnace and Kiln Product Manager at Datapaq Ltd., Cambridge, UK. “Compared to our previous, successful heat treatment solution TPAQ21, the new DATAPAQ TP3 provides even more detailed insight into high-temperature processes. It is more resilient and includes numerous new features, such as full connectivity including Bluetooth, fully certified TUS capability for AMS 2750E and CQI-9, integrated correction and calibration functions, and flexible charging with multiple battery options.”

The new series comprises 20- and 10-channel loggers that store up to 3.6 million data points. One logger can perform up to ten measurement runs before data download. Thermal and ingress protection have been enhanced to ensure optimal performance in extreme applications, such as vacuum brazing, aluminum solution reheat, and water or gas quench. The DATAPAQ TP3 logger is being released along with new, durable thermal barriers for use with the industry-specific temperature profiling systems from Datapaq: Furnace Tracker® for metal-working, Kiln Tracker® for ceramics, and Oven Tracker® AutoPaq® for premium paint cure processes in the automotive OEM assembly market. Each profiling solution includes Insight™ analysis software and thermocouples tailored to the application. www.flukeprocessinstruments.com MORE INFORMATION 15 | Industry Asia Pacific | July 2016

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

The mould routine maintenance workshop.

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

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

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The moulding workshop The moulding workshop is the core production activity at the Muzillac plant. Twenty-two Engel, Fanuc or Ferromatik injection presses are served by a suspended crane fitted with a 3-tonne VERLINDE EUROBLOC VT hoist for mould changing operations. These presses are used for the moulding of connectors for small pneumatic hoses and for compressed air system couplings in industrial buildings. For the car industry, five presses are dedicated to the production of motor fuel distribution circuits integrated by Parker Autolive in its manufacturing facilities. Mickael Le Pon, injection facility production manager, explains.”We carry out between 300 and 350 parts series changes per month involving just as many injection mould changes. To ensure the moulding workshop works at full capacity it is first of all vital that the moulds are in perfect condition and as their 15 | Industry Asia Pacific | July 2016

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manipulation can only be carried out with the suspended crane, the latter must be totally available and reliable.” Mould routine maintenance, a decisive production factor Mickael Lepon: “Even if our activity is complex, it has to be understood that it is based in the main on two basic equipment units – plastic injection presses and moulds. To ensure production quantity and quality in phase with our targets, we have to ensure without fail regular inspections and routine maintenance of the moulds because we depend to a large extent on them to guarantee the productivity and the manufacturing quality of our products.” A special workshop for mould routine maintenance The 500 m² workshop dedicated to mould routine maintenance consists of three successive square 10 m x 10 m work stations. After a certain number of duty cycles, the mould is removed, cleaned ultrasonically and the toolmaker is sometimes required to recondition the spindles by electroerosion or replace possible faulty parts.


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

Installation of suspended cranes and VERLINDE MONOBLOC VT hoists Before the EUROPONT suspended cranes were installed, a single jib crane served the three work stations. As the manipulation of metallic moulds whose weight varies between 50 and 1500 kg necessitates taking numerous precautions, the toolmakers frequently had their work interrupted while awaiting the availability of the jib crane. It was therefore decided to make each station autonomous with its own suspended crane fitted with two VERLINDE hoists of a lifting capacity of 1.6 tonnes. The three EUROPONT cranes travel on the same metallic structure and to avoid accidental collisions, limit switches guarantee travel safety. Following this new work organization making each work station autonomous, the productivity of the mould routine maintenance shop has risen by 25%. As moulds are made of two parts whose sizes and weights vary, each crane is fitted with two VERLINDE EUROBLOC VT hoists in order to facilitate their manipulation in complete safety.

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

Lifting hook with safety latch.

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The two parts of a mould raised by VERLINDE hoists.

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

VERLINDE, a long-time partner of PARKER HANNIFIN at Muzillac Mickael Lepon: “We have enjoyed a relationship of trust with SERE Maintenance for decades and so quite naturally we called upon them to re-organize our mould routine maintenance workshop. They delivered and installed the cranes and hoists and together we inspected the equipment at reception before testing the strength of the metallic structure under load. Our experience with a varied range of Verlinde equipment led us to install EUROBLOC VT hoists whose reliability meet our requirements with a high level of cost effectiveness. To this can be added the fact that SERE Maintenance is located not far from us making their preventive maintenance service very convenient. In the mid/long term, we envisage installing a second suspended crane in the moulding workshop to be accompanied by a further Verlinde hoist.”

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Sere Maintenance, managed by Ludovic Mathis, is a partner of Verlinde and has been a member of the EUROPONT overhead crane manufacturers’ network for more than forty years. A workforce of fifteen ensures the smooth running of the company’s different activities: lifting operations representing 80% of the company’s turnover, together with an activity involving the cathodic protection of metals, mainly for water, gas and compressed air circuits for industry. A whole range of services are also available to customers, such as lifting and handling equipment maintenance. 15 | Industry Asia Pacific | July 2016

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www.verlinde.com


NEWS

HIGH-TEMPERATURE PYROMETERS FIT FOR HARSH ENVIRONS

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

Fluke Process Instruments introduces the Endurance series of high-temperature infrared thermometers. Featuring a stainless steel IP65 housing and galvanically insulated I/Os, these units enable continuous process monitoring of the most demanding industrial applications, including primary and secondary metals manufacturing, carbon processing, and silicon production.

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roviding a measurement resolution of 0.1 °C, they also meet the requirements of the semiconductor industry. Two models cover wide measured temperature ranges of +550 °C to +1,800 °C and +1,000 °C to +3,200 °C, respectively. They can be operated in one- or two-color (ratio pyrometer) mode. An optical resolution of up to 150:1 allows measurements of smaller objects from a distance.

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

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

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NEWS

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

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

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

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

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Pelloby prides itself on being the UK’s leading jib crane manufacturer and was therefore able to produce a fast and accurate quotation for this rotating jib crane, while tailoring every aspect of it – from the power slewing operating system to the choice of hoist and paint colour – precisely to the client’s requirements. The company was also able to provide detailed renderings and drawings of how the finished system would look during both the quotation and design phases. The EUROBLOC VT electric wire rope hoist earnt its selection for the project due to a host of end user benefits. For instance, it is the only hoisting unit with wire rope and a 15 | Industry Asia Pacific | July 2016

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hook that offers in its standard version the market’s smallest hook approach ‘C’ dimensions and ‘F’ approach distance. In addition, the pulley block minimises lateral shift during hoisting, while EUROBLOC VT hoists also offer users the possibility of adjusting speed while travelling. Further attributes include enhanced safety, ergonomic and easeof-maintenance features. Pelloby oversaw all stages of the project at Yarmouth Harbour, from manufacturing the various parts of the system at its production plant in Telford and delivering the crane to the Isle of Wight via a trusted logistics partner, through to installation and final commissioning to guarantee its safety and suitability for use. It is operated via an easy-to-use handheld radio control system which governs the jib arm rotation, the longitudinal travelling motion, and the movement of the VERLINDE EUROBLOC VT hoist and carriage. www.pelloby.com

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NEWS

PCVUE INTRODUCES PROXIMITY-BASED CONTEXTUAL MOBILITY FOR SCADA

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

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

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

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


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

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Profile for Induportals Media Publishing

Industry Asia Pacific 15  

Industry Asia Pacific is the portal for Asia technical engineers.

Industry Asia Pacific 15  

Industry Asia Pacific is the portal for Asia technical engineers.