Industry Asia Pacific 17

17 | N O V E M B E R 2 0 1 6

Industry

Asia Pacific THE INDUSTRY MAGAZINE FOR ASIA

ACURO® AX73 COMPLETES HENGSTLER’S RANGE OF ATEX-RATED ABSOLUTE ROTARY ENCODERS

14 AVAILABLE NOW: EPLAN SMART WIRING “THAT’S CERTAINLY EASY”

22 NORD SEVERE DUTY PERSEVERES

32

MAYR PNEUMATIC SAFETY BRAKES WITH THE SAME POWER AS HYDRAULICS

28

17 | Industry Asia Pacific | November 2016

THE INDUSTRY MAGAZINE FOR ASIA

ESPRIT

TYCO GFD

4

6

DE DIETRICH PROCESS SYSTEMS

7 LEROY-SOMER CONTROL TECHNIQUES

HAINBUCH

8

KENNAMETAL

12

10

HENGSTLER

ASCO

KOLLMORGEN

14

16

18

BALLUFF

EPLAN

21

22

HMS INDUSTRIAL NETWORKS AB

24

STAHL

FIM

MAYR

25

26

28

WIDIA

NORD

30

32 ADVERTISERS: MEPAX 37

www.industry-asia-pacific.com

INSPECTORATE - BUREAU VERITAS

35

SCOTT SAFETY - TYCO

36

Contact: Long WEI Editor in Chief: editor@industry-asia-pacific.com Send your press releases to: editor@industry-asia-pacific.com To receive Industry Asia Pacific magazine free of charge, please subscribe online at www.industry-asia-pacific.com Industry Asia Pacific is the English-language magazine for engineers, published by IPM (Industrial Portal Media) It contains the latest product and company news for industrial markets.

Industry Asia Pacific edits its articles with the greatest of care, however we cannot guarantee the accuracy of the information presented in them. Our teams disclaim all responsibility concerning the content of this media or how it might be used.

INDUSTRIAL

PORTALS MEDIA

NEWS

DP TECHNOLOGY CONTINUOUSLY FORGES PARTNERSHIPS WITH ACADEMIA TO ACCELERATE SMART MANUFACTURING

DP Technology along with the College of Electromechanical Engineering at Beijing Union University and the Beijing Intelligent Mechanical Innovative Design Engineering Research Center hosted the ESPRIT CAM & Smart Manufacturing seminar on September 22, 2016.

The ESPRIT CAM & Smart Manufacturing seminar hosted by DP Technology in Beijing, China on September 22, 2016 was a great success.

D

MORE INFORMATION

P Technology joined the College of Electromechanical Engineering at Beijing Union University and the Beijing Intelligent Mechanical Innovative Design Engineering Research Center to host the ESPRIT CAM & Smart Manufacturing seminar in Beijing on September 22, 2016. The seminar brought into focus the most critical manufacturing topics in China today in order to better support the ten-year national plan, Made in China 2025.

The Made in China 2025 program promotes the transfer into smart manufacturing, improves applications in smart manufacturing and fosters the next generation in a wide array of manufacturing industries. The event was attended by more than 60 people from local manufacturing companies, universities and members of the press. The seminar was a joint speaking engagement for outstanding businessmen and technicians. It featured many topics to support attendees and ESPRIT users on their path to success, including Industry 4.0, smart manufacturing, manufacturing automation and the partnership between industry and academia.

Guang Cheng, Dean of College of Electromechanical Engineering of Beijing Union University, addressed the current status and major trends in the future of

17 | Industry Asia Pacific | November 2016

4

smart manufacturing from historical, conceptual and practical aspects. Mr. Cheng stated that the College of Electromechanical Engineering is committed to developing high quality application engineers with an international point of view. He also stated that, “We would like to facilitate cooperation with DP Technology to further the development of smart manufacturing. The current research focus of Beijing Intelligent Mechanical Innovative Design Engineering Research Center covers a wide range of smart manufacturing technologies, including prototype design and manufacturing, human-machine interaction and usability testing, and smart manufacturing and service.”

“With more than thirty years’ experience, ESPRIT CAM is the only software which is capable of supporting B-axis multitasking, 2-5 axis milling, 2-22 axis turning and 2-22 axis, Wire EDM and offers a platform which gives users customized solutions through any object-oriented programming language. With customers across the world, ESPRIT CAM has been applied in a wide range of industries, including aeronautics and astronautics, automotive, industrial machinery, education, medical machinery, energy and so on. In order to provide better service to customers, DP Technology operates sales and technical support centers in

NEWS DP Technology application engineers provided training in ESPRIT CAM programming

Mike Lauer, General Manager at DP Technology Asia Pacific, explained how ESPRIT CAM supports the Made in China 2025 plan.

Guang Cheng, Dean of the College of Electromechanical Engineering, addressed the current status and future trends of Chinese manufacturing.

multiple locations: Beijing, Tianjin and Guangzhou in order to provide high performance professional and efficient services. DP Technology also adds value to education in China as a part of their ongoing commitment to support the ‘Made in China 2025’ plan. For many years DP Technology has partnered with higher education institutions, technical middle schools, technical high schools, and technical colleges. DP Technology works hand in hand with local schools and colleges to create certification and training centers and to help build the education revolution in China.

DP Technology will be an official and major sponsor of the 7th National Vocational Students Skills Competition- CNC machining contest and will also provide technical support at the event. To sponsor the biggest machining contest in China, DP Technology is taking a proactive approach in engaging with the stakeholders in these industries, but also shows the capability and determination to support the Made in China 2025 plan “, said Mike Lauer, General Manager at DP Asia-Pacific.

David Zhang, Vice General Manager for DP China, presented ESPRIT to the Chinese audience.

has always been committed to being the world’s leading CAD/CAM technology to college educators and students, specifically when multi-tasking machining with high-speed cutting. Introducing CAD/CAM technologies also helps provide high-end technical personnel to the industry. While we have been in this game for a long time, we will never stop learning and improving upon our cooperation with academia.” said David Zhang.

Cliff Ji also shared several benefits of ESPRIT CAM in the seminar.

1. ESPRIT CAM offers customized solutions for any type of machine tool to cut parts with any shape of geometry 2. ESPRIT CAM provides edit-free post processors with accurate G-code 3. ESPRIT CAM’s full machine simulation prevents machines from collisions 4. ESPRIT CAM is a cloud-enabled CAM to simplify the selection of cutting tools and automatically obtain the recommended ones.

In the seminar, application engineers from DP Technology also demonstrated ESPRIT CAM’s multi-tasking and 5-axis capabilities with ease to allow attendees to experience the power of the innovative ESPRIT CAM software.

The manufacturing industry has evolved into a new generation with automation, numerical control and smart manufacturing. DP Technology continues to improve their technologies by watching new cutting edge developments in the manufacturing industry, fulfilling customer requirements, and providing innovative solutions to improve product quality, productivity and reduce production cost.

MORE INFORMATION

In the seminar, David Zhang, vice General Manager in DP China, and Cliff Ji, sales engineer in DP North China also shared the most up to date CNC technology in ESPRIT CAM. “With a continuing thirst for new technology in the modern industry, CNC manufacturing has become popular in many areas. ESPRIT CAM is able to provide a complete package for customer’s manufacturing solutions in many different industries. In addition, ESPRIT CAM is compliant with IoT and the Industry 4.0 initiative. In this way, ESPRIT CAM not only provides users a new concept of automatic machining but also reduces the programming time with easy operations for high quality parts. As a global CAD/ CAM company, DP Technology believes that through the cooperation with educational institutions, they have the power to improve manufacturing in China. DP Technology

Cliff Ji, Sales Engineer in DP North China, shared several benefits of ESPRIT CAM.

www.espritcam.com 17 | Industry Asia Pacific | November 2016

5

NEWS

ITRANS 2 FIXED GAS DETECTOR OFFERS UP TO 2 POINTS OF DETECTION FROM A SINGLE DEVICE

Tyco Gas & Flame Detection is pleased to introduce the iTrans 2 fixed gas detector featuring a unique intelligent electronics platform that provides up to two points of detection from a single device.

T

his state-of-the-art gas detector is able to monitor a combination of gases using a combination of available sensor technologies to include electrochemical, catalytic bead, and infrared. The iTrans 2 boasts a wide range of safety features including automatic sensor recognition, access code security, and zero and calibration fault protection. A single or dual-channel, split screen LED display provides optimal visibility in dark places with operator interface made simple using a magnetic wand.

MORE INFORMATION

Available in aluminum or stainless steel enclosure, the explosion-proof device is designed for use in a wide range of applications and harsh environments. Other options include HART communications protocol, RS-485 Modbus, programmable relays and remote sensing. Certifications include CSA, ATEX, IECEx, INMETRO, CCC and China Ex. For more information visit www.TycoGFD.com

17 | Industry Asia Pacific | November 2016

6

NEWS

THE VERTICAL DRYER IS AN ADVANTAGEOUS ALTERNATIVE TECHNOLOGY

This new solution from De Dietrich Process System adds an important benefit for drying of powders in process industries, cosmetics and food. Recently, the GueduÂŽ vertical dryers have been installed by several clients, providing decisive quality and productivity improvements.

Short cycle times, reduced handling The vertical dryer is unlike hot air dryers and tray dryers. The powder is stirred under vacuum, that allows an improvement of the drying time by a factor 2 to 10 compared to tray dryers, and a total cycle time reduction by a similar ratio (by reducing the necessary handling). In fact, the vacuum drying technology allows savings due to the total cycle time reduction (a single pan dryer can replace several tray dryers) and also savings from the improved heat transfer during drying (reducing utilities costs).

To assist in the choice amongst its various drying equipment, De Dietrich offers to perform trials in its test hall in Semur, France. www. .com/en/solutions-and-products/vacuum-dryingsolutions/pan-dryer

Pristine quality The mechanical mixing during drying improves product homogeneity. Therefore, at the end of the cycle, the product comes out perfect evenly dried, with residual moistures below 0.1% where required.

MORE INFORMATION

A ready-made Solution De Dietrich Process Systems is able to supply its customer not only with the appropriate drying technology, but also to design and supply the peripheral equipment, support structure as well as the automation and control systems.

17 | Industry Asia Pacific | November 2016

7

NEWS

TOPLUS IQ CLAMPING CHUCK WINS THE “MM AWARD” FOR INNOVATION AT AMB 2016

The Toplus IQ chuck scored high ratings in all categories.

After receiving the “100 places for Industry 4.0” award last May, from the Baden-Württemberg Industry 4.0 Alliance, for two manufacturing/networking solutions, Hainbuch, has now scored a second success in 2016.

A

MORE INFORMATION

t the AMB exhibition, the newly-developed intelligent Toplus IQ clamping chuck won the MM Award for innovation. A large number of AMB exhibitors were in the competition for the innovation prize. In the clamping device category, an 8-member jury had the task of selecting a winner from three finalists, and Hainbuch's chuck emerged victorious. The jury praised the pioneering spirit and the exceptional engineering performance of the family-run company from Marbach.

The chuck scored good ratings in all the decisive criteria, including degree of technical innovation, usefulness for industry, environment and society, and economic efficiency.

“Innovation is when the customer says »Wow«. And it seems like we got that reaction from the jurors”, said CEO Gerhard Rall smiling joyfully after the award. “In the past, not to put too fine a point on it, it was all about iron and steel, but now mechatronics and digitalization play a very important role in product development”, explained Rall.

17 | Industry Asia Pacific | November 2016

8

A chuck with exceptional capabilities With its sophisticated integrated sensor technology, it permanently measures the actual clamping force applied to the workpiece. Using contactless transmission of both data and energy, measurement results are sent directly to the machine´s control system for processing. The control system performs a comparison with the target values and then outputs messages or makes adjustments as required.

In-line checking of the dimensions of each workpiece when it is clamped can even be performed directly using an integrated system of measurement sensors. The temperature near to the workpiece is also monitored to allow temperature compensation for example.

Data produces big pay-offs Using the data harvested by the control system, it is possible to perform long-term monitoring, so-called »Condition Monitoring«. Condition monitoring has two objectives: safety and machine efficiency. Monitoring the status of the machine is a mandatory prerequisite for need-oriented and status-oriented preventive maintenance and servicing.

Modern condition monitoring systems however put very tough requirements on the sensor systems, data capture and automated measurement data processing, as well

NEWS

A happy and visibly proud Gerhard Rall holds the award in his hands [from left to right: Attillio Mandarello, Research & Development Manager at Hainbuch, Sebastian Ivenz, Research & Development Engineer at Hainbuch, Anke Reichenecker, Marketing Manager at Hainbuch and Gerhard Rall, Hainbuch CEO.

as system specific knowledge. However they also have the greatest cost savings potential, because the expected working life of critical machine parts can be exploited to the maximum while any required maintenance interventions can simultaneously be planned to mesh in with production schedules. This makes it possible to prevent unnecessary downtime which in turn increases machine availability and reduces production shortfalls. It is good for the bottom line because the chuck can detect reject parts. For example if a workpiece breaks, it is discarded and the value-adding process is interrupted.

This improves quality and reduces personnel costs. As a result, employees can focus more on proactive tasks.

Permanent monitoring reduces the risk of workpiece loss and the resulting damage to man and machine. And that is a very significant advantage. www.hainbuch.com

MORE INFORMATION 17 | Industry Asia Pacific | November 2016

9

NEWS

AC/DC DRIVES FROM CONTROL TECHNIQUES GIVE CRANE OVERHAUL SPECIALIST A LIFT

A US-based specialist in the supply of complete electrical packages for oil rig cranes is using Control Techniques AC and DC drives as part of a landmark $500,000+ order involving the upgrade of 10 LeTourneau cranes.

T

hree cranes have already been completed with no reported down-time in the first 18 months of operation, whereas prior to the upgrade, maintenance would be required on a weekly or even daily basis in some instances. The financial benefits for the oil rig operator are proving substantial.

Headquartered in League City, Texas, JC’s Marine Oilfield Services was established in 1992. The company’s Power & Distribution Division specialises in a variety of motor control solutions that are customised to match the needs of oil rig cranes, as well as drilling barges, supply vessels and land rigs.

MORE INFORMATION

When a Texas/Louisiana-based customer was seeking an electrical contractor to help upgrade the drive systems on 10 LeTourneau oilfield cranes, JC’s Marine Power & Distribution was in prime position to secure the order thanks to its technical support and AC/DC capabilities. As a long-standing advocate and user of drive technologies from Control Techniques, the company proposed the use of a Unidrive SP AC variable speed drive for the boom, and two Control Techniques Mentor MP series DC regenerative drives for the swing and hoist.

17 | Industry Asia Pacific | November 2016

10

“The technical advice offered by Control Techniques is one their best selling points,” stated John Costanza, President at JC's Marine Oilfield Services. “Their technicians always address problems quickly and comprehensively, which means a lot to a business such as ours, and is certainly better than we have experienced elsewhere. We exclusively use Control Techniques drives on our projects, ranging from 75 to 750kW, both AC and DC.” Around 1600 LeTourneau cranes are currently in service on oil and gas rigs around the world. Although they were originally fitted with large motor-generator sets, these do not offer variable speed, meaning there is total reliance on the skill of the boom operator to lower heavy loads.

“By changing to a Control Techniques variable speed drive for the boom we can ensure complete control over the speed and rate at which the boom moves, so that loads up to 50 tons are ‘feathered’ rather than ‘banged’ to the ground,” said Mr Costanza.

The boom motor drive system comprises an SP5402 Unidrive variable speed AC drive rated at 210 Amps continuous, while the hook motor drive system features a

NEWS

Mentor MP420A4R DC drive rated at 420 Amps continuous.

A Mentor MP210A4R, rated at 210 Amps continuous, is fitted to the swing motor drive system. All of the drives are purposely sized for twice the normal power required, which means the system never runs at its maximum capacity.

“I’ve been operating with the new system for 12 months and have not had one issue,” said Justin Hillard, LeTourneau crane operator on Atlantic 7 rig. “The controls are user friendly, very smooth and have a wide variable speed in hook, swing and boom. In my opinion the boom is the biggest operating improvement. With its variable speed you can ease into boom and keep the load stable and personnel safe on deck.”

Jason also praised the increased safety afforded as a result of the new system: “The crane is also much quieter without the motor-generator sets running; you can hear what the crane is doing and what’s going on around you. I’ve also noticed that if you’re in a position where you cannot see the hook, you can actually hear the hook motor running and know how fast the hook is travelling. I highly recommend this system, it’s safer, smoother, quieter and virtually maintenance-free.”

David Powers, fellow LeTourneau crane operator on Atlantic 7 rig, also likes the new control system, which carries a Certificate of Design Conformance from the American Bureau of Shipping (ABS): “The new system gives the crane a better parameter of operation and is more responsive. Most importantly, these changes have made a much safer work environment.”

“Braking is automated, which promotes safety and takes responsibility away from the operator,” added Mr Costanza.

“Also, there is better reliability as the load is not being »snatched«” Further benefits delivered to the end user as a result of AC and DC drive technologies from Control Techniques include conformal coating on the PCBs, which helps impart protection in marine environments, while the large working temperature range is also advantageous.

The project to complete the upgrade of the 10 LeTourneau cranes will continue through to the end of 2017. www.emersonindustrialautomation.com www.emerson.com

MORE INFORMATION 17 | Industry Asia Pacific | November 2016

11

NEWS

PCD PERFORMANCE

KBDM PCD inserts are available in a variety of sizes. Here, a mini-tip suitable for finishing cuts is shown.

Automotive aluminum has met its match with the new KBDM face milling platform from Kennametal.

A

nyone who’s replaced a head gasket on an internal combustion engine knows a smooth, flat surface on both cylinder head and block is needed for proper operation. No one understands this better than automakers, who strive for predictable, controlled surface finishes and high production output, together with maximum tool life and the lowest tooling cost per machined component.

MORE INFORMATION

Many machinists might think, “What’s the big deal?

Aluminum is one of the easiest materials around.” And while that is certainly true of the ubiquitous 6061-T6, nothing could be further from the truth when it comes to the aluminum alloys used in automotive applications. Grades 319 and 390, for example, are readily cast into the complex shapes needed for engine blocks, pistons, heads, pulleys, and similar parts, but due to their high silicon content— easily 20 to 30 times that of 6061—they’re like cutting sand.

Fortunately for those charged with machining these abrasive metals, there’s a better alternative than carbide cutting tools, one that produces mirror finishes and produces tens of thousands of parts per edge.

“Finishes of 2 to 3 μm Ra are easily obtainable, as is tool life between indexing of 40,000 engine blocks, cylinder heads, and other automotive components,” says Tim Marshall, Senior Global Product Manager for Indexable Milling at Kennametal. “This new face milling platform uses a fine-pitch aluminum body with wedge-style clamps and adjustable pockets. A variety of polycrystalline diamond (PCD) inserts are available, from mini-tips for light finishing cuts to full face wipers, standard cartridge inserts, and 1/2 in. (12.7 mm) axial cutters for heavy roughing and shoulder cutting.”

He’s talking about the KBDM PCD face milling system from Kennametal. Designed for high-volume machining, the KBDM is stocked in standard sizes of 2.5 - 8.0 in. (63 - 200 mm), although Marshall is quick to point out the company’s custom solution capabilities. “We can offer cutters up to 21.5 in. (550 mm) in diameter. This allows customers to machine very large components in a single pass. We also have options for integral shank bodies, HSK mounting, left hand cutter rotation, as well as special edge preps and nose radii.”

There’s more to the KBDM than a robust body design, however. Since automakers often create their own

17 | Industry Asia Pacific | November 2016

12

NEWS

KBDM cutters are stocked in standard sizes of 2.5 - 8.0 in. (63 - 200 mm), although specials up to 21.5 in. (550 mm) in diameter are possible.

proprietary aluminum alloys, Kennametal has developed two PCD grades to complement it: KD1400 uses small diamond grains and offers excellent chipping resistance and good wear attributes, while KD1425 uses large diamond grains, giving it excellent abrasion resistance and thermal stability but only slightly lower performance where chipping is a concern. Both are capable of very high cutting parameters—depending on the alloy and setup rigidity, Kennametal recommends an initial cutting speed of 3280 ft/min (1000 m/min) and feedrates of .004 in. per tooth (0.01 mm), although substantially higher values are possible.

“A major machine builder conducted cutting tests for us against several competitive solutions,” Marshall says. “Using a 24-tooth, 6.0 in. (150 mm) diameter face mill at 80% radial engagement and 0.04 in. axial DOC (1 mm), we ran at a feedrate of 0.006 in. IPT (0.15 mm) and 9600 ft/min surface speed (2926 m/min). This comes out to 6112 rpm, with a table feed of 880 IPM (22,350 mm). It was really moving.

Even so, the KBDM produced a 14.7 Ra surface finish, several points better than the other cutting tools.”

to its final height position. If using a wiper insert, set it 0.0006 - 0.0008 in. (0.015 - 0.020 mm) higher than the rest.

“It’s simple to set up,” Marshall says. “You can easily get everything within a couple microns. That's one of the keys to successful face milling, not only for proper balance at high spindle speeds but also for achieving the desired surface finish—when you're finishing a deck face on a block or head, both are critical.”

Adjusting the KBDM is a straightforward process—use an optical presetting device whenever possible, and DON’T OVERTIGHTEN! www.kennametal.com

MORE INFORMATION

Marshall recommends presetting the KBDM offline using an optical or video style presetter. A small amount of lubricant should be applied to the adjustment and locking screws, and also the wedge side of the pocket. Turn the axial adjustment screw until the insert is 0.0004 - 0.0006 in. (0.010 - 0.015 mm) below the final set height, tighten the locking screws to 31 in/lb. (3.5 Nm)—don’t overtighten—then adjust each insert 17 | Industry Asia Pacific | November 2016

13

NEWS

ACURO® AX73 COMPLETES HENGSTLER’S RANGE OF ATEX-RATED ABSOLUTE ROTARY ENCODERS

The new Hengstler ACURO® AX73 is ideal for ATEX-rated applications demanding precision or smooth speed regulation.

The new Hengstler ACURO® AX73 is a class-leading optical encoder offering attributes such as ease of installation, high precision and compact dimensions. In addition, the introduction of the AX73 completes the company’s comprehensive family of ATEX-rated absolute rotary encoders, both optical and magnetic.

Equipment designers now have an unprecedented choice for a host of hazardous environment components.

MORE INFORMATION

I

n the development of equipment for use in hazardous environments, selecting the right encoder is vital. Here, explosion protection is the first consideration, which is why the Hengstler ACURO-AX73 carries ATEX and IECEx certification for gas and dust explosion proof requirements.

However, this advanced optical encoder offers many more features of specific benefit in applications such as winches, cranes, drills and other oil and gas industry equipment, as well as at paint plants, petrochemical facilities, bottling plants and grain mills, for example.

final encoder installation to be done in separate steps. This provides significant cost and time savings during installation, as cabling can be done in advance. Emergency servicing can also be completed more quickly, resulting from the ability to simply unplug the cable and connect it to the replacement encoder. Since many oil and gas platforms use heavy and cumbersome cables measuring 40m in length or more, the design of the AX73 represents an attractive proposition for customers looking to lower their total cost of ownership (TCO).

Among the principal advantages is the connection concept of the AX73, which allows the routing of cabling and the

Another ease-of-maintenance innovation is the use of just two screws for the connection hood. Many comparable encoders use six or even eight screws, while insufficient corrosion protection makes such units very difficult to uninstall. Instead, special patented screws are deployed on the AX73 to protect against dust, water and corrosion.

17 | Industry Asia Pacific | November 2016

14

NEWS

The introduction of the AX73 completes the family of ATEX-rated absolute rotary encoders from Hengstler.

Inherent precision is a further beneficial characteristic of the ACURO® AX73. The optical scanning system provides a highly accurate, 22-bit resolution sensor signal for wherever precision or smooth speed regulation is necessary. However, despite its accuracy, the encoder is of robust design, with impressive resistance to shock, vibration and external magnetic fields. In addition, the unit provides users with IP67 protection class rating for the stainless steel housing, and offers an Ex-related ambient temperature range of -40 to +70°C. Although the AX73 is seen as the ‘big brother’ of the AX65 introduced by Hengstler last year, with a housing diameter of 76 mm it is still smaller than comparable competitor products. This will prove extremely valuable to system designers seeking space-saving solutions. Available immediately, the AX73 can be ordered with SSI, BiSS-B, BiSS-C and Profibus interfaces.

MORE INFORMATION

The introduction of the AX73 now completes Hengstler’s ACURO®-Xproof absolute shaft encoder line. The new AX73 and AX65 offer the special mounting system, while also available are the AX70 and AX71 absolute encoders, as well as the RX70 and RX71incremental variants, with integrated cable. www.hengstler.com

17 | Industry Asia Pacific | November 2016

15

NEWS

EOVE VENTILATORS GIVE PATIENTS BACK THEIR MOBILITY

EOVE revolutionizes the market by significantly reducing the weight of its life-saving ventilators. ASCO is proud to have contributed to this improvement.

E

OVE designs, manufactures, and markets medical and surgical devices used during home care. Launched in 2015, the EO-150 has a big advantage over its competitors. Weighing just 1.8 kg, it is the lightest ventilator on the market and allows patients greater mobility. “The EO-150 is designed mainly for patients with serious medical conditions, many of whom use a ventilator 24/7,” explains Fabien Cotteaux, founder of EOVE. “Mobility is not just a convenience, it is also a reason for living. Patients who are active and mobile live longer and have undeniably better social relations”.

MORE INFORMATION

“The ASCO solenoid valve is an essential component of our ventilators,” says Mr. Cotteaux. “This is because it meets a twofold need – it contributes to controlling a complex process and is light enough to ensure that our ventilators remain portable”.

Expiration is achieved by a pneumatic valve on the patient circuit that is controlled by ASCO's PreciFlow IPC solenoid valve. The unit operates in a closed loop via various sensors.

Control is achieved by varying the current and the function was entirely programmed by EOVE. “The first thing we wanted was a solenoid that could combine high-precision control with high repeatability. We contacted our regular partner, ASCO, which immediately proposed a solution that proved to be ideal due to its progressive opening and excellent repeatability,” says Mr. Cotteaux.

ASCO's PreciFlow IPC proportional solenoid valves are especially suited to medical and industrial analysis applications, in particular medical ventilators and mass flow controllers. The core of these solenoid valves is held in the core tube between two specifically profiled flat springs to completely eliminate friction and offer excellent control performance with a hysteresis of less than 5% and a repeatability and sensitivity of less than 1%.

“In terms of the EO-150's portability, ASCO was the only company to come up with an adequate solution. Unlike

17 | Industry Asia Pacific | November 2016

16

NEWS

during the tests we conducted with the competitors' valves, the PreciFlow IPC does not overheat, control and reliability are not affected, and the consumption is extremely reasonable,” says Mr. Cotteaux.

www.asco.com/en-gb

The EO-150 consists of a portable module with six hours of battery life and a docking station. The module can be safely be removed from the docking station for easier portability.

It is also networked, making it possible to obtain data remotely.

MORE INFORMATION

The Series 202 PreciFlow IPC (Inlet Pressure Compensated) solenoid valve proportionally controls the flow of air. This innovation enables high pressures and flow rates with a lowenergy coil (2.5 W max.). Although compact, it offers a high variable flow rate (190 l/min at 2.6 bar) without a minimum operating pressure. The PreciFlow IPC is available in 2/2 NC function with a 3 mm orifice and can be used over a pressure range of 0 to 7 bar with a maximum inlet pressure of 10 bar.

The valves were delivered to EOVE in order to immediately meet the requested function of being fitted with an adequate connector with a specific cable length.

“Since being launched in 2015, more than a thousand EO150s are in use. There have been zero reports of failure, which is crucial considering what it the EO-150 is used for,” says Mr. Cotteaux. These devices meet stringent safety standards and bear the CE marking for medical devices.

17 | Industry Asia Pacific | November 2016

17

NEWS

FOR AUTOMATED DECORATION CDDR DIRECT DRIVE AND AKD PDMM MOTION CONTROLLERS FOR ACCURATE LACQUERING OF SCREW CAPS

View of Todema COLTAL machine for printing and decorating screw caps and cages for the beverage sector.

A fully servo-driven machine that can be used for various types of printing and lacquering. The machine has the capability to increase production whilst retaining high quality: today Todema meets the goal – Thanks to CDDR direct drive motors and to the KOLLMORGEN AKD PDMM motion controller.

T

MORE INFORMATION

odeschini Mario Srl company, known by the brand name Todema (www.todema.it), was founded in 1960 in the province of Lecco and, since then, has acquired expertize in the manufacturing of industrial machinery and in the implementation of evolved automated systems. These automated systems include machines for the production of capsules,cages for bottling wine and other liquids, bending machines, lamination and printing systems, systems for the production of electro-welded chains, packaging systems and lines for the household appliances industry, as well as control systems that can be integrated in woodworking. The client portfolio ranges from a number of different industries, from the food sector to the metal and woodworking industry, and from different countries including Italy, Germany, Spain, USA, Argentina, Australia and New Zealand.

During the past few years, the design and programming of automated and robotic lines has given a strong boost to the industrial processes covered by Todema.

17 | Industry Asia Pacific | November 2016

18

“For this project, we contacted Kollmorgen because we needed to develop a system for colouring and printing screw caps for bottling wine and spirits. Our client required highquality and production standards concerning rotogravure colouring, tampography, silk screen and hot foil printing.

Our objective was to build a fully servo-driven machine, which was going to be a first of its kind in this sector,” Ing. Giovanni Todeschini, owner and Chief Technical Officer, explains.

The biggest challenge was to replace the traditional mechanical systems of our machine with mechatronic systems in order to obtain a new type of machine, which would be highly versatile and configurable by the client depending on their production needs. It was necessary to develop an integrated mechanical and electronic control system, achieving a seamless combination of the two engineering aspects. More specifically, the Todema design team, consisting of mechanical and electronic engineers, had to work quickly and systematically with KOLLMORGEN experts from the very first drafts of the project.

NEWS

In the fully servo-driven Coltal machine, the table control takes place by means of the Cartridge DDR motors, which are controlled by AKD drives. One of the advantages is the considerable increase in the production speed. The high quality of printing and embossed lacquering is noteworthy.

Coltal machine Aluminium screw caps are largely used for bottling spirits, mineral waters, oil and most recently wines too. Todema provides COLTAL for the lacquering of cylindrical objects and capsules: lacquering and silk screen printing or embossing, from video, hot foil or tampographic with very high visual quality. COLTAL is effective on various materials, such as Tin, Aluminium, Plastic and Poly-laminated materials. An integrated servo-driven system fully controls the machine operation ensuring a check of the result even with variable or unforeseeable conditions, such as the different quality and level of deformation of the materials, the type of friction or the difference in dyeing.

AKD PDMM: motion controller, PLC and servo-drive in a single device The process is controlled by a smart AKD PDMM system with integrated PLC and motion control for the development of a virtual master for the generation of the main reference, and electronic cams for the positioning and motion sequential control. This key development, which has led to a great reduction of costs in terms of hardware and installation, as well as space needed in the electrical cabinet (up to 30%) and wiring reduction, was made possible due to the cooperation with KOLLMORGEN from the very first steps of this project.

The AKD servo amplifier combines innovative technology and outstanding performance within very small dimensions.

These servo amplifiers with multiple features provide solutions for nearly any application, from basic torque and speed control, to register control, through to fully programmable multi-axis applications with embedded Kollmorgen Automation Suite™.

MORE INFORMATION

High performance in a small space: Direct Drive Cartridge DDR servomotors In order to check the exact positioning of the two spindleholding tables without further mechanical parts, 2 Direct Drive Cartridge DDR servomotors are used together with the related AKD drives. Such motors allow a direct control of the motion, thus eliminating all the mechanical transmissions that used to generate too much elasticity in the motion. In order to ensure the required precision, a direct-drive motor system was needed. Cartridge motors are the quickest and simplest solution to implement.

The quality of printing and embossed lacquering depends on the precision and accuracy of the machine movements, which are provided by the torque motors and the related Kollmorgen control systems. The disposal of the mechanical

transmission systems has considerably reduced the frequency of maintenance operations,need for spare parts and ease of maintaining the overall machine accuracy level over time.

Universal AKDs set the standards for efficiency and power density. The ADK series has been designed with the versatility, connectivity and power needed to increase the 17 | Industry Asia Pacific | November 2016

19

High performance in a small space: Direct Drive Cartridge DDR servomotors.

NEWS

Multi-programmable motion controller: Integrated IPC, AKD D, fully programmable.

machine performance as well as the speed of integration.

The motor setup mainly occurs through plug-and-play and offers a wide range of feedback. Among the various possibilities of Ethernet connection, options for both open and closed protocols are available. Online diagnostics and the data verification enable faster and error-free programming. A wider power range, enclosed in a compact design, allows you to use these robust drives with a single interface.

“Our client’s objective – Todeschini recalls – was a machine with a production of approximately 60/70 pieces per minute.

We largely exceeded that target”.

MORE INFORMATION

Recap “Our clients are highly satisfied with COLTAL – Todeschini points out –, the quality standards have been fully met and the production targets have exceeded our expectations by 15%. Kollmorgen staff worked with us painstakingly and quickly to ensure that the components that we used were highly reliable and high-performing. Our initial objective has been fully achieved and in fact we have highly exceeded our expectations particularly in terms of accuracy and quality”.

17 | Industry Asia Pacific | November 2016

20

Direct Drive Cartridge DDR servomotors www.kollmorgen.com/en-gb/products/motors/directdrive/cartridge-c-and-ch/cartridge-ddr/ AKD PDMM www.kollmorgen.com/en-gb/products/drives/servo/ akd-pdmm/akd-pdmm-programmable-drive-multi-axismaster/ AKD servo amplifier www.kollmorgen.com/de-ch/products/drives/servo/ akd/akd-ser voverstärker/?utm_source=pr&utm_ campaign=press-release-ch www.kollmorgen.com

NEWS

MORE EFFICIENCY AND FLEXIBILITY IO-LINK SENSOR/ ACTUATOR HUB WITH EXPANSION PORT

IO-Link actuator/sensor hubs from Balluff feature eight ports for 16 in-/outputs.

T

hey allow for example signals from up to 16 switching sensors to be collected from a distance of up to 20 m so that they can be made available to the machine controller via IO-Link and an IO-Link master using a simple 3-conductor cable. Brand new in the market are versions with an expansion port.

Here Slot 7 can be reconfigured as an expansion port by means of a simple parameter entry. A complete valve plug or an additional sensor hub can be connected to it. For the user this means a significant gain in flexibility and efficiency.

Now it is possible not only to cost-effectively process additional in- and outputs, but also expand the range to a circle of another 20 m. Thanks to plug-and-play and the use of unshielded standard cables, the system can be started up in no time at all. www.balluff.co.uk

MORE INFORMATION 17 | Industry Asia Pacific | November 2016

21

NEWS

AVAILABLE NOW: EPLAN SMART WIRING “THAT’S CERTAINLY EASY”

Introduced at the Hannover Messe – and now available: Eplan Smart Wiring software opens up new potential for wiring switchgear systems. This system is easy to use since the technical switchgear knowledge is anchored within the system. It also enables better weathering of personnel shortages. Solutions provider Eplan is forging new technical pathways with this software, which can also be used on mobile devices: the system is being made available free of charge for up to four months.

E MORE INFORMATION

plan Smart Wiring software has been available for customers since early September, opening up completely new perspectives for wiring switchgear systems. The most important highlight is the system’s simplicity: the clearly arranged, touch-optimised user interface is suitable for mobile devices and is therefore always ready for use directly at the control cabinet.

17 | Industry Asia Pacific | November 2016

22

Furthermore, the specific expertise is just as important, but now instead of being stored in people’s minds it is instead anchored within the system. Step-by-step directions for the wirer make the process practically foolproof. Significantly, no schematic is necessary for wiring – thus making superfluous any interpretation of this often complex documentation.

Eplan Smart Wiring visualises the mounting layout, devices, connections and routing tracks, based for instance on data from Eplan Pro Panel. But even without a 3D layout from Eplan Pro Panel, Eplan Smart Wiring can be used to increase productivity. Connection lists and wiring list can for instance be prepared in other ECAD systems, read into an MS-Excel format and then processed in Eplan Smart Wiring. The automatic project comparison for last-minute changes ensures that all changes find their way into production and are taken into consideration in a timely manner. Problem and error reporting, status reports and manufacturing reports can be prepared at the push of a button and can

NEWS

then be e-mailed to engineering or those responsible in production planning.

The system’s simplicity further means that even lessqualified personnel can take over the wiring process. This offers companies optimal scalability of their resources while simultaneously increasing efficiency along the entire workflow.

Free Introduction – For a Limited Time Solutions provider Eplan has released Smart Wiring in German and English, and it will be available in sixteen additional languages starting in November. Aside from forging new technical pathways, Eplan is further offering use of the software free of charge from 1 September 2016 to 31 January 2017 with a user’s licence restricted to four months.

Interested parties can therefore take the system for a test drive, put it through its paces and, after the restricted licence expires, can then decide whether they wish to purchase the system. Prospekts can find out more at www.eplan.de/ smart-wiring or contact an Eplan sales representative.

Conclusion Eplan Smart Wiring is the next logical step for integrated engineering through to manufacturing. Data relevant to manufacturing can be standardised with Eplan Pro Panel, thereby be quickly prepared and made available for manufacturing with Eplan Smart Wiring. This provides greater flexibility in the wiring process and high-quality results.

Eplan at the SPS IPC Drives Hall 6, Stand 210

MORE INFORMATION 17 | Industry Asia Pacific | November 2016

23

NEWS

ANYBUS WIRELESS BOLT CONNECTING DEVICES WIRELESSLY

HMS Industrial Networks now introduces The Anybus Wireless Bolt — a wireless access point designed to be mounted on a machine or cabinet to give it wireless access via WLAN, Bluetooth or Bluetooth Low Energy. This access makes it possible to do configuration via a regular tablet or smartphone or connect to a cloud service, realizing Industrial IoT.

T

he Anybus Wireless Bolt is mounted onto a machine or cabinet (just like a bolt) to give it a robust and IP67-classed wireless interface. It is typically used for configuration purposes. For example, the Bolt makes it possible to Bring Your Own Device (BYOD) such as a tablet or smartphone to a machine and use it as an HMI. Another typical use case is connecting a machine to a cloud service.

MORE INFORMATION

The Wireless Bolt can communicate wirelessly up to 100 meters via WLAN, Bluetooth or Bluetooth Low Energy. On the wired side, the Anybus Wireless Bolt can communicate with devices on serial (RS232/485), CAN or Ethernet. Regardless of communication method, it has the same connector (2x9p Plug Connector) for both power and communication.

17 | Industry Asia Pacific | November 2016

24

Industrial quality “We have seen a steadily growing interest in wireless connectivity through our Anybus Wireless Bridge,” says Martin Falkman, Product Manager at HMS Industrial Networks. “Therefore, we wanted to offer machine builders a robust, industrial-grade wireless solution for on-machine mounting. The Anybus Wireless Bolt is yet another way that HMS enables customers to realize IIoT with solid and secure wireless solutions, getting them ready for the communication demands of the future.” www.anybus.com/products/wireless-index/anybuswireless-bolt

NEWS

SPOT ON IN ZONE 1 VERSATILE AND ROBUST LED FLOODLIGHTS The new 6125 series (for zone 1) and 6525 series (for zone 2) floodlights from R. STAHL are designed for challenging environments such as chemical, food and oil and gas extraction. Offering a service life is of 50,000 hours, they feature high corrosion resistance supported by a robust IP66/67-rated enclosure.

The extremely robust new LED floodlights from R. STAHL provide highly efficient and long-lasting lighting solutions for zone 1, 21, 2 and 22 hazardous areas.

E

nergy-efficient LED technology makes R. STAHL's new generation of flexible floodlights for hazardous areas shine. High-quality TIR lenses minimise scattered light and glare effects and enable light distribution focussed on angles of 10°, 40° or 120°. The devices are therefore not only suitable for spot and wide-angle lighting, but can even be installed as pendant lights. The new 6125 series (for zone 1) and 6525 series (for zone 2) floodlights achieve excellent luminous flux: 21,000 lm in versions with 210 W power consumption and 12,000 lm in 120 W models.

With this luminaire efficiency of 100 lm/W, they are not only far more efficient than conventional HID lights, but also require significantly less maintenance. The lense panel modules are equipped with hinges for easy installation, maintenance and repair of the removable components.

For some applications such as general lighting in production and storage facilities in the food industry, they can be ordered with a scatter protection for the glass front panel.

The robust enclosures provide IP66/67 ingress protection and a very high shock and impact resistance (IK10). They are available either in powder-coated steel sheet or stainless steel versions.

For explosion protection expert R. STAHL, these new floodlights are the final complement to a now comprehensive portfolio of highly efficient LED lighting solutions.

MORE INFORMATION

Even under extreme conditions, the service life of these products is specified at 50,000 hours of operation at maximum ambient temperatures. Their superior durability fully enables them to sustain challenging environments e.g. in the chemical industry or in oil and gas extraction over the long term.

Their high tolerance for ambient temperatures in a very broad range from -40 °C to + 60 °C is a stand-out feature in this product class. Featuring a corrosion-resistant body and comparably low weight, these floodlights are an especially good choice for onshore and offshore applications. Special designs with heat sinks made from sea-water-resistant aluminium are also available.

R. STAHL presents further information about this new series, LED technology in general and real-life experiences with explosion-proof luminaires in harsh conditions www.stahl-explorers.com

17 | Industry Asia Pacific | November 2016

25

NEWS

© Stephane Lariven

STRONGER TOGETHER: INNOVATION, CREATIVITY, AND INDUSTRIAL COOPERATION IN EUROPE

An interview with Bruno GRANDJEAN, new President of the FIM (Federation of the Mechanics Industries - France).

T

oday, the main challenges in the mechanics industry are dealt with at the European level, and rely on improved European industrial cooperation. In this context, the “Industrie-du-Futur” project shall result in fruitful partnerships, based on the French industry strongest points, such as collaborative spirit, quality, creativity and innovation.

What are the key strengths of French industry?

In our country, there is a strong industrial tradition, as well as a culture of creativity and innovation. France has the largest network of high-speed trains, a first class aeronautic and aerospace industry, a highly-respected automotive industry and we are one of the few leaders in the nuclear industry.

We benefit from the wide-ranging skills and passion of our highly qualified engineers, technicians and workers as well as a strong research sector. It is no accident that France has an outstanding presence in the luxury and aeronautics industries, two sectors of excellence.

MORE INFORMATION

The French industry has had to face the challenge of globalization and has lost some market share. How can it come back to the top?

At the heart of the Industrie-du-Futur's project is the idea that the digital revolution provides the opportunity to come back into the race. French industry must take advantage of this dynamic to get back among the top 5 of the world's industrial nations.

17 | Industry Asia Pacific | November 2016

26

NEWS The rebound of investment in production and factories' modernisation is going along with the Industry-du-futur's plan; more than 3000 french companies have joined this effort of modernization with the support of our technical centres.

The development of a French additive manufacturing industry, as highlighted by the Fives-Michelin joint venture, BeAM and Prodways (Gorgé group), is a good example of a rebound of investment driven by innovation. Further examples are Dassault with the Rafale jet fighter sold around the world, Alstom, whose TGV (high speed train) has been selected to connect Boston to New York, Bolloré with its “Blue Car”, an innovative concept of electric car and service, or Renault, which is launching a brand new production of the Alpine, a high-end car and a symbol of French excellence.

The network of companies involved in the mechanic industries is supplying every other industry sectors with essential technologies. It follows that the mechanic industries is at the very heart of this renewal.

Should the European Union adopt an industrial policy?

Today, Europe has become the home market for all industrial companies in the EU. It is clear that many of the challenges of globalization have to be handled at a European level, which is why policies need to be coordinated in order to optimize investments. So, France and Germany would benefit from the development of converging strategies in the energy or in the defense sectors.

It is essential that Europe shall not accept standards imposed from outside, especially in terms of safety for the digital data exchanges and for the bank transfers. We must also protect our patents, fight against dumping, and obtain a full balance for international exchanges rules. Many issues which cannot be solved apart from the European level.

How to improve European cooperation in regards to industry?

The addition of the international strengths of German and Italian industries, together with the French innovation and creativity, appears to me as a really fruitful idea.

In the mechanical industry, strong ways of cooperation already exist. Many German and Italian companies are also located in France and vice-versa. There are successful examples such as SEW Usocome, Schaëffler, or Bonfiglioli.

REDEX, the company I manage, is also located near Stuttgart and in Milan since a long period of time.

Today, very few products are from pure French, Italian or German origin; the value chains are integrated, and the final added-value is commonly created by additionnal inputs of several countries.

Bruno Grandjean is the CEO of REDEX, a middle size industrial French company whose products are exported to over 50 countries worldwide, and which is an European leader in “precision engineering”, high-tech equipment for steel and non-ferrous industries, and for the high-tech machine tool industry.

He has been appointed as new President of the F.I.M. (Federation of Mechanical Industries - France), in June, 2016. Graduated engineer, graduated from Stanford University, Bruno Grandjean is involved in the industry for over twenty five years. He holds several patents, and is heading the Redex Group since 2005.

MORE INFORMATION

The FIM (French federation of Mechanics Industries), regularly exchanges with the VDMA, its counterpart German organization. At the heart of these exchanges are the Industrie 4.0 , sponsored by the German government, and the Industrie-du-Futur launched by the the french AllianceIndustrie-du-Futur These positions are shared by political leaders, as it was shown by the summit between Angela Merkel and François Hollande at the Elysee Palace in October 2015, during a common conference on digital. It is somehow the evidence that the competitiveness of European industry is an unifying topic for our countries. www.fim.net/fr 17 | Industry Asia Pacific | November 2016

27

NEWS

PNEUMATIC SAFETY BRAKES WITH THE SAME POWER AS HYDRAULICS

With the new pneumatic ROBA®-guidestop, mayr® power transmission provides an innovative braking concept which fulfils the high safety requirements and achieves high performance density without the use of hydraulics.

Image: mayr® power transmission

High-performance, highly rigid ROBA®-guidestop profiled rail brakes.

A

compact safety brake in a small construction space with high forces and all this without using hydraulics – mayr® power transmission has developed a new, high-performance, pneumatically-released version of the ROBA®-guidestop profiled rail brake. With this innovative braking concept, which fulfils the ever- increasing safety requirements and achieves a high performance density without the use of hydraulics, the company sets new standards.

mayr® power transmission is extending the tried-and-tested ROBA®-guidestop series with a pneumatically-released version, which provides users with new possibilities thanks to the high holding forces. For machines, in which a hydraulic system is already available, users can still use the hydraulically-released ROBA®-guidestop safety brakes.

However, in applications where a hydraulics system would have to be installed first in order to operate a brake with high holding forces or in which several brakes would be necessary to achieve the required forces, the pneumatically-released ROBA®-guidestop safety brake is now used. It clamps profiled rails equally accurately and backlash-free while achieving the same high holding forces as the hydraulic design of the brake.

MORE INFORMATION

Innovative concept with pressure booster The pneumatic ROBA®-guidestop is opened with compressed air at 20 to 30 bar. In order to achieve the necessary operating pressure, a compact pressure booster is used in combination with the brake, which mechanically increases the system pressure from 4 to 6 bar as is usual in pneumatic networks, without the use of external energy.

This innovative concept enables a selective pressure increase directly prior to the brake, i.e. directly in the system where 17 | Industry Asia Pacific | November 2016

28

NEWS

In order to achieve the necessary operating pressure, a compact pressure booster is used in combination with the brake, which increases the pressure existing in the system purely mechanically and without external energy. This innovative concept enables a selective pressure increase directly prior to the individual brake.

Image: mayr® power transmission

the higher pressure is required – as a result, short highpressure lines suffice. The pneumatic ROBA®-guidestop safety brake is available in five construction sizes – each size in both a standard design and in a compact, short design – covering a range of holding forces from 1 to 34 kN. The brake is designed for the different rail construction sizes of conventional linear guidance manufacturers.

Like all safety brakes by mayr® power transmission, the brakes of the ROBA®-guidestop series operate according to a fail-safe principle, i.e. they are closed in a de-energised condition. They reliably guarantee operational and functional safety in machines and systems around the globe. www.mayr.com

MORE INFORMATION

Safety thanks to direct clamping Just like the hydraulic brake design, the pneumatic ROBA®guidestop safety brake acts with extremely high rigidity directly applied to the linear guidance. This means that it is mounted directly on the masses which should be held.

This provides a decisive advantage, especially concerning gravity-loaded axes, where the hazard risk for people should be reduced: Drive elements between the motor and the moving mass, such as spindles, spindle nuts, shaft couplings or gearboxes, therefore have no influence on the safety – as opposed to the concepts using motor brakes, where all drive elements transmit the braking torque to the carriage.

Systems using ROBA®-guidestop safety brakes therefore enable a significantly higher rigidity than solutions featuring rotary brakes integrated into servomotors.

technological advantages for heavy machining, for example.

The machining produces less vibrations and therefore the surface quality of the workpiece is positively influenced. In case of a stationary axis, for example during machining, the brake can absorb the load. As a result, it is possible to switch off the drive motor in this phase and remove it from the controls. This eliminates control movements and is therefore gentle on the ball screw spindle. The closed brake absorbs the axial forces. The service life and maintenance intervals of the drive components are extended.

Reliable and precise The backlash-free clamping of the ROBA®-guidestop directly onto the profile rail provides yet further advantages: The additional rigidity of the NC axis increases process accuracy, improves machining performance and can provide further 17 | Industry Asia Pacific | November 2016

29

NEWS

HIGH TEMP TOUGH

WIDIA offers a variety of coolant-fed cutter bodies such as shell mills, shoulder cutters, end mills, and more, all able to accept WS40PM and other indexable milling insert grades.

WIDIA’s new indexable milling grade is the first choice for titanium and other superalloys.

J

osef Fellner, WIDIA Products Group’s Manager Portfolio Management for Turning and Indexable Milling, says the company recently took its newest advanced milling grade, WS40PM, on a world-wide testing tour. The results have been quite impressive: • An aircraft manufacturer enjoyed a 90% reduction in machining time per piece and increased tool life by 50% during Ti-6Al-4V face milling operations.

• Insert flank wear decreased by more than 90% at a UK shop cutting Inconel 625, resulting in a 70% reduction in tooling costs.

MORE INFORMATION

• At a turbocharger producer in China, tool life increased 80% while machining an austenitic stainless steel component using WS40PM, with improved part surface quality, reduced cutting forces and better chip flow.

• In another titanium component, the WS40PM/VSM490-15 platform doubled metal removal rates and delivered 80% longer tool life through increased depth of cut and feed per tooth in face and shoulder milling operations.

17 | Industry Asia Pacific | November 2016

30

• The testing laboratory for a well-known brand of machine tools reports metal removal rates 49% greater when shoulder milling Ti-6Al-4V. In each instance, WS40PM competed with the test subject’s legacy carbide grade. Speeds and feeds were kept the same or in some cases increased to take advantage of WS40PM’s exceptional toughness, wear-resistance, and ability to resist thermal cracking.

WS40PM was designed to meet the needs of the aerospace, defense, and medical industries, where titanium is used for everything from landing gear and seat tracks to lifesaving implants and surgical instruments. As the testing results show, however, WS40PM is suitable for far more than titanium. High-temp steel alloys, austenitic and PH stainless steels, nickel-based super alloys such as Hastelloy and Nitronic—these materials cause tool failure due to builtup edge (BUE), notching at the depth of cut line, cratering, chipping, and extreme heat generation, which in the case of wet-cutting operations leads to cracking.

“WS40PM’s advanced cobalt-rich substrate provides robust fatigue resistance and edge integrity, while the multiphase

NEWS

WS40PM’s cobalt-rich substrate provides robust fatigue resistance and edge integrity, while the multiphase AlTiN-TiN PVD coating reduces tool wear, making it the first choice for a wide range of hightemp steel alloys, austenitic and PH stainless steels, nickel-based super alloys such as Hastelloy and Nitronic, and titanium.

AlTiN-TiN PVD coating reduces wear,” says Mike Sperhake, EMEA-region Product Specialist for WIDIA. “Using an initial cutting speed of 175 ft/min (53 m/min) we’re seeing 25-35% productivity gains and consistent improvement in tool life, even when milling very tough materials like Ti-5553 and Super Duplex steels.”

Sperhake recommends a balanced approach to cutting parameter selection. “As radial engagement increases, cutting speeds should be reduced proportionately,” he says.

“That’s because the amount of heat entering the insert goes up substantially on heavy cuts. At around 90% engagement, for instance, you’ll probably want to reduce the RPM by 25% or so, depending on the material. Feedrates may also have to be lessened somewhat, depending on setup and machine rigidity. And smaller cut widths, of course, spindle speed and feedrates should be kicked up substantially.”

Finally, consider the machine tool, toolholder, and spindle interface. Rigidity across the board is needed for productive titanium machining. WIDIA offers the KM4X platform, which according to Global Product Manager Bill Redman is “the strongest connection available, period,” and is available on a wide variety of toolholders and machine tools alike.

Says Sperhake, “From Tier 1 aerospace suppliers to the job shop on the corner, everyone wants the same things from a tooling solution: higher accuracy, better surface finish, reliability and productivity. All are critical factors to their success, and that’s what we intend to deliver. WS40PM is a big part of that.” www.widia.com

MORE INFORMATION

“Going too easy” is a common mistake when machining titanium and other difficult materials, Sperhake says, leading to poor productivity levels and shortened tool life. For example, problems such as BUE and edge wear can often be eliminated by pushing the tool harder. “Tool life, especially in superalloys, is a three-legged stool of feed, speed, and cutter engagement. Each has a direct impact on the others.”

body for the application is likewise important. WIDIA’s VSM490 shoulder mill offers a state of the art insert and cutter design, one that supports WS40PM and other highperformance grades.

Success with superalloys takes more than a good carbide grade, however. Sperhake also recommends increasing the cutting fluid concentration, and using a high-pressure coolant pump wherever possible. Selecting the right cutter 17 | Industry Asia Pacific | November 2016

31

NEWS

NORD SEVERE DUTY PERSEVERES

Corrosion-proof drives in washing and packaging line for agricultural products.

T

MORE INFORMATION

he nsd tupH corrosion protection treatment introduced by NORD DRIVESYSTEMS is an economic method to significantly extend the lifespan of drive systems with an aluminum casing in applications with aggressive atmospheres, high humidity, or spray water.

Ambit Projects, a manufacturer of food industry machines, uses nsd tupH protected drives in washers.

In the English town of King's Lynn, Ambit Projects Ltd. designs and manufactures custom equipment for cleaning, processing, and packaging of various food and agricultural products. One of Europe’s leading fresh produce growers and suppliers is a regular Ambit Projects customer. They required a major upgrade and line expansion. The machine in question removes the root and flag of celery stalks and then washes, inspects, and packages them. Given the constantly wet environment and regular washdown with water and foaming agents, the old drives had suffered.

Even a high-specification anti-corrosion coating was not enough to provide lasting protection. The paint had split and was threatening to peel. In order to keep debris away from the celery produce, the drives had been outfitted with trays and covers. The drives installed on the belt conveyor in immediate proximity to the washing process were in particularly bad condition. High-pressure jets are used here to remove soil and stones from the produce. The equipment manufacturer was therefore on the lookout for alternative drive solutions that required no extra enclosures.

Protection that goes under the skin NORD Gear Ltd., the English member of the NORD DRIVESYSTEMS Group, told Ambit Projects about a materials

17 | Industry Asia Pacific | November 2016

32

NEWS

The nsd tupH surface treatment gives aluminum drives a smooth, permanently corrosion-resistant surface ideally suited to process industry applications (image: Ambit Projects Ltd.)

Freshly harvested celery is automatically cut, cleaned, and packaged in a continuous operation. (image: Ambit Projects Ltd.)

high-pressure steam jets is therefore not a problem. Due to their excellent thermal properties, the aluminum systems can be washed down without cooling down first from the regular operating temperature.

Made for hygienically demanding applications Ambit Projects replaced all conveyor drives and the drives in the retrofitted machine sections with new nsd tupH units. These are fitted with stainless steel DIN and standard parts and stainless steel output shafts. Food-grade oil is used as gear lubricant. Paul Oakley, Sales Director at Ambit Projects, is delighted with his new drives: “NORD nsd tupH drives have provided a real value for money solution in terms of extended protection and trouble-free reliability. This application demonstrates our commitment to working closely with our customers and suppliers with upgrades and capacity expansion initiatives that reflect the latest technology improvements – and we will certainly be using nsd tupH protection in other machines we develop.”

The new drives in the celery processing line are based on smooth-surface motors and SMI worm gearboxes. NORD has optimized these components as well as other gearbox types for hygienically demanding applications. Smooth surfaces all around without any dead spaces ensure that dirt cannot easily accumulate and that rinsing liquids run off easily.

MORE INFORMATION

engineering innovation: NORD has developed a technology called nsd tupH that profoundly fortifies aluminum surfaces by permanently altering the material through an electrochemical process. Instead of applying a protective layer, as is commonly done with anti-corrosion coatings, the aluminum material itself is thoroughly hardened. A great number of NORD drives treated in this way already have a proven track record going back several years. Before the technology was deployed, systems using nsd tupH were tested for resilience against blistering per ASTM D714, corrosion per ASTM D610-08, scribe per ASTM D1654-08 according to DIN EN ISO 2409, salt spray per ASTM B11709 according to DIN EN ISO 9227, and chipping per ASTM D3170 (Gravelometer test). In many industrial environments, scratches or blows to the drives are to be expected. Under such conditions, even high-quality anti-corrosion coatings cannot reliably provide effective protection. Once the surface layer has been damaged, corrosion easily spreads to adjoining areas. Even rework will not undo the damage for good. nsd tupH is immune to this potential problem.

Gravelometer testing showed absolutely no loss of adhesion or chipping. High process safety is therefore ensured. The treatment is approved for food applications according to FDA Title 21 CFR 175.300. It also makes the drives resistant to cleaning agents in the pH2 to pH12 range. Notably, nsd tupH is perfectly suitable for use in marine environments: the salt spray test produced no corrosion even after 2,000 hours.

NORD supplies a range of geared motors and mechatronic drives with IP66/IP69K ingress protection. Cleaning with

Smart full-scale solutions The use of aluminum drive systems featuring nsd tupH protection against corrosion and mechanical damage 17 | Industry Asia Pacific | November 2016

33

NEWS

Smart solution to drive applications in aggressive atmospheres: nsd tupH can be applied to all components with an aluminum die-cast housing. (image: NORD DRIVESYSTEMS)

reduces maintenance costs and significantly extends the product life. These drives are perfectly suitable for hygienically sensitive applications in the food industry and many other demanding process applications. nsd tupH is available for all aluminum-enclosed drive components from NORD – four gearbox families, smooth-surface motors, and distributed drive electronics. Drawing on an exceptionally comprehensive modular pinion range, NORD is able to custom-configure each gearbox to precisely match application requirements. Users can choose hollow or solid shafts as well as foot or flange mounting. NORD also offers motor starters and frequency inverters with high protection ratings and with nsd tupH. These allow for distributed installations with minimal wiring effort and provide an economic way to ensure protection and efficiency.

Typical applications include conveyors, pumps, mixers, and agitators in harsh environments. The units feature all required communication and sensor interfaces and are capable of internally storing routines. NORD provides plugand-play solutions for all kinds of industrial application.

MORE INFORMATION

www.nord.com

17 | Industry Asia Pacific | November 2016

34

NEWS

INSPECTORATE LAUNCH NEW OIL & GAS TESTING FACILITY IN INDONESIA

Global Testing & Inspection Organization Expands its South East Asian Service Network with New Office and Laboratory in Karimun Island in Indonesia.

I

nspectorate, global leaders in testing and inspection for the oil and gas industry, announced today the opening of a new testing facility in Karimun, Indonesia, specializing primarily in the in the testing of Jet A1, Gasoline (MOGAS), Diesel (Gas Oil) and Fuel Oil.

“The ability to rely on the industries’ benchmark systems and resources from our established, state-of-the-art laboratories greatly helps to deliver high-quality services in a new location from day one,” said Ravi Parameswaran, Regional Technical Manager - Asia, Inspectorate.

Strategically located in between the international maritime shipping traffic - 7.5 nautical miles from Straits of Malacca and 25 nautical miles from Singapore - the 24/7 laboratory and inspection office will provide support services for major shipping companies, traders and energy suppliers needing real time data for oil and gas quality in the Asia Pacific.

A dedicated team of highly trained marine surveyors will be available to provide for any local needs for all inspection operations such as sampling, quantity inspection, tank transfers, blending and lightering.

This facility has testing capabilities for Jet A1 recertification, full specification for Gas Oil as per ASTM D975, Gasoline as per Platt’s specification, and Fuel Oil as per ISO 8217.

MORE INFORMATION

Senior staffs from Inspectorate’s Regional Technical Centre in Singapore will be fully responsible for continuous support and assistance to the Indonesian facility, ensuring fast sample turn-around times, accuracy and value adding technical advice for customers.

“The Indonesian laboratory further consolidates Inspectorate’s already extensive network of testing and inspection facilities and reinforces our commitment to supporting customers in this important region,” said Amit Ghosh, Vice President – Asia, Inspectorate. www.bureauveritas.com

17 | Industry Asia Pacific | November 2016

35

NEWS

SCOTT SAFETY LAUNCHES NEW DURAFLOW POWERED AIR RESPIRATOR WITH REAL-TIME AIRFLOW CONTROL

Respiratory expert Scott Safety introduces Duraflow, a lightweight and ergonomically designed Powered Air Respirator with sophisticated real-time air flow control technology. The new solution gives complete wearer assurance of respiratory protection to focus on the job rather than the protective equipment itself, in a multitude of hazardous situations and industries.

M

ark Andrews, Global Product Line Manager Powered Air, Halfmask & Airline at Scott Safety said: “Our design intent for Duraflow was to bring to the market a reliable, durable powered air product at an affordable price for those currently using respirators with filters fitted directly to the mask (negative pressure mode).”

MORE INFORMATION

Duraflow’s automatic monitoring features ensure the airflow rate is maintained at precisely the correct level to afford protection for the user. Visual and audible diagnostics alert the user of any drop in airflow below the required level or when the battery needs re-charging. 2 high energy density battery options are available –standard and extended duration which can be selected depending on shift coverage required- less downtime more working time.

17 | Industry Asia Pacific | November 2016

36

Duraflow will help employers meet the needs of workers across all demographics- with its low respiratory burden.

As highlighted in Scott Safety’s latest whitepaper, changes in lung function in older employees working in manual positions can reduce their ability to undertake certain active tasks. By providing workers with a cooling stream of purified air, Duraflow can for some workers make the difference between whether a job can be completed or not.

Highly versatile, Duraflow is compatible with a plethora of Scott Safety headtops, filters and accessories, protecting workers from a variety of environmental hazards.

For further information, please visit www.scottsafety.com/emea

OPTIMIZE YOUR INTERNATIONAL PR AND ADVERTISING FOR THE INDUSTRIAL MARKETÂ !

International capability

Outstanding results

Optimized process

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

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

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

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

www.mepax.com info@mepax.com

THE MOST INNOVATIVE PR AGENCY

@mepaxIntPR