Industry Asia Pacific 24

24 | APRIL 2018

Industry

Asia Pacific THE INDUSTRY MAGAZINE FOR ASIA

NIDEC SWITCHING TO A DYNEO® PERMANENT MAGNET MOTOR SAVES A FISH FEED PRODUCER AT LEAST 135,000 KWH PER YEAR

10 LEUZE ELECTRONIC GLOBAL AVAILABILITY OF INFORMATION IN THE CONTEXT OF INDUSTRY 4.0

18 KENNAMETAL EXTENDING EXCELLENCE

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NEW SECO SOLID-CARBIDE CUTTING TOOLS BOOST KNEE IMPLANT MACHINING SPEEDS

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24 | Industry Asia Pacific | April 2018

THE INDUSTRY MAGAZINE FOR ASIA

NORD

HAIMER

NORD

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LEROY-SOMER NIDEC

ELECTROTEK CONCEPTS

AEROTECH

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10 BALLUFF

KENNAMETAL

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16

LEUZE ELECTRONIC

18 DE DIETRICH PROCESS SYSTEMS

SECO TOOLS

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ADVERTISERS: MEPAX 4

www.industry-asia-pacific.com

Contributing Editors: • Emmanuel AHOSSI • Nessren BAZERBACHI • Romain CLASS • Maria DE PABLOS • Anna HARDALOUPAS • Sofiane JEDIDI • Laura MUTTO • Marie RESPINGUE • Christophe VERGUET

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.

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NEWS

NEW PRODUCT: SINGLE STAGE NORDBLOC.1 HELICAL GEAR UNIT NORD DRIVESYSTEMS has extended its successful NORDBLOC.1 series with a single stage gear unit for applications with high speeds and torques.

The new single stage NORDBLOC.1 helical gear unit from NORD DRIVESYSTEMS was specially designed for applications with high speeds and torques. The gear unit is especially robust, efficient, quiet and compact.

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he new NORDBLOC.1 helical gear unit features ultimate efficiency, high torsional rigidity, low running noise and long service life. In addition, they also meet even the most stringent hygiene requirements thanks to their wash-down design. The innovative gear units do not have any separating joints or closing caps. This increases the stability of the product and at the same time provides a smoother surface on which neither liquids nor solid materials can accumulate.

The new NORDBOLOC.1 products are available in five sizes with motor powers from 0.12 to 7.5 kW for output torques of up to 280 Nm. All variants are available as flange mounted (B5 or B14), or foot/flange mounted versions. Options for IEC and NEMA motor mounting as well as a wide range of equipment variants for shafts, bearings and lubrication can be flexibly implemented.

Robust, efficient, quiet and compact – with the single stage NORDBLOC.1 helical gear unit, NORD has created a reliable, robust and economical drive solution for pumps, mixers and fans, as well as for conveyor technology applications. www.nord.com MORE INFORMATION

The FEM-optimised UNICASE housing ensures maximum strength and rigidity. In addition to increased rigidity the internally reinforced design also ensures especially quiet running. All bearings and seal seats are contained within the casing, eliminating joints which can weaken the housing and allow oil leakage. Bores and mounting faces are machined in one step, enabling extremely precise tolerances — thus ensuring accurate positioning of gear teeth, bearings and seals, and longer life for all components. The housing is made from high strength, corrosion resistant aluminium and is therefore especially lightweight and robust. Additional protection is provided by the optionally available nsd tupH surface treatment. The smooth, easy to clean housing makes the NORDBLOC.1 gear unit particularly suitable for users from hygienically critical sectors such as the food or pharmaceutical industries.

The gear units are generously dimensioned and can withstand large radial and axial forces. A particular benefit of the large bearings is the larger diameter of the internal shafts, which increases the bearing strength. The gear wheels are made from case-hardened steel and permit high short-term overloads.

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SAFE AS WELL AS EFFICIENT

In 2017 Iscar and Ingersoll received a license for cutting tools. Through the large offering of tool manufacturers Safe-Lock™ has become a standard for many industries. Picture: Haimer

The HAIMER Safe-Lock™ pull out protection system is becoming the industry standard.

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he HAIMER Safe-Lock™ pull out protection system ensures safe cutting tool clamping. Special drive keys in the tool holder perfectly match the spiral shaped grooves on the cutting tool shank, thus creating frictional clamping forces and a positive locking form-fit.

This effectively prevents the cutting tool from pulling out of the tool holder. Furthermore, it increases the productivity through faster permissible speeds and increased tool life.

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By now Safe-Lock™ has become a de-facto standard in the area of tool holding for milling operations. Within the last ten years, since the introduction of the Safe-Lock™ system, it has been confirmed over and over that this method of clamping the tool is often clearly superior to conventional Milling Chucks and Weldon shanked tool holders. This is proven by a large number of license partners, some of which rank amongst the world’s leading cutting tool and tool holder manufactures - for example Walter, Widia, Sandvik Coromant, Seco Tools, Sumitomo, Kennametal, Helical, Emuge Franken, Data Flute, Niagara, OSG and Mapal. In 2017, Iscar and Ingersoll also decided to offer tools with the Safe-Lock™ shank. Furthermore, the shrink, collet and hydraulic chuck Safe-Lock™ tool holder portfolio has become much larger within the last few years. In addition to 24 | Industry Asia Pacific | April 2018

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the Safe-Lock™ hydraulic chucks from Kennametal, Mapal is already working to introduce its hydraulic chuck offering with Safe-Lock™ to the market.

Andreas Haimer, Managing Director of HAIMER GmbH, explains: “We are proud that our Safe-Lock™ pull out protection system has established itself as the new standard in the heavy duty and rough milling industry and is also becoming more and more important in other areas such as trochoidal milling. We are also very happy about our new license partners, who help expand the Safe-Lock™ portfolio and also make it available for more end-users.”

Successful in the Aerospace Industry Safe-Lock™ has emerged from the requirements of heavyduty machining, which is a daily challenge in the aerospace and energy producing industries. Innovative materials such as various titanium alloys are not only light, but also very rigid, corrosion resistant and difficult to machine. This doesn’t only affect the machine concepts and processes, but also the cutting tools and tool holders that are being used.

Many workpieces are made from a solid block – during this milling process up to 90% of the material is being removed.

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MTU Aero Engines manages challenging roughing applications for the military turboprop engine TP400-D6 with Haimer Safe-Lock. MTU is responsible for the TP400-D6’s intermediate-pressure compressor, intermediate-pressure turbine and intermediate-pressure shaft and has a stake in the engine control unit. Furthermore, final assembly of all TP400-D6 production engines takes place at MTU Aero Engines in Munich. Picture: MTU Aero Engines

In order to optimize the process economically as well as qualitatively and in order to achieve a high metal removal rate, high torques and feed rates with low rpms are chosen.

But during this High Performance Cutting operation (HPC), high pulling forces occur. In combination with high cutting forces and aggressive feed rates, a flexing movement of the tool in the tool holder is created which in the end increases the risk of tool pull out. This especially affects all the tool holder designs which provide accurate clamping and a high run-out accuracy, like for example shrink, hydraulic or milling chucks.

Higher Productivity with Safe-Lock™ However, Safe-Lock™ has not only found enthusiastic followers in the aerospace industry. Working at Glätzer, Daniel Rautenbach knows how fiercely competitive and thorough the automotive industry can be. The Managing Director of the CNC-Machining Specialists located in Solingen explains: “Perfect quality and delivery reliability are the basic requirements in order to quote in our industry.

Pricing is highly competitive.” Therefore, in his business, the difference between profit and loss comes down to process efficiency. Hence quality without compromise is a must.

Through one of the biggest projects in this area Ingo Schulten, Operation Manager, became aware of the HAIMER Safe-Lock™ pull out protection system and started using it in the middle of 2013. The specific application was a part for a pneumatically operated truck disk-brake which consisted of spheroidal-graphite cast iron, Type EN-GJS-800-2. In order to mill concave contours the contact between cutting tool and the work piece isn’t just punctual, but it actually covers

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As a consequence Safe-Lock™ is now widespread within the aerospace industry. Alexander Steurer, Senior Manager NC - Programming Stator Components at MTU Aero Engines in Munich, explains the decision to use the HAIMER system: “Through the introduction of Safe-Lock™ and the shrinking technology from HAIMER, we can guarantee process reliability even with milling challenging high temperature materials. This is a prerequisite to guarantee smooth processing during manufacturing of frames and castings, given our high degree of automation.“ The combination of pull-out protection and highest concentricity of the SafeLock™ system leads to low vibration and as a result, a very stable machining process. Due to the increased cutting depths and feeds, the metal removal rate can be increased significantly. And thanks to the improved runout accuracy of HAIMER shrink fit chucks, tool life is improved by up to 50%.

The benefits of less than 3 µm runout, that the symmetrical Safe-Lock™ design provides, coupled with optimum balance and the possibility for easy length presetting were substantial reasons for MTU to switch to the HAIMER system instead of continuing to use Whistle Notch or Weldon tooling systems. While these other systems do in fact prevent tool pull out, both are unsymmetrical by design, hence providing insufficient runout and balance accuracy.

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Glätzer CEO Daniel Rautenbach (on the right) and Manager Ingo Schulten are continuously extending the use of HAIMER shrinking technology, with and without Safe- Lock™: “To us the switch to SafeLock™ seemed obvious, like using an electric starter instead of a crank to start a car.” Picture: Haimer

Trochoidal milling makes the milling operation three times faster and deeper, even in hard materials like stainless steel or titanium. Ideal tools for machining are the HAIMER Power Mill end mills with Safe-Lock™-chuck. Picture: Haimer

between 30 or 40 percent of the tool. Ingo Schulten explains: “The extremely high engagement and cutting forces cause the tool to want to pull out from the holder.” The utilized Weldon Chucks ensured that the cutting tool stayed in the holder, but the side lock screw prevented the tool from achieving good runout accuracy. According to Schulten “the tool life was very unstable which even led to tool breakage”.

The milling tests with Safe-Lock™ convinced him and the other employees at Glätzer. “To me the switch to Safe-Lock™ seemed obvious, like using an electric starter instead of a crank to start a car” Schulten explained enthusiastically. “The cutting data improved significantly. The tool life increased by 40% consistently.”

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Benefits of High Speed Cutting Safe-Lock™ is also becoming increasingly popular in other industries and during HSC machining with high-helix end mills as well as in trochoidal milling. During trochoidal milling operations, where the cutting speed and axial depth of cut can be increased through software support, the productivity is significantly improved. Thus milling operations are carried out three times faster with deeper depths pf cut, even when it comes to hard and difficult to machine materials.

However this also increases the danger of tool pull out. Even though only a thin chip is usually removed during trochoidal milling operations, often the entire length of the cutting tool edge is used during the process. This results in higher 24 | Industry Asia Pacific | April 2018

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Safe and Efficient Tool Clamping The Safe-Lock™ principle can be explained as follows: spiral-shaped grooves are ground into the cutting tool shank, which have the same angle like that in the tool.

In combination with special EDM form closed drive keys in the tool holder (shrink fit chucks, collet chucks or also hydraulic chucks) the grooves prevent the cutting tool from twisting or being pulled out of the chuck during extreme machining, which causes very high costs when producing expensive work pieces. The combination of pull out protection and high runout accuracy leads to less vibrations and very efficient metal removal rates.

With this it is possible to increase the metal removal rates significantly by increasing the cutting depth and the feeds. In addition tool wear will be reduced. axial forces which force the operator to pay attention to safe cutting tool clamping. A shrink fit chuck with Safe-Lock™ is the ideal solution since it offers more security than the Weldon system, is easier to install and can be clamped very precisely. The ideal balancing and runout characteristics of the shrinking technology in combination with the clamping safety of the Safe-Lock™ system permit the possibility of greater productivity achieved through faster permissible speeds and increased tool life all with complete tool security assurance. www.haimer.biz

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PREDICTIVE MAINTENANCE AND OPTIMAL USE OF RESOURCES

In applications with steady long-term load profiles, the drive PLC determines the best oil change interval without costly sensors.

NORD DRIVESYSTEMS is developing cost-efficient and reliable virtual sensor functions for condition monitoring.

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he meaning of virtual sensors is explained using the oil lifespan as an example. This is to empower drive technology to schedule maintenance dates solely based on calculations, with no expense for hardware sensors. The onboard PLC evaluates extensive operational datasets on current, voltage, and speed. From this data available in the inverter, the drive is always able to indirectly infer the current oil temperature. Taking product-specific characteristics of the lubricant into account, oil aging can be determined, allowing for optimal utilization of the lubricant.

At a glance: Virtual sensors for predictive maintenance • Function in frequency inverters with an integrated PLC • Precise definition of maintenance intervals helps - reduce operating costs - increase plant availability • Due for launch: late 2018 • Pure software solution without hardware costs for sensors/ control units www.nord.com

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NORD has validated through testing that the calculated oil temperature curve is nearly congruent with the real, measured temperature curve. Working up to launch a fully operational solution soon, NORD is currently validating temperature curves under various load conditions.

Predictive maintenance functions are expected to be commercially available in all NORD drive electronics units with an onboard PLC from late 2018.

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SWITCHING TO A DYNEO® PERMANENT MAGNET MOTOR SAVES A FISH FEED PRODUCER AT LEAST 135,000 KWH PER YEAR

A Denmark-based specialist in aquafeed production has replaced an ageing, damaged DC motor on its principal extruder with a Dyneo® motor from Leroy-Somer, part of the Nidec group. The investment is providing the company with significant annual savings in energy costs.

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quaculture, more commonly known as fish farming, is a rapidly growing sector. Companies such as Aller Aqua, which produces both freshwater and saltwater fish feed, is constantly looking for ways to improve its production technology and processes to benefit from this growth. Operating from headquarters at Christiansfeld, near Kolding, Denmark, Aller Aqua has been established for over 50 years and today has factories in Denmark, Poland, Germany and Egypt, exporting products to more than 60 countries worldwide.

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The company has a broad product range, consisting of feed for 30 species of fish. As a result, production schedules are demanding, which is why the company sought to maximise its potential gains when the DC motor on one of the company’s main extruders at Christiansfeld had to be replaced.

“Aller Aqua had a particular interest in energy efficiency for its new motor solution as extruding feed stuff is a very energy-intensive process,”explained Carl Erik Niemann, Sales Engineer - Drives & Motors Technology at Nidec Industrial Automation Denmark A/S. “They knew this would help boost both competitiveness and sustainable development.”

After a comprehensive evaluation of the market, the company opted for a 310 kW (2400 rpm) Dyneo® permanent magnet synchronous motor. Offering an efficiency level exceeding IE4 requirements, this option will enable the saving of at least 135,000 kWh of electricity per year.

“Beyond energy performance, Aller Aqua is now able to benefit from significant savings in maintenance costs, allied to increased machine availability,” said Mr Niemann. “The previous DC motor featured a brush and collector system, which comprised wear parts.”

The implementation of the Dyneo® motor also allowed local service centre Ølgod Elektro to simplify the existing

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installation by eliminating the cooling/ventilation circuit required previously by the replaced IP23 DC motor.

Part of the Express Availability offer from Leroy-Somer, DyneoŽ LSRPM motor is available in a compact or IEC standard version. The solution is easy to integrate and offers rapid return on investment – fewer than three years in the case of Aller Aqua. www.nidec.com

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CROSSED-ROLLER BEARING BALL-SCREW LINEAR STAGES OFFER SUPERIOR PRECISION AND FLEXIBILITY

With travel lengths to 250 mm and anti-creep crossed-roller bearings, plus an optional center-mounted linear encoder for direct position feedback, the versatile features and options of Aerotech’s ATX series linear positioning stages enable convenient integration into larger machines or use as stand-alone positioning axes. Vacuum and cleanroom-compatible versions are available and ThermoComp® ensures reliable performance in changing environments.

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erotech’s ATX series linear positioning stages combine the performance capabilities of a highprecision crossed-roller-bearing positioner with the convenience and simplicity of a ball-screw drive mechanism.

Outstanding motion performance and a variety of advanced options and features offer superb value and make the ATX series an excellent choice for use in high-performance applications.

Superior Motion Performance Featuring anti-creep crossed-roller bearings and a precisionground, fine-pitch ball-screw, the ATX series boasts excellent geometric performance and minimal angular error motion.

With up to 250 mm of nominal travel, these linear stages offer superior minimum incremental step size and inposition stability compared to other stages that utilize recirculating ball bearings. This makes the ATX series ideal for many high-precision tasks such as vertical positioning of sensors and cameras, optics focusing, and beamline measurement and manipulation applications.

Linear Encoder Option ATX stages offer an integral center-mounted linear encoder to provide direct position measurement at the stage’s moving carriage. The typical effects of backlash commonly associated with screw drives are virtually eliminated when using the linear encoder as a position feedback device.

Applications that require exacting work-point performance

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benefit greatly from the direct linear encoder. Options are available with either incremental (1 Vpp and digital TTL) or absolute output signals.

Design and Integration Flexibility The ATX series is designed with a variety of standard features and options allowing them to be easily integrated into a larger subsystem or machine, or to serve as a stand-alone positioning axis. They mount to both metric and English optical tables and feature a versatile customer mounting interface on the moving carriage to which other positioning stages or equipment can be mounted. Brushless, slotless servomotors, with or without a holding brake, as well as stepper motors are available. The ATX series can be equipped with an optional motor foldback kit in order to reduce the overall length of the stage. This is particularly useful in vertical-axis applications where space is limited. Vacuumand cleanroom-compatible variants are also offered.

stability to the user’s process even in extreme industrial environments.

For further information, https://www.aerotech.com/product-catalog/stages/linearstage/atx115slsle.aspx https://www.aerotech.com/product-catalog/stages/linearstage/atx165slsle.aspx

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Mitigate Thermal Errors with ThermoComp® Temperature changes and thermal effects are often the most detrimental sources of error in precision machines, and screw drives are particularly susceptible. All ATX-series stages are available with Aerotech’s ThermoComp® feature, an integrated temperature compensation solution that delivers accurate and dependable positioning performance in the presence of thermal disturbances. It protects the stage from the effects of variable-temperature environments and friction-induced self-heating, ultimately providing 24 | Industry Asia Pacific | April 2018

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ELECTROTEK CONCEPTS RELEASES PQVIEW 4

PQView 4 offers the most advanced operational support enterprise software platform available to utilities.

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lectrotek Concepts®, the leading provider of enterprise power quality and distribution fault location system solutions for electric utilities, today announced its new PQView 4 software that provides utilities with a platform to track and identify abnormal power quality events. PQView 4 offers the most advanced approach to fault detection and characterization of power quality anomalies on the utility’s distribution system.

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PQView® is a multi-component software system that builds and analyzes databases of power quality and energy measurements. It stores and quickly analyzes large quantities of power quality disturbance and steady state measurement data from thousands of utility end points.

Fault analysis and location functionality in PQView is enabled via its FaultPoint® Add-In Module.

“The PQView platform is rapidly becoming the utility industry standard as it is used by large investor owned utilities and municipal utilities alike. With its new and more expansive feature set, PQView 4 can integrate with most third-party devices and data sources used by utilities to track the health of their distribution systems,” said David Ellis, President and CEO, Global Power Technology (Electrotek parent company).

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Some of the new features include: • Enhanced Fault Detection and Characterization Algorithms • Fault Location Mapping using Eaton® CYMDIST or DNV GL Synergi Electric® Databases • Updated Event Filtering • Enhanced Data Log Trending • New and Improved Data Handlers for Downloading ThirdParty Monitors and Importing IEEE Std 1159.3 PQDIF Files • New Software Development Kit and API • OSIsoft® PI System® Data Federation • New Fully Implemented PQView Commercial Licensing “On average, use of the PQView reactance-to-fault methodology for fault location saves us close to one hour per feeder outage restoration job. It can also mitigate the use of capacitive discharge thumpers by providing a better starting point for the fault locating activities.” said Christopher Jones, Department Manager, System Design Distribution Engineering at Con Edison. www.electrotek.com

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FLEXIBLE, SELF-ADHESIVE CAPACITIVE SENSOR HEAD LEVEL DETECTION MADE EASY

Balluff offers a self-adhesive, capacitive sensor head with IP 64 protection for non-contact, continuous level detection on non-conductive vessel or pipe outer walls made of glass, plastic or ceramic.

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he flexible sensor head with a maximum detection range of up to 850 mm in length can be individually trimmed to length (minimum 108 mm) and easily attached to container walls without additional accessories using the integrated adhesive surface. For polar, aqueous media the wall thickness may be between 2 and 6 mm, or up to 2 mm for non-conductive media such as oil or bulk materials.

The sensor is designed for use with type BAE sensor amplifiers from Balluff. The optional amplifier allows levels to be continually detected over the entire measuring range as analog values (0...10 V, 4...20 mA) or via IO-Link or as minimum or maximum value exceeding. Both the IO-Link and the analog convenience amplifier feature versatile setting possibilities. www.balluff.co.in

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EXTENDING EXCELLENCE

Drilling in tight corners, reaming deep features—it’s no longer something to avoid, thanks to Kennametal’s new hydraulic chuck extensions.

Kennametal solves the age-long problem of tool stability when drilling in deep cavities, alongside tall shoulders, and past bulky fixtures.

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eaching deep inside a workpiece to drill holes can be a real bear. You’ve tried taper length and aircraft drills, but even those made of solid carbide are apt to wander when hanging out of the chuck unsupported.

Maybe you’ve combatted the problem with special extended-reach drill holders, although these are not only expensive, but limited to specific fixed lengths. A double angle or ER-style collet extension might be worth a try, yet these aren’t exactly compact, and any runout or imbalance is exaggerated at long length to diameter ratios—if drill walk isn’t bad enough, you’re now left fighting the holder itself as it flexes and vibrates. Hole accuracy becomes questionable, tool life is poor, and productivity suffers as you reduce feed rates in an attempt to keep the drill running true. Surely there’s a better way.

Decades of Experience Kennametal thinks so. The Latrobe, PA tooling manufacturer recently developed a hydraulic chuck extension that meets these challenges while also increasing flexibility and reducing costs. Michael Schuffenhauer, Senior Global Product Manager Tooling Systems at Kennametal, says the company has been producing hydraulic chucks for the past 30 years, and has become quite knowledgeable about the technology behind them as a result. This new tool leverages that extensive experience.

“We asked our customers, ‘How do you drill holes in deep cavities and complex pockets? Do you have problems with reaching past clamps and fixtures?’” he says. “We wanted to know how they were dealing with these issues, and the effectiveness of their existing solution. Then we set out to develop a better one.”

Happiness through Hydraulics Kennametal’s new line of hydraulic chuck (HC) extensions meets that goal handily. Michael Schuffenhauer lists a number of key features that make the product unlike any other currently available. These include:

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Kennametal’s hydraulic chuck extensions provide integral throughthe-tool coolant channels, promoting tool life and increasing penetration rates in all drilling and reaming applications.

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When coupled with a KM quick-change adapter, Kennametal’s hydraulic chuck extension makes previously difficult setups both faster and more predictable.

- Runout to within 3 µm (0.00012 in.) at 2.5 x D (half that of its nearest competitor), providing exceptional tool life and hole quality.

- Because it’s balanced to G2.5 at 25,000 rpm, vibration is greatly reduced at higher spindle speeds.

- Vibration is further dampened by the hydraulic clamping mechanism within the chuck body.

- Internal channels make through the tool coolant easy to setup—no hoses or adapters needed.

- An ultra-slim design allows, for example, a 12-mm drill to be clamped in a 20-mm chuck body (or a ½-inch drill in a ¾-inch shank).

- A variety of reducer sleeves is available for both inch and metric sizes, providing maximum flexibility at minimum cost.

- Drill and reamer shanks down to 3 mm (0.125 in.) can be accommodated.

- Suitable for rotating and stationary applications alike.

“That’s an important point,” notes Michael Schuffenhauer.

“With traditional collet nut systems, the amount of torque applied during tool changes can vary widely, increasing the chance of runout or tool slippage. The same can be said for competing hydraulic extension chucks. But with our solution, there’s no chance of over or under-tightening.

It’s not only extremely accurate, but it’s extremely accurate every time.”

A Peek Inside For all its performance, the design is simple—just set any h6 tool shank inside the HC Extension and turn the clamping screw on the end of the unit until seated. This causes a hydraulic piston within the unit to move forward, compressing the locating sleeve, and gripping the tool.

Again, total runout as measured 2.5 x D from the chuck face will not exceed 3 µm (0.00012 in.), and the extension’s superior balance characteristics make it an ideal choice for today’s high rpm machine tools.

At the end of the day, says Michael Schuffenhauer, customers want to achieve the safest, most economical, and predictable way to machine parts, hopefully with tooling and equipment that is easy to use. The HC Extension meets all of these criteria and more. “If you look at it from a high level, the HC Extension gives you the flexibility of a collet system with the precision of shrink fit, and easier setup than either. You get the best of all worlds. And because of the HC’s extreme accuracy and balance, you don’t have to settle for substandard tool life and performance as would with purely mechanical clamping systems. We’re very pleased to have it as part of our portfolio.”

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“Our HC Extensions are for customers that need the flexibility of a modular system but want to avoid the expense and limitations of a custom solution, as well as the constraints that come with traditional toolholders,” Michael Schuffenhauer says. “We believe the improved performance and ease-of-use offered by this new product will soon make it the leading drill extension on the market. It’s quite simply a great design.”

Cruising Easy Street Ease of use means no need for heat shrink machines. Tool lengths are adjustable up to 10 mm (0.393 in.) axially. A specially-ground chamfer on the end of the shank eases insertion into the hydraulic chuck. Prepared wrench flats provide safe and convenient handling, without the need for a torque wrench. A one-piece design eliminates concerns over contamination and downtime due to maintenance.

And most importantly, the clamping mechanism eliminates operator to operator tightening variations.

www.kennametal.com

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GLOBAL AVAILABILITY OF INFORMATION IN THE CONTEXT OF INDUSTRY 4.0

Networking replaces hierarchical automation.

The core business of Industry 4.0 is to make information available from diverse sources and to link this information. Initially the origin of the information should be differentiated. This can be achieved by applying the automation pyramid or the RAMI model 4.0 as orientation: On the one hand this provides information, which has been generated on the field or control level. On the other hand it supplies information, which is managed centrally, e.g. in ERP systems.

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he classic flow of data in the automation pyramid takes place from one level to the next – for example from the component level to the control level. This represents a system transition. There are different types of system transitions: On the one hand the technological system transition, for example from one software tool or bus interface to the next. On the other hand, the system transition from one level of the automation pyramid to the other. Undoubtedly the most complex system transition is from one company to another. Each of these system transitions represents a hurdle in classic communication, which generally acts like a data filter, as different physical transfer media and different protocols are normally used in the automation pyramid levels. In the case of company transitions there is the additional factor of mapping to different data models. These hurdles are overcome by using gateways or protocol converters, which often requires great effort and expense.

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Therefore the central aim has to be to eliminate these hurdles to make data and information available fast and universally.

It is only possible to devote oneself to the actual target – the linking of information from different sources – when data availability is given. These hurdles, however, cannot be eliminated using conventional processes. Instead a central pool is formed, parallel to the existing transfer processes, which can be addressed directly from different sources. The term “Cloud” is currently being used synonymously for this purpose. There are no classic hurdles in the cloud. Different companies can exchange data unobstructed using diverse tenants in the same cloud. The individual companies set up a “private Cloud” in their own tenant as a basis, on which the access permissions are kept completely “private” at first. If it becomes necessary as part of a new business idea to make individual information available to other companies or clouds, it can be exchanged between different tenants. The scalability of the cloud capacities allows for the recording of data, which is as yet unknown to the user and could give rise

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Secure data exchange using authentication and certificate exchange .

to additional knowledge or generate business cases in the future as applicable.

For this reason we, the sensor people at Leuze electronic, have committed ourselves to the subject of data availability and for the first time have brought data directly from the sensor into the cloud, across all systems. This involves the integration of an OPC UA server in our sensor and docking onto the Microsoft Azure Cloud with the publishersubscriber model. We have extended this transition by the IoT Proxy from Microsoft to enable data transfer universally in all directions. The proxy now makes it possible to analogically operate client-server communication to local shop floor concepts. The major difference of these solutions is that this communication and consequently the data is available globally and not just locally. Therefore, the data can also be networked globally across systems and company borders for interpretation and evaluation purposes.

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In American English the term “Internet of Things” (IoT or IIoT) is used instead of Industry 4.0. This term was intentionally associated with the developments of the “World Wide Web” around the turn of the millennium twenty years ago. The developments in this area were very similar. The sudden availability of different data in a common data space has lead to new networking and eventually to new business models. From our point of view, we can outline a very similar course of development for Industry 4.0 and IoT/IIoT. Firstly, the primary aim has to be making data available from different sources. The networking of this data is the next step and finally new business models emerge. Metaphorically speaking, we are currently constructing a highway for transporting goods at a later stage, to which we can then attach business cases. At the moment no one knows exactly where this highway will lead. This can be illustrated through the development of industrial communication relations: In the past, point-to-point connections between the control unit and the respective device - sensor or actuator - have dominated industrial automation. Today the master/slave communication model dominates between the levels of the automation pyramid. This means that a control unit typically operates several end devices (fieldbus installation) through one cable. Thus, a transition to a netlike communication architecture is created, which we already know from the IT sector. This enables data transfer between all levels in

arbitrary directions. It is essential for the networking and assessment of the data that the data is up-to-date and has a specific, for example geographical, reference. This development again models itself on the classic IT systems.

Example of “Google Maps”: Data on traffic congestion is taken directly from the vehicles, linked to geographical data and is made available for evaluation within a few seconds.

This global availability immediately raises the question of data integrity. It is an inevitably accepted prerequisite that data integrity must be ensured on communication channels and in globally available systems. OPC UA is tested in line with the federal institute for security and information technology 24 | Industry Asia Pacific | April 2018

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Author: Herbert Köbel Head of Competence Center Software Leuze electronic GmbH + Co. KG

implement this standard in its Ident products. Thus, seamless integration of information from Leuze bar code readers into the I4.0 management shell is possible. Seamless means that the information can be transferred from the sensors via OPC UA and can be applied in the management shell data model without additional transformation.

To consistently structure the availability of information, detection and addressing of data sources has to be made possible across all system borders from the cloud. This does not entail making unprotected access possible but rather is an installation aid. It is not practicable to manually publicize a large number of edge devices (for example sensors and actuators) to a global cloud system, or to register them in the cloud system. Instead technological mechanisms are required, which make it possible for the cloud system to autonomously identify edge devices that are centrally assigned to it. These mechanisms are called global discovery functionalities. There are two different mechanisms, which are integral parts of the OPC UA standard: Local discovery mechanisms (Local Discovery Server) on the one hand, and on the other hand global discovery mechanisms (Global Directory Server). These mechanisms require an extensive certificate exchange (Trust List Type) to safeguard access.

Sensors from Leuze electronic are – corresponding to its client promise “Smarter Usability” – available with secure access in all forms of the discovery mechanisms.

and offers all four generally stipulated safety features for secure communication: Authentication, authorization, verification and encryption. In this way tested methods and procedures from the world of information technology (IT) are transferred into the world of automation technology (OT – Operations Technology). This can be subsumed under the heading “IT2OT” (or “ITgoesOT”). This raises questions about global authorization procedures: Future authentication will take place using certificates. In the future, sensors from Leuze electronic will therefore be equipped with a unique safety certificate in addition to the identification data to date such as their serial number.

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To make data in the cloud available and easy to use, without having to use big data and neural network technology on the data in the cloud, it is essential that the data is clearly structured before being sent (for example from a sensor) and has been transformed into information in place of raw data. Ideally the aim is to provide information from related data sources in a standardized structure. Different attempts and approaches have already been undertaken in this direction. Consequently there will be a specification of the management shell from ZVEI with the OPC UA description model. An application-specific companion standard from the “Advancing identification matters user organization” has also been specifically defined for sensors in the auto ID sector (for example bar code scanner). The use of applicationspecific device descriptions and profiles standardizes the interpretation of information. Leuze electronic will 24 | Industry Asia Pacific | April 2018

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As outlined at the beginning, one of the core points of Industry 4.0 is the holistic information provision in the life cycle of an asset. This means that different information should be bundled in so-called management shells and be made available to the different users quickly and transparently.

In this system approach the ideas of augmented reality technology fit in seamlessly. With the help of data glasses this technology enriches the actual visible environment with virtual information in the user's field of vision. This technology is especially suitable for Industry 4.0 with the definition of extensive asset descriptions, as the diverse information can be made visible directly at the object's actual place of use, without physically intervening in the system. A decisive advantage is the visualization of the features and characteristics, which were to date only available in graphics in manuals and web portals and are now visibly on display in the field of vision at the appropriate point in the actual space. This applies in particular to optical sensors, with a reading beam or reading field that is not visible to the user.

The user no longer needs to avail of cumbersome transfer services. Leuze electronic shows the benefit of usability with the data glasses from Microsoft. Taking the example of two bar code readers which are installed on a conveyor belt and conduct active readings, their different information such as current status and device description appears in the user's field of vision, when looking at the device. www.leuze-electronic.fr

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NEW SECO SOLID-CARBIDE CUTTING TOOLS BOOST KNEE IMPLANT MACHINING SPEEDS

Seco Tools has introduced the industry’s first product line specifically dedicated to knee implant machining.

The new Jabro® medical range of solid-carbide cutting tools combines different machining strategies such as high-speed machining to shorten part cycle times when machining knee implants by as much as 50 percent.

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he tools’ continuous grades and optimized coatings result in exceptional part surfaces that reduce, and often eliminate, the need for polishing or fine finishing operations. These features also promote excellent process stability and long tool life.

For more information on the Jabro medical cutters, please contact a local Seco representative or visit our Jabro product page. www.secotools.com

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The Jabro medical range includes 9 advanced geometries and 39 tools, most of which are positioned in Jabro Tornado high-speed cutting family. Each geometry is designed for particular applications in the machining of tibial tray and femoral knee implant parts. And because the new dedicated tools excel in the machining of CoCr (Cobalt Chrome) and Ti6Al4V ISO-S12 parts (3D printed), they maximize machine performance for other medical components such as those for hip replacements and bone plates as well.

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DE DIETRICH PROCESS SYSTEMS IS SUCCESSFUL WITH HYGIENIC DRYING IN A VACUUM SPHERICAL DRYER FOR API PRODUCTION

Spherical Dryer in RosenmundÂŽ Design.

Fast drying. Emptied completely. Cleaned in a flash. Following the manufacture by wet chemical processes, Active Pharmaceutical Ingredients are precipitated or crystallized out from the solvent. The subsequent steps are usually isolation and drying. Hygienic drying in a vacuum requires a lot of attributes. The innovative spherical dryer design provides the highest performance according process control and latest GMP standards. De Dietrich Process Systems is currently delivering several units in that field.

Important advantages at a glance - Fast drying, mixing and granulation - Easy cleaning (WIP/CIP) - Total product discharge - Short drying time due to high heat transfer design - Easy to inspect by quick lock opening - Explosion pressure shock resistant design - Compact design allows easy installation in existing production buildings

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The lower half of the sphere is removeable either by pivoting or dropping. This allows total and full visual and manual access to the process area and the accessibility, cleanability and a fast and residue-free discharge are the most important prerequisites for the production of high-quality products.

Effective trouble free washing and cleaning (WIP/CIP) is required to maintain the systems in order to meet strict hygienic standards.

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These conditions are a real challenge to agitated vacuum dryers and are met by the characteristics of the patented top driven RosenmundÂŽ Spherical Dryer design.

Superior mixing with three arm agitator The spherical dryer achieves a high grade of mixing via a three arm agitator specially designed to conform to the spherical wall. The agitator drive together with the shaft seal is mounted on the upper sphere. For sealing the rotation either gas or liquid lubricated double acting mechanical seals are supplied.

By heating the agitator and a high rational speed, the heat exchange can be increased. A reduced clearance between the body and the agitator improves the heat transfer and prevents wet goods from being baked onto the hub and blades. These are ideal conditions for excellent solid mixing in contact with the heated wall surface which results in short drying times and reproducible drying results.

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RosenmundÂŽ Spherical Dryer Pilot Scale Machine.

To prevent the formation of agglomerates, a high speed chopper can break up the lumps and assist the removal of moisture from within.

Fully dischargeable At the center and lowest point of the sphere, a dead-space free design of valve allows the product to flow without restriction and the risk of building bulk bridges. With this free passage and a gentle rotating agitator valuable products can be fully discharged without being jammed.

Pack off system For the packing of the discharged product the dryer can be supplied with a pack off system. These systems are regularly supplied with a continuous liner to prevent active ingredients being exposed to the ambient. With a weighing scale and a permanent actuated discharge valve the product can be dosed to a preset value. A mill can also be placed between the discharge valve and the pack off system as an integrated part to achieve smaller particle sizes.

Due to the spherical design and the location of critical parts like the mechanical seal above the product level, washing and cleaning in place (WIP/CIP) procedures can be carried out efficient with minimum quantity of detergents. Moving and retractable cleaning ARD- Nozzles (Aftertreatment Regeneration Device) with rotating spray heads enter by pressure of the cleaning liquid from the vessel wall to the center of the sphere and enable a good coverage of the detergents on the product contacted surfaces. When the spraying is completed, the ARD nozzles retract themselves under spring load to be flush with the inner surface of the vessel, thus closing free of dead spaces. Due to the slope in direction to the outlet valve cleaning fluids and dissolved product residues are drained at the lowest point of the vessel.

For the purpose of conducting a qualitative coverage test of the spray devices, a riboflavin test can be performed to measure the accuracy of the cleaning. The results of this procedure can be useful for in the development of cleaning validation protocols.

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Cleaned in a flash In the pharmaceutical industries federal agencies set requirements for cleaning process equipment. These good manufacturing practices are regulations put in place to ensure equipment is maintained in a clean and orderly fashion. The main concerns is to avoid contamination of the product and cross-contamination (by improper cleaning,

bad maintenance) both of which can lead to product callbacks.

Easy access for inspection To allow a quick inspection at any time the RosenmundÂŽ top driven spherical dryer can be opened easily by swiveling the lower half of the sphere. This operation is simply achieved by 24 | Industry Asia Pacific | April 2018

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NEWS Module Description 1000 1025 1100 1300 1700 2000 4500 7500 7600 8000

Sphere Discharge valve Quick lock (bayonet) Sampling valve Hydraulic actuated hinge Drive unit/Agitator Mechanical seal Chopper Spray balls (ARD nozzles) Dust filter

a hydraulic driven quick lock bayonet at the main flange and a hinge at the joint of the two spheres.

A further advantage of this partition into two halves is the possibility to install the dryer between two floors. The product discharge area with its lower part of the sphere can be located in a classified clean room whereby the upper part of the sphere is separated in the technical area.

Versatile design features and sizes Since dryers are usually designed for vacuum operation, the risk of thermal decomposition or dust explosion requires them to be designed for higher pressures in many cases.

The spherical shape with maximum volume and minimum surface is the ideal geometry for an explosion containing shock resistant design.

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The dryer can be manufactured either in stainless steel or, for high corrosive applications, in nickel alloys with high resistance to acids. The size ranges are from 100 to 4’000l net volume. The vessel is fully jacketed, insulated and covered by welded metal sheeting. Normally the dryer come along with skids for heating / cooling and vacuum including a condensation of the vapors. Particle fines which can be fluidized during drying are withheld by a dust filter with cartridges whereby the filtration media can either be made of a textile cloth or by a sintered wire mesh.

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To optimize the performance it is important to adjust the peripheral equipment like heating / cooling and condensing / vacuum to match the specific requirements of the drying performance.

For heating / cooling mostly indirect loop systems are used in which a thermal liquid such as water, a glycolwater mixture, or thermal oil circulates through the dryer jacket. This liquid passes through a heat exchanger that respectively transfers the heat from the heat source (e.g. steam). Sensitive products may require rapid cooling at the end of the drying to maintain product quality so care must be taken that heat from the product can be removed to the coolant.

Condensers, typically shell-and-tube type, are used mostly to recover valuable process solvents which are evaporated during drying. Condensers used with dryers are operated in a way that vapors are condensed inside the tubes instead outside. The advantage is that the straight tubes bundles can be cleaned more efficiently.

For the fast and gentle drying at reduced evaporation temperature a vacuum system is required. A wide range of pumps are available on the market whereby screw or liquid ring vacuum pumps are generally used.

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Three arm agitator with enhanced heat transfer design and high speed chopper.

Optimizing and scale up the drying Process Either to optimize existing processes or to develop the best possible process parameters for new or modified products, trials are recommended. The Rosenmund® spherical dryers cover a wide range of applications. From pure drying to combined processes with mixing and granulation results on drying and product quality can be optimized. Therefore pilot scale machines are installed at the site of the pharmaceutical manufacturer to implement the spherical dryer to the running process.

To summarize: Spherical dryers are the ideal dryer in the production of high valuable products like pharmaceutical ingredients. The spherical design allows a full discharge and cleaning can be performed easily to avoid the risk of cross contamination. From pure drying up to mixing and granulation the Rosenmund ®spherical dryer can cover a wide range of application. Due to the high heat transfer and optimized peripheral equipment drying time can be reduced significantly.

Rosenmund ® is a brand of De Dietrich Process Systems, dedicated to filtration, drying, containment solutions: https://www.dedietrich.com/en/solutions-and-products/ liquid-solid-separation https://www.dedietrich.com/en/solutions-and-products/ vacuum-drying-solutions https://www.dedietrich.com/en/solutions-and-products/ containment De Dietrich Process Systems designs, produces and markets solutions based on equipment which uses glasslined steel, stainless steel, special alloys, and borosilicate glass technologies respectively for the chemical and pharmaceutical industries.

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De Dietrich's business also covers the engineering, planning, installation and commissioning of chemical units in materials resistant to corrosion and provides the corresponding service provisions.Founded in 1684, De Dietrich Process Systems has a strong global presence, with offices located in fifteen countries. www.dedietrich.com

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