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Asia Pacific THE INDUSTRY MAGAZINE FOR ASIA

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36 THE EXOSKELETONS ARE HERE

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Send your press releases to: editor@ipmediaonline.com To receive the Industry Asia Pacific newsletter, please subscribe online: www.industry-asia-pacific.com Industry Asia Pacific is the magazine for engineers published by INDUPORTALS MEDIA PUBLISHING. 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. https://induportals-media-publishing.com

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English version

THE EXOSKELETONS ARE HERE While the use of exoskeletons in industry is still at the lower end of the spectrum, there is growing awareness about the benefits of exoskeletons in industrial applications.

I by Milton D’SILVA

n nature, some animals and insects have exoskeletons or external skeletons unlike most other living creatures, including humans, who have internal skeletons or endoskeletons. Crabs, lobsters, cockroaches, grasshoppers and several types of beetles are examples of natural exoskeletons. The early body armour adopted by human beings for combat was inspired by these exoskeletal creatures. The exoskeleton as a wearable device to augment human capabilities is of more recent origin, even as the idea was considered by many early inventors. An early example is a passive spring body brace invented in 1890, which supported the upper body in a stooping position, to relieve fatigue. However, the concept received serious attention only in the 1960s when GE developed the Hardiman in collaboration with the US Army and Navy for military use. Though the project was not successful, it paved the way for further development of the concept.

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Example of a natural exoskeleton – the Japanese Spider Crab.

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The highly ergonomic Comau MATE upper body exoskeleton.

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The FORTIS from Lockheed Martin is suitable for handling heavy tools.

Exoskeletons thus made for human beings may be described as mechanical or mechatronic devices attached closely to the body, which support the musculoskeletal system using various mechanical principles. These wearable devices mimic the structure of human limbs, joints and muscles and boost the capabilities, enhancing the performance. Depending on the type, exoskeletons work in different ways, but basically shift the weight from one part of the body to another, reducing continuous strain. Besides augmenting the capacity to carry heavier loads without causing fatigue, exoskeletons also improve the body posture and minimise the risk of injury.

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Modern exoskeletons, developed mostly during the last two decades, are of two types – active and passive. Active exoskeletons are equipped with sensors and actuators, and powered by battery operated electric motors, pneumatics, hydraulics, or a combination of these systems. Passive exoskeletons are purely mechanical devices and use the restorative forces of elements like springs and dampers. There are further divisions in exoskeletons based on form – upper body, lower body or full body exoskeletons. Based on applications, exoskeletons are divided into two broad categories – medical and industrial. Medical exoskeletons 35 | Industry Asia Pacific | July 2021

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are used in the rehabilitation of patients post-surgery or to assist in those recuperating from paralysis or muscular dystrophy and other disabilities. Industrial exoskeletons also have military applications – in fact these were initially used in defence services and more recently have been deployed in industry. Exoskeletons are variously called exosuits or wearable robots, but unlike robots, which are autonomous and work independent of human support, the exoskeleton works in tandem with the human body, not as a replacement for any limb. This article is basically about industrial exoskeletons used by workers engaged in various activities. In spite of mechanisation and automation of workplaces with various handling equipment like trolleys, hoists, pallet trucks and overhead cranes, there are a lot of activities in industry, which are physically demanding yet cannot be automated. These vary from lifting of heavy loads or working in assembly operations that involve working long hours in standing or bending positions. Also many assembly operations in automotive and aerospace industries involve workers engaged in tasks with their arms continuously stretched upwards, carrying heavy tools. These activities cause pressure on the lumbar spine and/or on muscles in


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various parts of the body, which in turn result in work related musculoskeletal disorders or WRMSDs. Growing health concerns Across the developed world – the Americas, Europe, Japan and now even China – the population is ageing and so is the working class – people working in factories and utilities – the typical blue collar jobs where manual labour in various forms is routine. These are also the jobs where the risks of workplace injuries, often of serious nature, are high and WRMSDs are common, adding to the overheads in terms of productivity loss due to sickness and absenteeism as well as high insurance costs. Apart from the unfairness of letting ageing employees go, there is that matter of the younger generation not so enthusiastic about jobs in factories and anything that involves physical activity. The situation is ripe for the induction of exoskeletons on the shop floor. According to a discussion paper published by the European Agency for Safety and Health at Work, over 40% of workers in Europe suffer from lower back pain or shoulder complaints. Furthermore, 63% of workers perform repetitive tasks or frequently work (46%) in potentially hazardous positions. This not only results in injuries and absenteeism, but also costs about 2% of the gross domestic product

of the European Union. Across the Atlantic in the US, the Centers for Disease Control and Prevention states that back pain is the most prevalent work-related health problem. The Occupational Safety and Health Administration estimates that employers pay nearly $1 billion for direct workers’ compensation. Against this backdrop industrial exoskeletons are becoming popular to address the many concerns of worker safety and productivity. The potential benefits of industrial exoskeletons are many, as these are designed to ease the load on the spine, decrease muscle activity and improve the posture, reducing the risk of injuries. Upper body exoskeletons reduce shoulder discomfort and increase productivity in assembly operations. While the use of exoskeletons in industry is still at the lower end of the spectrum, there is growing awareness about the benefits of exoskeletons in industrial applications, especially in automotive, construction, manufacturing and logistics sectors. An expanding market According to a recent analysis by Frost & Sullivan, the global industrial exoskeletons market is expanding rapidly, driven by high injury costs and aging and shrinking skilled workforces across sectors. It is estimated to witness nearly a

The Skelex exoskeleton is powered by FlexFrame Technology.

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seven-fold growth, reaching US$426.6 million by 2025 from US$62.7 million in 2020, up at a compound annual growth rate (CAGR) of 46.7%. (These figures do not include medical or military exoskeletons, only industrial ones.) “Manufacturers are investing in R&D to develop technologically advanced exoskeletons, which improve performance and productivity,” says Anjan Roy, Chemicals, Materials & Nutrition Research Analyst at Frost & Sullivan. “To deploy the latest innovations, manufacturers will focus on the robot-as-a-service (RaaS) model to improve affordability for end users and test products for large-scale deployment.” Among the end-use industries, manufacturing – driven by the automotive sector – held the highest revenue share in 2020 and is projected to top US$271.4 million in 2025. Other manual, labour-intensive industries such as construction and transport will also make extensive deployments of industrial exoskeletons over the next four to five years as companies across these sectors focus on reducing the cost of on-the-job injuries. “From a product segment perspective, active or powered industrial exoskeletons – which are technologically advanced PPE that are powered by batteries or electricity – are expected to have the highest revenue share at 69.9% over the forecast period, whereas passive industrial exoskeletons will constitute 30.1% market share,” adds Roy. Industrial exoskeletons in the market When the Swiss startup noonee launched its prototype Chairless Chair in 2014, German automaker Audi AG was one the first to test the wearable seating passive exoskeleton at its assembly lines at Neckarsulm plant. “With the use of the Chairless Chair, we are continuously improving ergonomics in assembly operations. We also anticipate new applications for colleagues with reduced physical capabilities,” Dr Mathias Keil, Head of Industrial Engineering Methods at AUDI AG, had then stated about the experiment. More automakers have since adopted the ‘Chair-olution’ as noonee called its invention, and it has undergone many refinements since. “Through active sitting on the Chairless Chair, your back and thigh muscles are strengthened while your spine, intervertebral discs and knees are relieved. The Chairless Chair supports a healthy and upright sitting posture and takes preventive action so that pain does not occur at all,” claims the company in its latest flyer made available during the presentation at the Digital Hannover Messe 2021. The new Chairless Chair 2.0 is a passive exoskeleton that allows workers to change easily between sitting, walking and standing.

Swiss startup noonee’s Chairless Chair tested extensively by Audi AG.

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German company Ottoblock designs and manufactures the Paexo range of exoskeletons for the back, shoulder, wrist, neck and even the thumb! Paexo was developed based on Ottobock’s nearly 100 years of expertise in the fields of biomechanics, orthopaedic technology and product ergonomics. The company worked with automaker Volkswagen AG and the Institute for Biomechanics and Orthopaedics at the German Sport University Cologne to develop these products. The close cooperation with Volkswagen led to insights in production, work ergonomics

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The Paexo Thumb exoskeleton protects the tip of the thumb.


y X exoskeleton from German Bionic, at Hannover Messe 2019.

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and occupational health and safety. At 1.9 kg, the Paexo is the most lightweight exoskeleton for overhead work. At Automatica 2018, Comau, the global leader in advanced industrial automation solutions, launched MATE, its first wearable exoskeleton. Designed to improve work quality in an efficient and highly ergonomic manner, MATE works by providing consistent and advanced movement assistance during repetitive as well as daily tasks. It uses an advanced spring-based passive structure and delivers lightweight, breathable and highly effective postural support without the need for batteries, motors or other failure-prone devices. In December 2020, Comau launched a new version, the MATE-XT, which fully accommodates the specific needs of workers in demanding industrial, non-industrial and open-air environments. Perfect for carpentry, construction, agriculture, assembly, logistics and more, MATE-XT replicates the user’s physiological shoulder movements to provide optimal upper body support and offers 8 different levels of assistance that can be quickly set – or changed – by the worker without interrupting the task at hand. At the 2019 Hannover Messe, German Bionic, a robotics company, presented the first connected robot exoskeleton compatible with IIoT. The Cray X exoskeleton, having undergone many improvements, is said to be the first cloud connected exoskeleton, enabling complete integration into Smart Factory and Industry 4.0 environments. Skelex, a Dutch startup, is another company that has successfully introduced an upper body passive skeleton in the market, primarily for the aerospace and automotive industries. Gaurav Genani, an engineer by day is a guitarist after work, performing in a band and nursing a wrist injury, apart from having gait issues not uncommon with guitar players. While doing his master’s thesis on musculoskeletal disorders amongst musicians at TU Delft in Rotterdam, Gaurav had his Eureka moment that led to exoskeletons and the founding of Skelex. What started as an idea in 2013 finally found its way to the market in 2017 as Skelex 360, with Airbus Industrie among its first customers. The Skelex exoskeleton is powered by the proprietary FlexFrame Technology, the device adapting to the user’s body shape, and supporting biological movement of the shoulder joint, transferring the weight to the lower body. Skelex however does not manufacture these exoskeletons, preferring to concentrate on design and innovation, and has outsourced manufacturing to another Dutch company.

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Collaboration and outsourced manufacturing is a trend that has caught up in exoskeletons, and even aerospace companies have got into the act. Boeing – one of the largest aerospace manufacturers – has been testing different types of exoskeletons as part of its Working Smart strategy. The company has tested the Ekso Bionics’ EksoVest extensively and found it leads to increased worker strength and speed, as well as reduced fatigue on repetitive tasks, such as overhead drilling. These are now inducted in assembly operations. Lockheed Martin, the well-known global security and aerospace company, manufactures exoskeletons for its own requirements as well as for military

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Ottoblock designs and manufactures the Paexo range of exoskeletons.

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Ekso Bionics’ EVO allows full flexibility of the torso and waist.

Hyundai Motor Group’s VEX and CEX exoskeletons. 35 | Industry Asia Pacific | July 2021

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applications, based on designs of well-known companies like Ekso Bionics and Boston Engineering. While Ekso Bionics has been engaged in developing exoskeleton technology to enhance natural abilities and improve quality of life since 2005, Boston Engineering is a product design company. One of the more interesting exoskeleton products of Lockheed Martin is the FORTIS exoskeleton for handling heavy tools through a spring loaded arm. Held in a gimbal for smooth rotation and flexibility, the FORTIS takes the weight of a heavy tool off the user’s body and directly passes it off into the ground, allowing effortless handling while retaining the controls. Having undergone several revisions since it was first introduced in 2017, the latest version of the FORTIS features a new, redesigned spring arm, which is connected to the exoskeleton at the waist. A set of counterweights at the back keeps the operator steady. Korean company Hyundai Motor Group is also engaged in research and development of exoskeletons as part of its robotics project. Hyundai’s latest exoskeleton wearable robot, Vest Exoskeleton (VEX), has won the Product Design category (Innovative Product field) at the Red Dot Design Awards, the prestigious international design competition. VEX was developed in line with Hyundai Motor Group’s commitment to the health and safety of its industrial workers. It is designed to prevent injuries while advancing the field of robotics. The compact design is achieved using the latest technology that eliminates the need for a battery. VEX, which wears like a backpack, utilises a polycentric axis to provide a maximum force of 5.5 kgf – an astonishing achievement given it weighs only 2.8 kg. In addition to VEX, Hyundai has also designed another lightweight wearable robot, the Chairless Exoskeleton (CEX). With CEX, workers can easily maintain a sitting position without a stool or chair. While all the examples quoted above are of passive exoskeletons which are more common among industrial versions in general, there are also active exoskeletons available for industrial use. ULS Robotics, a Shanghai based startup designs and develops exoskeletons for industrial applications. The company has already in production three types of industrial exoskeletons for upper body, lower body and the lumbar region respectively. MAPS-U is the upper body exoskeleton with four degrees of freedom that provides 10kg of load assistance to the arms for lifting endurance, also reducing shoulder fatigue while preventing work injuries. HEMS-L is a waist that provides 20kg of load assistance, while HEMS-GS is a lower limb exoskeleton with 12 degrees of freedom and 50kg load bearing capacity. All three models are fully electric with battery power for 5 hours of continuous work and quick and easy replacement facility to continue the job beyond. The company says it has many international clients in the automotive and aviation sectors, as well as logistics.

The way ahead The exoskeletons have arrived and are in use across various manufacturing sites and assembly operations globally. These are getting better and lighter with new materials like ultralight carbon and soft, super strong technical textiles used in their construction. Once prohibitively expensive, exoskeletons are now within the affordable range of large companies, and with growing popularity and mass production, prices are expected to fall further. But it is still early days and the jury is out on the safety and efficacy of the exoskeleton. In the absence of empirical evidence based on detailed studies as well as absence of standards, there are concerns expressed about the health and safety aspects. For example, the US Consumer Product Safety Commission (CPSC) has warned that muscle strain could occur if a powered exoskeleton moves beyond the normal range of motion of a user’s joint. There is also the risk of skin irritation or chemical burns if an exoskeleton battery leaks corrosive materials. A study has pointed out that some upper body exoskeletons do not reduce the total load on the worker, merely shift it from the shoulders to the lower back and legs. Other risks include pressure wounds or compressed nerves from prolonged use. When such wearable devices are used by multiple users, poor hygiene could spread infectious diseases. In 2017, ASTM International, the international standards organisation, proposed a guide to provide standardised tools to assess and improve the usability and usefulness of exoskeletons. Accordingly the ASTM Committee F48 was formed to develop voluntary consensus standards for exoskeletons and exosuits. It is currently working on the proposed standard, WK68719, working through six subcommittees that include about 150 members, including startups, government agencies, and enterprises such as Boeing and BMW. The F48 committee has already published the first two standards regarding terminology and Standard Practice for Labelling and Information for Exoskeletons, many others are under development. In February 2021, the committee approved a new standard to help establish ergonomic parameters and test metrics. According to ASTM International board member Christopher Reid, the new standard can be used during the iterative design process of exoskeleton creation as well as for comparisons between commercially off-the-shelf ready systems. It is a work in progress and the standards are still evolving. But the exoskeleton has arrived.

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No article on exoskeletons can ignore the contribution of Dr Homayoon Kazerooni, academician and entrepreneur. A professor in the Mechanical Engineering Department at the University of California, Berkeley, Dr Kazerooni is also the director of Berkeley Robotics and Human Engineering Laboratory. The laboratory’s mission is to develop fundamental scientific and engineering principles on robotics, control sciences, exoskeletons, and bioengineering. Dr Kazerooni founded Ekso Bionics which became a public

company in 2014, and is the founder and current CEO of US Bionics (DBA suitX), which brings advanced exoskeleton technologies to various markets. Most of the technologies developed in this lab at Berkeley have found their way to market. In fact, suitX offers all three individual exoskeleton modules designed to be able to work in unison to assist the shoulders, back and legs. Each module can be worn individually or in combination to make seven different configurations to cater to customers’ specific needs.

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MONTH’S PRODUCT

DEEP INSIGHT WITH LIGHT REVOLUTION

How do you make a car rim glow without melting the tyre? Patrick Llewelyn-Davies does it with light, and thereby creates an unusually enlightening picture of this everyday object. His Light Revolution System redefines the contrast of light and shadow, as it uniformly irradiates the object from a complete circular path. A precision motor from FAULHABER ensures the uniform movement of the lamps and exact adherence to 360 degrees.

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ost photographs have the snapshot noise in common: whether a smartphone selfie or an artistic professional photograph – the shutter allows the light to pass through the aperture for just a fraction of a second. Fittingly, the analog shutter noise is even simulated by fully digital cameras to acoustically mark the brief moment in which the image is captured.

But there is also a long tradition of light painting, in which the aperture remains open for an extended period of time and moving lights leave their trace on the negative or image sensor. Fascinating images and views can be created using this technique. A familiar example is the red and white streaks of light from headlights and tail lights that can be seen on long-exposure images of motorways at night. Unlike with “normal” photography, movement is not stopped, but rather captured.

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Plastic glow British photographer Patrick Llewelyn-Davies bridges the gap between “moving” light painting and still life. In his images, the resting object is at the centre, and he uses the moving light like a pen for colouring in. Only that he adds no additional colour to his images. Instead, he causes the objects to glow and illuminate. His use of light also allows for the creation of new and sometimes X-ray-like glimpses into the photographed objects. They take on a quasi three 35 | Industry Asia Pacific | July 2021

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dimensional plasticity even though they never optically leave the 2D world.

or less than 360 degrees. And they should accomplish this in precisely the specified amount of time.”

The secret to the light-painted still lives is a seemingly simple apparatus called “Light Revolution System”, which has two meanings. Revolution here means both rotation as well as a fundamental renewal. Two intensely bright LED lights complete a cycle around a round table on which the object of the photographic efforts has been placed. It generally takes six seconds for them to complete their rotation. The time can be varied, however, depending on the desired light effect. The system does not just travel a round path but rather opens completely new possibilities for photographic image composition – there has never before been anything like it on the market.

The inventor/photographer reports of earlier attempts with simpler components that were not able to meet these requirements. The greatest challenge was in moving the central axis of the system both very precisely as well as jerkfree. At the same time, the portable device needed to be as light as possible. When making the selection of the right drive, the experts of the British FAULHABER sales partner EMS provided assistance. “The support from EMS was great,” explains Patrick Llewelyn-Davies. “They provided the necessary technical expertise for the drive and the controller. It is decisive for the high quality of the product. Moreover, motors from FAULHABER have proven themselves in highly critical areas such as aerospace. That’s how I knew that they would have the accuracy and reliability required by the Light Revolution System.” The experts from EMS identified the brushless motors of the BX4 series as the optimum solution. They were able to ensure the desired precision and repeatability of the sequence. “Once we selected a motor family, we could try different sizes without intervening in the programming,” explains Dave Walsha, Commercial Development Officer at EMS, with regard to the joint development work. “As a result, we were able to respond very flexibly to changes to the system.” Thanks to the compact and lightweight design of the BX4 motors, the “ideal weight” was also maintained.

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Maximum precision during rotary motion The lights are fastened to two arms and can be adjusted in height to achieve different angles of incidence. The arms are firmly attached to the rotating central axis. At first glance, this arrangement does not call for any spectacular technology, but in detail, maximum precision and extremely smooth operation are decisive. “Any pause or jerk in the rotation, regardless of how short, would result in uneven illumination,” explains Patrick Llewelyn-Davies. “There would be brighter and darker patches that would affect or destroy the intended effect. The same applies for travelling the complete circle. The arms must not move one degree more

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Detailed 3D models of museum objects Of course, the photographer thoroughly tested his Light Revolution System himself. In his online gallery, you can admire examples of the unique light effects that he has achieved with his system. The “glow” that he elicits from unassuming everyday objects like a chicken egg or a fishhook is created by placing the circling LED lamps very low above the table. Because part of the light is laterally reflected by the objects onto the base, a glowing aura is created that appears to emanate from within the objects.

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The system is currently being tested in various application areas. Instead of the lights, a camera can also be attached to one of the arms. If it is attached to an arc-shaped arm, the object can be photographed at a uniform distance from various angles. This method is used, e.g., by museums to calculate high-resolution 3D models of their valuable objects from image data. Researchers can then exchange this data worldwide and use it for their studies. Furthermore, precise replicas can be created using 3D printing. “Up to now, a considerable amount of hand work was associated with the creation of such images,” says Patrick LlewelynDavies. “With the Light Revolution System, the process can be largely automated and greatly accelerated.” https://www.faulhaber.com/en/home/

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NEW: TWO BECOME ONE. Gear unit and motor in one: the new DuoDrive.

Extremely high system efficiency Compact wash-down design Maintenance reduction System solution and simple commissioning via plug-and-play NORD Drivesystems Pvt. Ltd. | Fon +91 (0)20-3980 1200 | india@nord.com | www.nord.com


IT

ETHERNET/IP NETWORK EXTENDED TO IN-CABINET RESOURCE-CONSTRAINED DEVICES

ODVA announced today that The EtherNet/IP™ Specification has been enhanced to allow vendors to bring the network to resource-constrained devices in-cabinet, including push buttons and contactors. Cost, size, and power restrictions have historically limited the usage of EtherNet/IP at the edge, where many nodes are still hardwired. However, the continued decrease in the cost of semiconductor chips has enabled increased connectivity of simple devices, as evidenced by the rapid expansion of the Industrial Internet of Things (IIoT). The sustained, strong growth of EtherNet/IP combined with accelerating IT/OT convergence has made it possible to deploy EtherNet/IP within cabinets on lower-level automation devices such as contactors and push buttons.

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he inclusion of resource-constrained devices within cabinets on an EtherNet/IP network is enabled by recently published enhancements to The EtherNet/ IP Specification including the physical layer In-Cabinet Profile for EtherNet/IP along with low overhead UDP-only resource-constrained EtherNet/IP communication. Resource requirements have been reduced via enhancements such as an IT friendly LLDP node topology discovery mechanism, auto-commissioning support, and auto-device replacement support. Additionally, a specification for a new select line circuit facilitates the efficient delivery of system wide sequential commands.

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The EtherNet/IP in-cabinet bus solution reduces interface components through use of single pair Ethernet (IEEE Std 802.3cg-2019 10BASE-T1S) and reduces node cost via multidrop cabling that spans a single cabinet with one interface per device and one switch port that supports many devices. Cost is further reduced via cables that use composite network and control power to eliminate separate parallel runs. The select line for topology eliminates configuration switches by enabling discovery based on relative position and allows for direct connection with programming tools during assembly for parameterization. Assembly time is lowered by eliminating most wire or cable preparation with insulation displacement (piercing) connectors. Nodes will also be able to be replaced with compatible nodes of the same type during normal system operation without any engineering tools in a plug and play manner.

“Expanding the connectivity of EtherNet/IP to include devices with the smallest physical footprint and most limited hardware resources opens up tremendous opportunity for further digital transformation within automation at the edge. The ability to obtain diagnostic, prognostic, and asset identity information remotely from more devices will further drive down incidents of unplanned downtime and improve the efficiency of existing assets,” said Dr. Al Beydoun, President and Executive Director of ODVA. “The connection of resource-constrained devices to EtherNet/IP increases the value of existing networks for end users and reduces the need for secondary lower-level networks and associated gateways.” The extension of EtherNet/IP for in-cabinet resourceconstrained devices will dramatically increase the returnon-investment of adding the simplest of in-panel devices to the digital network. This will be made possible through reduced hardware requirements enabled by UDP-only EtherNet/IP communication, usage of single pair Ethernet, and shared in-cabinet external power and cabling. Adding low-level in-panel devices to the network will enable the benefits of additional remote diagnostics, asset information and parameterization capability, automatic node topology discovery, and plug and play device replacement. The lowered cost and improved value of these devices along with the ability to use one seamless network for both constrained and non-constrained devices is a clear win for automation end users. Visit odva.org to obtain the latest version of The EtherNet/IP Specification including the In-Cabinet Profile for resource-constrained EtherNet/IP devices. https://www.odva.org/

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AU TO M OT I V E

FPT INDUSTRIAL SIGNS TWO MEMORANDA OF UNDERSTANDING WITH LANDI RENZO GROUP FOR JOINT COLLABORATION ON CLEAN FUEL PROJECTS

FPT Industrial, the world’s largest designer and manufacturer of low-impact sustainable engines, and Landi Renzo Group, a leading company in the design, production and distribution of Compressed Natural Gas, Liquefied Natural Gas and Hydrogen components and systems, have signed two Memoranda of Understanding aimed at exploring the possibility of collaborating on Clean Fuel projects. The Memoranda are focused on the possible development of Natural Gas and Hydrogen technology respectively.

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onsidering that the green economy and sustainable mobility will play a key role in all industrial transportation segments and in recognition of the strengths and values of each other’s business and technological capabilities, the two companies will explore potential collaborations on developing complete, efficient and fully sustainable mobility solutions. The Memoranda of Understanding will allow FPT Industrial and Landi Renzo Group to leverage their proven and renowned specific competences and technological capabilities for both Natural Gas and Hydrogen in light of the enhancement of their role as active players in the green economy in line with the European Green Deal strategy, boosting the growth of renewable energies in the transportation sector. In the Natural Gas sector, the signing of the Memoranda of Understanding is intended to support the development of new fuel injection and management systems tailored for FPT Industrial applications, using Landi Renzo Group dedicated components. The collaboration will aim at optimizing the performance of the entire gas system and engine, evaluating how best to integrate Landi Renzo Group components into both Compressed Natural Gas and Liquefied Natural Gas applications.

Cristiano Musi, CEO of Landi Renzo Group commented: “Natural gas, biomethane, bio-LNG and hydrogen will play an ever-increasing role in the transport decarbonization effort, and we are very happy and proud to be at the side of a key player like FPT Industrial. This partnership acknowledges the major developments delivered by our Group as a technology innovator and system integrator, positioning the company to find new and increasingly efficient solutions.” Founded in 1954 and based in Cavriago (Reggio Emilia), Italy, Landi Renzo Group is the world leader in the design and production of components and feeding systems for CNG, LNG, Hydrogen and LPG fueled vehicles. It operates through 16 companies in 13 countries across 5 continents and has longstanding collaboration agreements with importers and distributors worldwide. The Group’s international vocation is proven by the export share of its total turnover, which is over 80%.

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The companies’ cooperation in the Hydrogen sector will also consider to cover areas of development that leverage the synergies that Compressed Natural Gas and Liquefied Natural Gas can offer in bridging the introduction of hydrogen to the transportation sector, from its use as a blend in natural gas to up to 100% hydrogen.

Pierpaolo Biffali, FPT Industrial Vice President Product Engineering, stated: “The road to Green Mobility means offering complete, state-of-the-art and viable solutions. And high added-value partnerships, like the one envisaged in the MoU just signed with the Landi Renzo Group, are key to our strategy, which aims at offering customers real opportunities and turn-key solutions, to lower the ecological and economic impact of their transport business.”

https://www.fptindustrial.com/

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ELECTRONICS

SERIAL PRODUCTION OF HEXADRONE’S TUNDRA MODULAR TOOL-CARRIER DRONE WITH FISCHER CONNECTORS’ RUGGED, MINIATURE CONNECTIVITY SOLUTIONS

The Tundra in flight.

Hexadrone unveiled its first serial drone, the Tundra, a ruggedized, multi-functional, modular drone that will be industrially manufactured in a factory under construction in France. The Tundra uses ultra-rugged, miniature Fischer UltiMate™ and Fischer MiniMax™ connectivity solutions, able to withstand the harsh environments the drone may need to operate in.

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esulting from more than three years of development, the Tundra is the first French modular, multi-rotor drone. Designed in Hexadrone’s workshops in the Haute-Loire in an open innovation logic, this collaborative tool carrier, in its beta version, won the prestigious Red Dot Design Award in 2018.

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Unveiled on April 30, 2021 in its serial version, the Tundra is a unique 100% modular, multifunctional unmanned aerial vehicle (UAV), designed and manufactured as a development hub for integrators. The body is equipped with numerous interfaces that allow the integration of accessories, sensors and other modules already available on the market, or the development of new ones. This enables the Tundra to adapt to custom features and rapid changes in the state of the art, which also helps it combat obsolescence. The drone’s arms are interchangeable and easy to remove. The user can choose from three different types, depending on the various missions and flight scenarios planned. With the most durable arms, the Tundra can carry a payload 35 | Industry Asia Pacific | July 2021

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of up to four kilos for a flight time of 30 minutes – a high performance in the world of multirotor drones. The serial production of the Tundra, made possible thanks to the construction of an industrial building underway in Saint Ferréol d’Auroure in the Haute-Loire, is the logical next step in this drone’s development that meets the market needs analyzed by Alexandre Labesse, Hexadrone’s Chairman and Founder: “With this multifunctional, modular tool carrier, our customers are opening up the field of possibilities in their collaborative projects and lowering their development costs when they adapt the drone to users’ new needs and new technologies on the market. This is not possible with most of today’s drones, which are designed for a single type of use and quickly become obsolete due to rapid technological advances. In response to obsolescence, we’ve opted for adaptability and durability.” The Tundra’s durability is ensured through a robust design that allows for intensive use in the field. The drone is waterproof and can cope with harsh conditions. Moreover,


The Fischer UltiMate™ Series interface on the Tundra’s body.

The Tundra with Yellowscan’s Mapper, equipped with three Fischer MiniMaxTM Series connectors.

The standard interface module can be adapted with Fischer MiniMaxTM connections.

transportation and assembly in the field are easy, as the landing gear can be fitted and the arms screwed on in less than a minute. Two types of robust, miniature connector for intensive, durable use To fulfill the drone’s technical requirements for modularity, reliability, durability, ruggedness and ease of use, Hexadrone chose Fischer Connectors’ high-performance, ultra-robust, push-pull connectivity solutions. The Tundra comes equipped with a rugged Fischer UltiMate™ USB 2.0 connector that is waterproof and reliable in all conditions. The standard interfaces can accommodate external modules linked, among others, by Fischer MiniMax™ connectors and cabling, which optimize the high-density miniaturization of on-board electronics, such as a companion computer, a storage module, a security key or a lidar that the Tundra can be fitted with for certain aerial remote-sensing missions using lasers.

technical requirements in terms of robustness and reliability, miniaturization, sealing up to IP68, and data transmission”. • Tundra: www.tundra.hexadrone.fr • Shop for Hexadrone’s drone: https://hexadrone.fr/ • Fischer UltiMate™ Series: www.fischerconnectors.com/ global/en/fischer-ultimatetm-series • Fischer MiniMax™ Series: www.fischerconnectors.com/ global/en/fischer-minimaxtm-series • F ischer Connectors’ solutions for UAVs: www. fischerconnectors.com/global/en/applications/roboticsunmanned-vehicles

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Guy Lacroix, Director of Fischer Connectors France, is very happy with the technological partnership established throughout this rugged drone’s development: “We’ve been supporting the Tundra’s innovations from the outset. Our experts are gratified to have been able to see the project through to serial production with suitable connectivity solutions. Since connectivity lies at the heart of this rugged UAV, our high-performance solutions proposed in this modular offering cover the whole range of integrators’ 35 | Industry Asia Pacific | July 2021

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ELECTRONICS

FISCHER ULTIMATE™ SERIES: NEW FIELD-READY SOLUTIONS FOR UNPARALLELED FUNCTIONALITY AND RUGGEDNESS IN EXTREME ENVIRONMENTS

The global connectivity solution provider Fischer Connectors has extended its flagship series of ultrarugged and harsh-environment connectors with two new products: the Fischer UltiMate™ 80, a fieldready NATO STANAG 4695-compatible connector offering unparalleled functionality and ruggedness in comparison with similar harsh-environment quick-release connectors; and the standard Fischer UltiMate™ connector now available in size 15 with various pin layouts of up to 27 signal and power contacts.

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ntermateable with other NATO STANAG 4695 connectors, the field-ready Fischer UltiMate 80 connector comes in two layouts featuring 6 or 7 signal and power contacts (size 08) with up to AWG 22. Engineered in Switzerland, it offers an ultra-rugged, lightweight and IP68-sealed connectivity solution for any harsh environment, especially for defense & security applications and soldier modernization programs. Its design is exceptionally rugged by any market standards and compliant with MIL-STD-810 and MIL-STD-202, providing environmental and mechanical performance and endurance that outperform by far other suppliers’ similar connectors:

• Ruggedness: high resistance to corrosion (500h salt mist), up to 10,000 mating cycles for the plug / 5,000 for the receptacle, random vibration 7.7 Grms, shock resistant (100 G), cable bending resistance (+/-45° for 5000 cycles), temperature (-55 °C to +135 °C), triple key coding • Light weight: housing material in aluminum: 2.7 g • Environmental sealing: connector Ingress Protection mated and unmated: IP68 sealing 2m/24h. The Fischer UltiMate 80 connector comes as a pre-cabled plug, and a pre-cabled and/or panel receptacle. As for the new Fischer UltiMate connector in size 15, it meets special power and high-speed data requirements for further design and technology developments with various contact layouts (2, 4, 8, 4+12 or 27 signal and power contacts). These new connectors are part of the world-renowned rugged, compact, and lightweight Fischer UltiMate Series

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NEWS With the new Fischer UltiMate 80, Fischer Connectors has been able to design a highly reliable and cost-effective product offering best value for money. The new Fischer UltiMate in size 15 features up to 27 signal and power contacts.

used to ruggedize technology for field operations in extreme environments. Environmentally sealed to resist extreme shocks and vibrations, these durable and reliable connectors are ideal to interconnect devices, equipment, hubs and embedded electronic systems where weight matters, for example in defense & security, industrial, instrumentation, marine & underwater, as well as robotics and unmanned vehicles. The Fischer UltiMate connectors’ resin-sealed contact block offers extreme sealing (up to IP68 / IP69 even unmated, gastight, CBRN decontamination), high shock and vibration resistance, as well as superior cable resistance in terms of traction. https://www.fischerconnectors.com/global/en/products/ ultimate

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E N E R G Y / P O W E R

REDUCE HEAT EXCHANGER MAINTENANCE INTERVALS WITH WATLOW’S NEW HELIMAX™ ULTRA-EFFICIENT ELECTRIC HEAT EXCHANGER

Watlow®, an industry leader in the design and manufacture of complete thermal systems, introduces its new HELIMAX™ ultra-efficient electric heat exchanger with Continuous Helical Flow Technology™, which helps reduce the coking and fouling typically associated with standard heat exchangers. Diminishing the coking and fouling rates can minimize heat exchanger maintenance intervals ultimately reducing downtime.

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ome heat exchanger design methods, such as segmental baffles, have known dead zones where hot spots can occur. These fluctuations within the heat exchanger to either the sheath or tube skin temperature or the localized flow rate are common causes of coking and fouling, which can lead to system failures and expensive downtime.

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HELIMAX with Continuous Helical Flow Technology enables ultra-high heat transfer rates that lowers the skin and shell temperature rise above the process fluid and offers the ability to push the limit on high outlet temperature applications. It also minimizes fluid bypass assuring tighter sheath temperature control and provides smaller shell diameters. As a result, high pressures can often be handled with thinner shell walls or without resorting to expensive exotic materials.

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“Watlow is excited to now offer the new HELIMAX heat exchanger to our customers,” said Dennis Long, director of strategic marketing. “HELIMAX’s Continuous Helical Flow Technology improves the velocity profile on the heating elements, allowing better heat transfer and flow rates improving overall system performance. This technology also reduces coking and fouling which keeps a system up and running. All of this in a smaller profile … the product is a win for any application requiring a heat exchanger.” HELIMAX is smaller and lighter weight compared to traditional heat exchangers offering significant benefits to space constraint applications such as offshore platforms or floating production storage and offloading vessels. www.watlow.com


IT

NEW AWS QUICK START FOR SOFTING EDGECONNECTOR SIEMENS AVAILABLE

The Quick Start offers a fast and flexible way to try out edgeConnector Siemens as connectivity solution with AWS.

Softing Industrial launches an AWS Quick Start for its edgeConnector Siemens docker container application, in collaboration with Amazon Web Services (AWS). The Quick Start automatically deploys edgeConnector Siemens and AWS IoT SiteWise in the AWS cloud. It demonstrates how to connect Siemens PLCs to the AWS cloud in a secure and scalable way.

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ustomers are increasingly facing challenges in connecting the cloud to the edge in a secure way. “Many customers that we speak to, are hesitant when it comes to connecting their machines to cloud and using the Internet of Things” says Dr. Christopher Anhalt, VP Product Marketing at Softing Industrial Automation GmbH. Industrial customers lack experience in edge computing and do not have access to reference artifacts and best-practices resources for edge computing and the Internet of Things.

edgeConnector Siemens is Softing’s first commercially available gateway product to support container technology. By leveraging Softing’s expertise in automation technology and IT/OT integration, it offers best-in-class connectivity for Siemens PLCs typically used in brownfield projects. As a Docker container, it seamlessly integrates into the AWS solution architecture for Industrial IoT and can be operated and managed efficiently. The AWS Quick Start for edgeConnector Siemens and AWS IoT SiteWise is available at: https://aws.amazon.com/quickstart/architecture/ softing-edgeconnector-siemens/

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The Softing edgeConnector Siemens Quick Start makes it easy for IT as well as for shopfloor personnel to gain firsthand experience with a secure and highly scalable endto-end solution for Industrial IoT. The Quick Start offers a fast and flexible way to try out edgeConnector Siemens as connectivity solution with AWS. It automates the deployment of Softing’s edgeConnector Siemens, a docker container application with gateway functionality, and AWS IoT SiteWise in the AWS cloud. A simulated Siemens S71500 PLC generates IoT sensor data that is sent to AWS via edgeConnector Siemens and visualized using AWS IoT

SiteWise. This entire deployment on AWS does not take more than 10 minutes.

More information is available here: https://industrial.softing. com/aws-quick-start.html

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FOOD PROCESS

BAKERY AND CONFECTIONERY EQUIPMENT SPECIALIST STANDARDISES ON QDOS PUMPS FOR PILOT INSTALLATIONS

An established Dutch food equipment designer, Tanis Food Tec, which specialises in process installations for bakery and confectionery products, is relying on Qdos peristaltic metering pumps from Watson-Marlow Fluid Technology Group (WMFTG) for all of its pilot machines. These pilot machines are deployed in R&D departments at major food manufacturers, where the accuracy of Qdos pumps in the dosing of colouring and flavouring is vital during development processes to help optimise the quality and cost of the end product.

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stablished in 1991, Tanis Food Tec has nurtured an enviable reputation for the development of sophisticated, fully automatic food processing solutions that involve operations such as weighing, preparing, pre-mixing, tempering, crystallising, plasticising, aerating, depositing, coating and decorating. The company says that these characteristics make it a future-orientated, reliable partner for confectionery and dairy manufacturers, as well as industrial bakers.

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While Tanis Food Tec has hundreds of continuous, software-controlled production lines around the globe making millions of carefully crafted treats, the Lelystadbased company also produces numerous pilot machines for customers looking to develop new products and manufacturing processes. Since 2017 Tanis has been using Qdos pumps from WMFTG for this purpose. “At Tanis Food Tec we use Qdos for the accurate dosing of colours and flavours within R&D departments, and today these pumps have become an integral part of our pilot machines,” confirms Piet Vader, the company’s Sales Manager. “The high precision with which the Qdos can handle both small and large volumes of fluid is crucial to adjust recipes and dosages, or perform exact process replication.”


“And yet Qdos pumps maintain very accurate and continuous dosage at different system pressures,” says Mr Vader. “Additionally, ease of use is a great advantage. The display screen on Qdos pumps shows all the important information.” “Among further benefits, removing and replacing the pumpheads can be done very quickly,” he adds. “Moreover, it is possible to change between pumping different substances without any risk of contaminating the surrounding environment or personnel.” “Another significant advantage is that Qdos pumps need hardly any maintenance,” says Mr Vader. “Unlike membrane pumps, peristaltic pumps do not have suction and discharge valves that often demand higher levels of maintenance.” Using Qdos means that process uptime is maximised by facilitating quick, safe and easy pumphead removal and replacement, with no requirement for tools, specialist training or dedicated technicians. Unlike on many other pump types, using Qdos pumps means there are no valves or seals to clog, leak or corrode, reducing maintenance costs considerably. Dosing accuracy saves on costs ReNu peristaltic pumphead technology is at the core of the Qdos pump, ensuring the delivery of accurate and repeatable flow for fluids of wide ranging viscosities.

Long-standing partner Watson-Marlow has been known to Tanis Food Tec for many years, and has enjoyed high levels of satisfaction with the pump manufacturer’s service and support.

“The accuracy of the Qdos peristaltic pump is a key feature because colours and flavours are often very expensive ingredients,” says Mr Vader. “In fact, these ingredients can cost more than €10,000 per kg, so precise dosing is extremely important. Qdos pump accuracy is therefore important for both the quality and prime cost of the end product.”

“In Watson-Marlow we’ve found a partner that offers quality at a fair price and honours all agreements between our companies,” states Mr Vader. “We really value these three factors when it comes to building relationships with suppliers.”

Of course, the accuracy of Qdos pumps is an important asset for many industries, not just the food sector. A case in point is personal care.

“Yes, especially for this type of pilot installation, for which Qdos is ideal,” concludes Mr Vader. “It has become our standard solution.” www.wmftg.com

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“At Tanis Food Tec we focus primarily on the food industry, however, the use of Qdos pumps has allowed us to diversify beyond our traditional markets,” says Mr Vader.” For instance, we currently have one of our pilot machines installed at a large company that develops personal care products. It goes without saying that the cosmetics industry also uses expensive components in its products, which is why accurate and repeatable dosing is so vital.”

So, is the Qdos pump set to remain the preferred choice at Tanis Food Tec?

Repeatable performance Repeatability is a critical factor as the products pumped by Qdos pumps differ greatly in terms of viscosity, for example. 35 | Industry Asia Pacific | July 2021

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IT

SEEQ ANNOUNCES AMAZON WEB SERVICES DATA INTEGRATION SOLUTION TO ACCELERATE INDUSTRIAL ANALYTICS

Seeq launches AWS Glue integration solution for process manufacturers to easily access and migrate their process data to AWS, and adds SOC2 Type 1 certification.

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eeq Corporation, a leader in manufacturing and Industrial Internet of Things (IIoT) advanced analytics software, today announced a new offering on Amazon Web Services (AWS) to accelerate access to manufacturing data for enabling AWS analytics on industrial data. The Seeq AWS Glue integration for Enterprise Historians, available on AWS Marketplace, simplifies industrial data discovery and migration to the AWS cloud using Seeq’s proven historian data access architecture.

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Seeq also announced the completion of its SOC2 Type 1 certification. SOC 2 compliance is a critical consideration for companies evaluating SaaS applications to ensure vendors have the appropriate controls to protect data handled on their systems.

Seeq enables engineers and scientists in process manufacturing organizations to rapidly analyze, predict, collaborate, and share insights to improve production and business outcomes. Seeq customers include companies in the oil and gas, pharmaceutical, chemical, energy, mining, food and beverage, and other process industries. AWS Glue is a serverless data integration service that makes it easy to discover, prepare, and combine data for analytics, machine learning, and application development. The integration of Seeq and AWS Glue creates a secure and virtualized connection to on premise historian databases, manages data discoverability, and enables data science teams to access this data for machine learning in AWS. The result is simplified access to machine data, process data, and contextual data stored in historian databases—including the OSIsoft PI system, OSIsoft PI Asset Framework (AF), AspenTech IP21—along with other data historians. “Timely, ad hoc access to operational data is essential to advancing Industry 4.0 use cases through centralized data science and machine learning efforts, yet providing this functionality continues to vex many organizations,” says Jonathan Lang, IDC Research. “Solutions which rapidly

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liberate this data will accelerate and expand the insights and benefits of manufacturing data science initiatives.” Seeq also announced the completion of a SOC 2 Type 1 attestation, performed by Tevora, an independent accounting firm which conducts audits of company practices and procedures related to customer data security. SOC 2 compliance is an important consideration for companies evaluating SaaS applications to ensure vendors have the appropriate controls to protect data handled on their systems. This audit affirms Seeq’s procedures, policies, and operations meet the SOC 2 standards relative to Security Trust Services Principle and Criteria including customer data protection, cybersecurity, and software management.

Seeq is available worldwide through a global partner network of system integrators, which provides training and resale support for Seeq in over 40 countries, in addition to its direct sales organization in North America and Europe. https://www.seeq.com/

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“Analytics software for manufacturing customers is an area long overdue for innovation,” says Megan Buntain, Director of Cloud Partnerships at Seeq. “By choosing Seeq SaaS to democratize innovations in big data, machine learning, and computer science, industrial organizations can easily access new capabilities to improve production and business success.” In addition to Seeq integration with AWS, Seeq connects to an extensive set of data storage platforms from vendors including OSIsoft, Siemens, GE, Honeywell, Inductive Automation, AVEVA, AspenTech, Yokogawa, InfluxDB, Snowflake, and others. 35 | Industry Asia Pacific | July 2021

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ELECTRONICS

SMART MEASUREMENT FOR SMART MANUFACTURING: THE NEW MANTRA

A Quick Dive Into Multi Sensor Measurement of Multi-pole Connectors. By Goh Kah Khoon, Vice President of Sales & Manufacturing Business Unit, Hexagon Manufacturing Intelligence, Korea, ASEAN, Pacific & India.

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he current global chip shortage has brought on new pressure. Manufacturers involved in consumer electronics, 5G telecommunications, IoT Smart devices, Cloud Servers and automotive industries – to name a few – have had to deal with the challenges arising from the disruption of the global supply chain which left many high, dry and some, stranded. In 2000, when the tech bubble burst, it left a ripple effect in the manufacturing sector. Equipment manufacturers had shifted to a leaner business model, holding very slim chip inventories while embracing a “just in time” approach to their materials.

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However, the current crunch has renewed the pressure. Components, manufacturing equipment, computing support and materials had to be sought and spot bought, including electrical and electronic systems, to cater to speed, volumes and design variety required as demand for smart devices, electric mobility, cloud servers, phones and gadgets spiked. Work schedules had to be adapted to suit Covid restrictions placed by governments. Production had to be adjusted to suit new workplace safety regulations and requirements. Pivots needed to happen across the value chain. Fast. 35 | Industry Asia Pacific | July 2021

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Here, complex technologies are often needed to ensure all design goals are met – efficiently and accurately, from start to finish, in order for products to be delivered with high quality and at optimum productivity. And, as any good engineer will attest, enhancing application flexibility and reducing the number of iterations lead to improved productivity and accurate results with reduced cycle times.


Precise metrology and production data is, therefore, increasingly essential. More importantly, it needs to be shared in real time across the entire manufacturing workflow, from design and engineering, through to production, logistics and supply chains. Flexible inspection capabilities and high measurement throughput The challenges faced by many manufacturers today is how to enable metrology systems to collaborate and provide the rest of the business the quality information they need in realtime, without compromising security, accuracy, precision or performance. While technologies for modularisation, miniaturisation and function extension open up opportunities for growth for connectors – a core component in all things electronics – in all areas of application, they also increase requirements for the measurement and inspection technology.

They are particularly suited for initial sample inspection of complex connector assemblies in fully automated measuring cycles. Such CMMs reduce the need for using multiple devices in the inspection area, and eschew multiple setups and consolidate multiple measurement results, thus increasing the productivity by up to 30%, depending on the complexity of the components measured. Dimensional accuracy of a connectors’ electrical contact elements, or its pins, is the crux of connector accuracy. In order to ensure this, a CMM measures the height of the pins (seating depth) related to a defined datum plane; in this case, the typical length tolerance is in the range of ± 0.1 mm.

Multisensor measurement of the pin height: typical length tolerances are in the range of ± 0.1 mm. Not only that, diverse connector types and housing variants need to be subject to variable dimensional inspection tasks at high measurement speeds. Not performed correctly, these measurement processes may cause false rejections and unnecessary rework. Even worse, poor inspection or an acceptance of a bad part could lead to painful bottlenecks or defects which affect product safety and recalls, as mistakes, scraps and wastages chalk up already ballooning costs. In short, “maximum technical performance at smallest size” best describes the requirements for the design, development and production of connectors. For quality control of the miniaturised assemblies, the measurement technology used therefore must offer both high resolution and accuracy.

With Hexagon’s OPTIV M, it is the perfect interplay of the non-contact sensors that form the solution. The camera sensor quickly locates the lateral position of each individual pin tip. The metrology software PC-DMIS provides a special image processing algorithm that allows for irregularly shaped pins to be reliably detected on the basis of a centreof-gravity calculation.

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Case Study – Hexagon OPTIV M: Dimensional accuracy of the contact elements By incorporating multiple sensor technologies and advanced lighting systems into a single, high-precision measurement platform, multi-sensor coordinate measuring machines (CMMs) provide a universal solution for the capture and analysis of the entire spectrum of possible geometric errors of connectors.

Measurement of the permissible positional deviation of the pin tips.

In the same measurement cycle, the vertical position of the pins is measured regardless of their shiny surface with the chromatic-confocal white light sensor. Due to the axial beam path of this non-contact distance sensor, there are 35 | Industry Asia Pacific | July 2021

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ELECTRONICS

Measurement of the flatness of contact and sealing surfaces on the connector housing.

no shading effects, so that even narrow and deep in the connector housing lying pin grids are reliably detected. In addition, the permissible positional deviation of each pin tip from its ideal zero position in the X and Y directions is measured. The corresponding datum is made using a constructed intersection that is derived from measured reference edges on the connector housing. The camera sensor’s variable lighting options also ensure highly accurate edge detection. All LED light sources – coaxial top light, telecentric backlight and multi-segment ring light – can be flexibly adapted to suit the texture and colour of various connectors. Additionally, at measurement routine execution, the PCDMIS function SensiLight checks whether an adjustment of the lighting is necessary and supports the user in selecting the correct lighting setting. Functional inspection of the connector housing For some connectors – especially in the automotive industry and the eMobility sector – resistance to environmental influences, dirt and humidity are important mechanical requirements. The flatness of contact and sealing surfaces must therefore be measured, and measured accurately. In scanning mode, the chromatic white light sensor and multisensors enable the ambient light-independent capture of line profiles to be measured with a high measuring point density. MORE INFORMATION

The metrology software PC-DMIS, for example, provides a range of CAD-based methods for contact and non-contact scanning. With the Perimeter Scan, the scanning path for the non-contact white light sensor is created directly on the imported CAD model of the connector. The scan then follows automatically along a defined offset of the nominal contour of the selected sealing surface. For 35 | Industry Asia Pacific | July 2021

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a quick conformity assessment of the dimensional accuracy of critical contact and sealing surfaces, the measurement data can be analysed against the CAD model during the measurement routine execution and visualised as a colourcoded presentation of deviations. The socket side of connectors also poses metrological challenges. In injection moulding or over-moulding processes, smallest cavities can be produced in very dense clusters. Their inclination related to a defined reference plane is one of the important functional dimensions of connectors and must be measured. To solve this task, the multisensory coordinate measuring machine OPTIV M combines camera sensor and touch-trigger probe in one measuring cycle, and all measurements are carried out according to the drawing and without re-clamping the workpiece. First, the position of the cavities is captured by optical measurement. Then standard geometry elements are measured with the touch-trigger probe in defined vertical section planes. A constructed centre line then provides the spatial orientation of the respective cavity. With two independent axes for the optical and tactile sensors, OPTIV’s Dual Z technology provides the best accessibility to the inspection features with a minimised risk of collision. In addition, programming and measurement times are reduced to a minimum. Real-time Data For Agility The benefits to smart factory initiatives are clear to see. In fact, a Deloitte study found that smart factory initiatives have given companies 12% labour productivity gains in the past three years, and these gains could grow at a compound annual rate of 2.3% between 2025 to 2030.


Multisensor measurement of the spatial orientation of the connector sockets.

To continue this trajectory of growth, consistent adoption of solutions that cut down manual work and offer users deeper insights is key. Take for example manufacturers Soldar Ltd. Having secured a new business deal to produce components for a highvalue OEM, it was clear over time that turnaround was too slow. The company saw a dip in on-time delivery. After investigating, they discover a significant bottleneck in the quality lab. The complexity of the new customer’s parts and the difficulty of alignment proved to be the stumbling block, which was time-consuming and prone to error.

What’s more, the ability to integrate this data into other software systems like Hexagon’s SFx Assets Management

A relatively simple technology upgrade like this can have a massive impact on KPIs, and the opportunities are there throughout the quality process As well as supporting business objectives and a range of KPIs, these incremental technology upgrades also prime your quality processes for greater autonomy, another important step in the smarter manufacturing journey.

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Smart automation like Hexagon’s EYE-D, which uses a camera to automatically identify and align the part to launch the correct measurement routine, would help make alignment faster, eliminate error, and drive quicker product output.

and Q-DAS software, could contribute to real-time equipment OEE, machine monitoring, availability, run-time alert, quality and data analysis. These smart functions could certainly support production teams in deriving subsequent improvements across their production and quality control processes, thus enabling manufacturers to drive smart manufacturing in areas that they might not have anticipated with thier initial investment.

www.hexagonmi.com

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MEASUREMENT

ROHDE & SCHWARZ DEMONSTRATES ITS TEST SOLUTIONS THAT ENABLE MOBILE CONNECTIVITY, TODAY AND BEYOND, AT MWC21 IN BARCELONA

Mobile World Congress 2021 is set to return to the shores of the Mediterranean in June 2021. Test & measurement specialist Rohde & Schwarz will participate in the mobile industry’s premier event both live in Barcelona and virtually. By presenting its solutions for key applications based on mobile radio technology, Rohde & Schwarz is signaling its continuous commitment to the entire industry.

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he GSMA is organizing Mobile World Congress 2021 (MWC21) to take place in Barcelona from June 28 to July 1 as a fully hybrid event, so that participants are able to connect in person or online. Rohde & Schwarz will showcase under the slogan “Enabling mobile connectivity – today & beyond” a wide variety of leading test innovations for 5G mobile devices, infrastructure equipment and mobile networks, plus solutions for private networks, automotive connectivity and early 6G technology in a two-way approach: Live at the Fira Gran Via in Barcelona, in hall 3, booth 3K30, and with supporting virtual activities on a dedicated webpage called Rohde & Schwarz Signals, which will go online for MWC21.

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5G reality & evolution 5G networks are being rolled out worldwide, some networks using an LTE anchor, others fully standalone (SA), some using millimeter-wave bands. Mastering the complexities of the technology is only possible with accurate and reliable test equipment, fully conforming to the current 3GPP specifications, and prepared for future developments of the technology. At MWC21, Rohde & Schwarz is demonstrating its test solutions for 5G for the entire ecosystem, from chipsets and devices to infrastructure and networks, across the complete lifecycle, from development and conformance to production, deployment and operation. The virtual and tradeshow highlights revolve around the future-proof solution for 5G NR device testing, the R&S CMX500 radio communication tester. At MWC21 it will demonstrate enhanced mobile broadband (eMBB) endto-end tests achieving extremely high throughput using eight component carriers in FR1 and FR2 using 256QAM modulation. Another demo will showcase 5G voice over NR (VoNR) voice services. Carrier acceptance tests in the FR2 millimeter frequency bands, using Over-the-air (OTA)


NEWS

The Rohde & Schwarz experts will be back in Barcelona for MWC21.

R&S 5G STS tool for deployment, troubleshooting and site acceptance. The solutions enable a faster rollout, efficient use of network resources, and awareness of issues before they become critical, at every phase of the 5G private network lifecycle. Having installed a 5G campus network in 2020 at its own plant in Teisnach, Germany, Rohde & Schwarz is able to optimize its own test offerings based on the experience and valuable insights from private network operation. Automotive The progression of Cellular-V2X communication from LTE to 5G presents the automotive industry with new opportunities for ultra-low latency and highly reliable vehicle connectivity, both key enablers for fully autonomous vehicles. At MWC21, Rohde & Schwarz is showcasing a complete range of C-V2X testing solutions for R&D, both in the laboratory and in the field for reliable real-world data, which ensure the performance and reliability of critical automotive network communications. measurements in the extremely compact CATR antenna test system R&S ATS800R will be on display, as well. For infrastructure tests of advanced wireless components used for instance in 5G NR base stations, Rohde & Schwarz showcases its duo of an R&S SMM100A vector signal generator and R&S FSVA3000 signal and spectrum analyzer, bringing laboratory performance and matching RF characteristics to midrange test instruments, ideal for mass market applications.

Private Networks With 5G Release 16, private networks for many industrial applications such as factories, transportation and energy facilities are becoming reality, providing an agile, adaptable and automated environment. At Mobile World Congress, Rohde & Schwarz is exhibiting its test solutions like the

Conference Program In addition to the booth presence, Rohde & Schwarz participates in the conference program of MWC21. Peter Riedel, President and COO of Rohde & Schwarz will share his insights as one of the expert speakers in the session called “Building security & creating trust for the connected device” and Bosco Novak, Executive Vice President Technology Systems at Rohde & Schwarz, will be part of the “5G IoT for industry 4.0” panel discussion. Rohde & Schwarz is showcasing its comprehensive test & measurement solutions for the mobile industry at Mobile World Congress 2021 at the Fira Gran Via in Barcelona in hall 3, booth 3K30 as well as online via the Rohde & Schwarz Signals webpage.

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From its mobile network testing portfolio, Rohde & Schwarz presents solutions for 5G NR site acceptance and site deployment as well as network engineering, optimization and troubleshooting. Visitors can learn about the successful R&S TSMx drive and walk test scanner family offering simultaneous measurements of 3GPP multi-standard networks. The ultracompact scanners already cover FR1 and FR2 frequency ranges and are used by operators of 5G networks worldwide for network optimization applications. For network benchmarking, the R&S Freerider 4 backpack supporting up to 12 test mobile phones is on display. The collected data can be analyzed with SmartAnalytics, providing operators with QoE insights into their network’s performance.

6G 5G will dominate the mobile radio market for many years, but what will follow? Fundamental research on what the next generation of wireless communications may look like has already begun. The D-Band from 110 GHz to 170 GHz includes potential 6G candidate frequencies, currently being investigated for short-range communication with ultra-high data rates. For MWC21, Rohde & Schwarz is presenting OTA measurements of antenna characteristics in the sub-THz region up to 170 GHz.

For further information, go to: www.rohde-schwarz.com/mwc

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MEASUREMENT

ROHDE & SCHWARZ AND HEAD ACOUSTICS DEMONSTRATE TEST SOLUTION FOR 5G VOICE OVER NR (VONR) VOICE SERVICE

Together with HEAD acoustics, Rohde & Schwarz has successfully verified voice services over 5G NR (VoNR). The test solution employs the latest generation of the R&S CMX500 wideband radio communication tester, combined with the labCORE hardware platform from HEAD acoustics and their ACQUA measurement and analysis software. This setup allows simulation of a voice connection in both 5G (VoNR) and 4G (VoLTE) networks. This enables manufacturers of 5G capable telecommunications devices to test the voice quality of their devices at an early stage before market introduction. The solution was presented at the Mobile World Congress in Shanghai in February 2021 for the first time.

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he test solution from Rohde & Schwarz is based on the tried and tested R&S CMW500 wideband radio communication tester for 2G/3G/LTE and WLAN. The test scope for 5G NR can be upgraded with the R&S CMX500 radio communication tester, allowing 5G NR devices to be tested in both standalone (SA) and non-standalone (NSA) TDD and FDD mode. The R&S CMX500 supports the sub6 GHz (FR1) and mmWave (FR2) frequency bands and provides all required technologies for VoLTE and VoNR calls in both SA and NSA mode.

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Mobile phones under test can register with the integrated IP multimedia subsystem (IMS) server of the R&S CMX500 platform via the simulated 4G or 5G mobile network, depending on the use case. The labCORE system is connected through wired Ethernet using the integrated IP forward mode of the IMS server, specifically developed for this use case. This allows users to forward the voice data of a call established with the R&S CMX500 directly to the labCORE system for detailed voice quality analysis. In this mode, the system fully supports the 5G speech codecs EVS (Enhanced Voice Service), AMR-WB and AMR-NB. Using the test suite of the ACQUA measurement and analysis software developed by HEAD acoustics for TS 26 131-32, the system fully covers all significant acoustical requirements. This reliable solution enables manufacturers of 5G capable telecommunications devices to test the voice quality of their devices at an early stage and prepare for rollout of 5G voice services.


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Test solution for 5G VoNR voice service shown at MWC Shanghai.

Christian Schüring, Sales Manager Telecom at HEAD acoustics, says: “The interoperability between our labCORE platform and the radio communication tester from Rohde & Schwarz is another milestone for our customers with regard to testing and optimizing the communications quality of 5G devices.” Christoph Pointner, Senior Vice President Mobile Radio Testers at Rohde & Schwarz, adds: “The successful collaboration between the two companies in the field of voice quality analysis for 2G, 3G and 4G, based on the R&S CMW500 platform, is extended to 5G with our R&S CMX500. The jointly verified test solution enables reproducible test results and allows device manufacturers and network operators to ensure an optimized 5G voice experience at an early stage.”

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As a leading solution provider for mobile communications, Rohde & Schwarz is tackling the challenges of future 5G and 6G functions with industry partners early on to offer customers in the entire communications industry even more comprehensive test solutions. For more information about 5G NR test solutions from Rohde & Schwarz, visit https://www.rohde-schwarz.com/_229437. html

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MEASUREMENT

ROHDE & SCHWARZ PARTNERS WITH UNH-IOL TO ENHANCE HIGH-SPEED ETHERNET AND INFINIBAND COMPLIANCE TESTING

By combining the UNH-IOL’s expertise in cable assembly and backplane compliance tests with Rohde & Schwarz test solutions, both partners are paving the way for automated compliance tests in line with the latest IEEE 802.3 Ethernet and InfiniBand standards.

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est and measurement specialist Rohde & Schwarz and the University of New Hampshire Interoperability Laboratory (UNH-IOL) extend their ongoing collaboration to expand Ethernet and InfiniBand compliance testing. Both have pooled their expertise to provide methods of implementation (MOI) for precise, fast and error-free compliance testing of high-speed cables and backplanes in line with IEEE 802.3 (up to IEEE 802.3ck) and InfiniBand standards (up to rate designator HDR), using vector network analysis test equipment from Rohde & Schwarz.

Data rates and data traffic grow faster than ever. The high data rates need to be transported between computer modules or high-speed data networks. The latest specifications planned to be published in fall 2021 for Ethernet IEEE 802.3ck will allow data rates up to 800 Gbps. InfiniBand, a communications standard to address very low latency and very high throughput rates, opts in the extension planned for 2021 even for throughput rates up to 1200 GB/s when combining several links. Long-distance transmission in both standards is handled via optical links. But to bridge short distances, high-speed copper cables are used. To secure reliable data transmission with these extremely high data rates, cable compliance tests are highly encouraged to provide confidence in the products.

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UNH-IOL is a worldwide reference for cable compliance tests, and cable manufacturers turn to the interoperability laboratory for their testing services. During a period of time in 2020, Rohde & Schwarz, provided UNH-IOL with a stateof-the-art R&S ZNBT40 multiport vector network analyzer with 16 integrated test ports, covering up to 40 GHz, to support efficient testing. 35 | Industry Asia Pacific | July 2021

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Rohde & Schwarz provided UNH-IOL with a R&S ZNBT40 multiport VNA with 16 integrated test ports.

UNH-IOL has created the methods of implementation (MOI) for IEEE 802.3 Ethernet and InfiniBand based on their superior experience. The MOI describe exactly how to perform compliance test measurements on high-speed cables and backplanes to fulfil the corresponding specifications. Martin Stumpf, Market Segment Manager High Speed Digital Design Test at Rohde & Schwarz, says: “The MOIs along with the included state files provide excellent guidance for the industry and describe the test steps as well as the calculations of channel operating margin (COM) and effective return loss (ERL). Later this year, we plan to provide automatic scripts based on our R&S ZNrun test sequencer software that will further simplify compliance tests. We are excited to pursue this goal together with the UNH-IOL.” Bob Noseworthy, principal engineer, at UNH-IOL, says: “After a successful collaboration with Rohde & Schwarz to develop this MOI, we look forward to further collaboration to extend UNH-IOL high speed cable conformance testing capabilities in the near future.” MORE INFORMATION

To access the Methods of Implementation, go to http:// www.rohde-schwarz.com/appnote/GFM356 for IEEE 802.3, and to http://www.rohde-schwarz.com/appnote/GFM357 for InfiniBand.

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S M A R T FA C TO R Y

CONTROL ANY AIR CONDITIONING UNIT FROM MODBUS OR BACNET-BASED AUTOMATION SYSTEMS VIA IR

HMS Networks now launches a new IR-based Intesis® AC interface that enables integration of any Air Conditioning unit, regardless of brand, into Modbus or BACnet Building Automation Systems. The importance of controlling Air Conditioning systems HVAC systems are usually the largest energy-consumers in a building. Therefore, it is crucial for building owners to monitor and control these systems to save costs and energy. Additionally, the Covid-19 pandemic has made it increasingly important to find new ways of installing and using AC units, as ventilation and “clean air” has become a major concern. The Air Conditioning market is growing fast with new brands and different types of AC units constantly emerging. This makes it challenging for building owners to integrate ACunits into their specific Building Management System (BMS).

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A Universal IR interface compatible with more than 100 AC Units The Intesis offering includes the most comprehensive portfolio of AC interfaces on the market, enabling monitoring and control of air conditioning units from any home or building automation system.

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The portfolio is now further strengthened as HMS launches a universal IR-based Intesis AC interface for integrating AC units to Modbus or BACnet-based automation systems. The new interface connects to the AC unit via the IR link which is already used by most AC units to communicate with their remote control. The Intesis IR-based AC Interface is already compatible with more than 100 IR remote controllers and their associated AC units. Fast configuration and diagnostic thanks to Intesis MAPS The new AC interface solution is configured using the Intesis MAPS tool, which brings many advantages for the system integrator. With a project-based configuration, all the interfaces installed can be configured in a single MAPS template, making it easy to copy device configurations and set up new projects. Thanks to the diagnostics function, the commissioning process and any post-installation assistance is also simplified. Learn more at www.intesis.com


MEASUREMENT

DIGITALISATION IN PROCESS TEMPERATURE CONTROL Remote monitoring, support and digital process-optimisation in the temperature control of food processes.

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ockdowns and pandemic-related employee absences are making it difficult for many food producers to maintain their usual production capacity. You don’t send a machine or plant operator to work from home lightly. Production of dairy products, pasta, pastries, confectionery, food additives, even new types of foods such as plant-based meat replacements must continue, even when everything around is at a standstill.

The use of temperature control units from Regloplas AG’s modular toolbox offers a series of additional advantages:

The food industry therefore made advances in digitalisation last year which would otherwise have taken many years. And this development has had a major impact on temperature control. Systems which operate for 24 hours per day must record the core parameters over the entire production process to comply with the regulations of hygiene and traceability e.g.: the temperature of grinders for chocolate production, the bath or screw temperatures of extrusion plants for pasta or confectionery, temperatures in doublewalled vessels (often with agitators) for tempering fluids, temperatures in pipe lines for transporting various semifinished or finished products, and increasingly also large reactors which can be used for everything from sugar production to the production of natural flavourings for foodstuffs.

- Technical improvement and increased reliability due to the use of a temperature control unit by a manufacturer specialising in temperature control

- Cost reductions compared to plant manufacturer’s own solutions (produced in small quantities) - Problem-free continued use of the temperature control unit in a new or upgraded system

With less outlay on the integration of high performance and flexible temperature control solutions, is equally attractive to plant manufacturers and to processing operations. Regloplas AG is continuously developing its offers and technical expertise for these users. The motivation, in addition to economic considerations is being able to contribute to a healthier, tastier and sustainable food supply. https://www.regloplas.com/en/technologies/digitalisation/ rt200-for-the-smart-factory/

Any deviations from the standard, temperature deviations, alarms etc. must trigger the necessary remedial actions immediately, especially at those times when there is no-one standing by the system. There are also the needs for remote support by the plant manufacturers’ service technicians and the ongoing optimisation of the whole production plant. To provide even better support to its customers during this development, Regloplas AG offers a range of solutions for its temperature control units and cooling systems (-20 °C to 350 °C and 3 to 80 kW heating capacity) which drive forward the digitalisation of temperature control in the food industry. Regloplas AG’s new RT200 control system with integrated OPC UA server now offers maximum flexibility for digitalisation within the production process. The central concept of digitalisation is data exchange of all the process and machine data across the network and to higher-level IT systems such as MES, ERP and PPS. All peripheral machines, devices and systems involved in the production process communicate with one another. This enables real-time process optimisations leading to higher productivity, reduced downtime, optimised machine capacity and improved product quality. MORE INFORMATION

Feeder-mixer-kneader-conche, throughput 400 kg/h, temperature controlled up to 90 °C. 35 | Industry Asia Pacific | July 2021

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MECHANICS

KENNAMETAL INTRODUCES THE FBX DRILL FOR FASTER AEROSPACE MACHINING

The FBX drill is part of a tooling concept specifically developed to maximize metal removal rates and decrease cycle times when machining aerospace structural components.

New modular drill delivers maximum metal removal rates for structural components.

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ennametal has introduced the FBX drill for flat-bottom drilling of structural aerospace parts. The patented FBX drill delivers superior stability and up to 200 percent higher metal removal rates when machining high temperature alloys, stainless steel, and other materials. The new modular drill is the critical first step in a three-part tooling concept—including the HARVI Ultra 8X and the HARVI end mill series—specifically designed by Kennametal to decrease cycle time for these types of applications.

Quickly removing large amounts of material remains a challenge for these types of components. Traditionally, the first process step is to enter the material by using ramping techniques. This is a time-consuming process and low metal removal rates are the norm. “The FBX drill dramatically speeds up the machining process by combining the advantages of a flat bottom drill and a z-axis plunge mill. The flat bottom design eliminates radial forces while four effective cutting edges provide increased feed and speed rates, leading to up to 200 percent higher metal removal rates than traditional ramping techniques and freeing up capacity for aerospace manufacturers,” says Georg Roth, Product Manager, Kennametal.

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Once the drill has shaped the basic structure of the component, roughing and finishing with indexable and solid end mills are the next process steps. Unique Design Features Four effective cutting edges provide stability in challenging applications like chain hole drilling, while large chip flutes ensure a hassle-free chip evacuation. Supported by a series of exchangeable coolant nozzles to help eliminate heat 35 | Industry Asia Pacific | July 2021

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The unique design of the FBX flat bottom drill directs cutting forces into the machine spindle, minimizing deflection while increasing tool life and metal removal rates.

buildup, the drill point is characterized by a center insert with two effective cutting edges and chip splitters for maximum feed capabilities. The drill bodies are available in diameters 60, 75, and 90mm, and come in a long and short version (150mm and 95mm). This modular drill connects to Kennametal’s bolt taper flange (BTF) mount adapters, available in various spindle connection styles. Versatility and Performance in One Tool The FBX is ideally suited for drilling into solid, chain hole drilling and plunging in a variety of materials such as high temperature alloys, stainless steel, and steels and cast irons. It is equally as versatile and high performing in similar applications for the general engineering and power generation markets. https://www.kennametal.com

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MECHANICS

KENNAMETAL INTRODUCES NEW LINE OF PCD TOOLS

A broad selection of PCD end mills in diameters up to 50 mm are available as standard.

Polycrystalline diamond round tools, available with short lead times enable, high efficiency aluminum machining.

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ennametal has introduced a new line of PCD round tools for aluminum machining that delivers up to 10 times higher productivity than carbide tooling. The new line of drills, reamers and end mills provides exceptional tool life and wear resistance even in very abrasive aluminum alloys and are available with very short lead times.

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“Our new PCD round tools line enables our customers to machine aluminum significantly faster, for greater productivity on the shop floor,” says Michael Hacker, Product Manager, Kennametal. “In drilling and reaming operations, these tools consistently perform at cutting speeds of up to 900 m/min (3,000 SFM). Milling operations can be performed at an incredible 6,000 m/min (20,000 SFM)—far higher than non-PCD tooling.”

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Long tool life, high productivity gains With through-the-tool coolant capabilities and an MQLready interface, these PCD round tools are ideal for both rough and finish machining. Extremely sharp cutting edges and low-friction rake surfaces eliminate concerns over built-up-edge. Low friction machining also produces superior surfaces in finishing operations, such as reaming. Surface roughness of Ra 0.1– 0.8 μm (0.0025–0.02 μ-in) is achievable – far superior to conventional carbide tooling. PCD grade KD1410 assures extended tool life and is particularly beneficial in the high silicon content aluminum used to make automotive parts like engine blocks or cylinder heads.


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The PCD round tool line includes a range of holemaking and hole finishing options, including modular reaming heads up to 42 mm in diameter.

The offering at a glance The line of PCD end mills features: - 6 to 50 mm diameter tools - Cutting depths up to 50 mm - Center-cutting, roughing, and finishing geometries - Various rake angles. The PCD drill offering features: - 6 to 20 mm diameter in 0.5 mm increments - Up to 5 x D - Inch and metric sizes The PCD reaming portfolio offers: - 6 to 20 millimeter in diameter in 1 mm increments - Through and blind hole versions - For larger diameters up to 42 mm, the PCD modular reaming system with KST coupling is available.

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“Many of these PCD round tools can also be requested as custom solutions to fit specific customer needs while still maintaining short lead times,” says Hacker. “Kennametal is leveraging its decades of experience with PCD tooling in the automotive industry to make this technology readily available to any manufacturer looking for a cost-competitive and highly productive solution for aluminum machining.” www.kennametal.com

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PROCESS

MAINTAINING OUR LARGE PUMPS IS NOW SIMPLER THAN EVER

The Rotor and Drive Joint Access from SEEPEX for large standard pumps saves up to 80% in maintenance time.

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EEPEX creates direct access at the beginning of the second quarter of 2021. With the so-called Rotor Joint Access (RJA) and Drive Joint Access (DJA) for the new BNM range, the Bottrop-based company has ensured that, from now on, one wrench will suffice for the maintenance of large standard pumps with an individual component weight of up to 300 kg. Due to the size of larger pumps, inspection and maintenance can be challenging requiring special tools, piping to be dismantled, and even the pump to be moved out of place in some instances. The pump specialist and expert in digital solutions now has a remedy: RJA and DJA for large standard pumps allows access to both the rotor and drive-sided joint. The often time-consuming disassembly or even complete removal for maintenance is now a thing of the past.

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Rotor Joint Access and Drive Joint Access for hopper pumps were the inspiration The individual components for large pumps often weigh several hundred kilos. From the piping to the pressure branch, stator and suction casing, almost the entire pump has had to be taken apart for the maintenance of our “giants” until now. Often it has even been necessary for them to be transported to a workshop. The maintenance could therefore extend over several days, meaning high costs and an enormous amount of work for the system operator. RJA and DJA for the new BNM range from SEEPEX provide a solution with user-friendly and cost-saving maintenance technology for the large models with an individual component weight of up to 300 kg. The maintenance solutions were developed on the basis of the already wellestablished Drive Joint and Rotor Joint Access solutions, which make the maintenance of hopper pumps easier and provide easy access to the joints and seals.   Technically, however, the maintenance solution for large standard pumps is different from that of hopper pumps. In the case of hopper pumps, two sliding housing elements at the beginning and end of the hopper provide access to


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New retaining straps would have to be fastened again with a special tool. SEEPEX’s special rotor connection makes it possible now for the joints of the pump to remain mounted for the replacement of the rotor. This solution is unique; until now, other manufacturers have performed the separation process behind the joint or in the middle of the coupling rod, requiring the joint to be dismantled to replace the rotor. RJA and DJA for large standard pumps are already patented in Germany, France, Great Britain and Denmark.

the rotor- or drive-side joint. For the considerably shorter block pumps, RJA and DJA make do with only one sliding housing element at the rotor connection. Access to the drive-side joint and the seal is made possible by the foot that is additionally attached to the suction casing. The entire rotating unit can therefore be removed without the need for an additional sliding housing section on the drive side.

Innovations for Maintenance With this solution, which will be available from the spring of 2021, SEEPEX is once again underlining its market leadership in the field of innovative maintenance solutions. These include the Smart Conveying Technology (SCT), which was introduced in 2008 and still sets standards in the maintenance of smaller standard progressive cavity pumps. While RJA and DJA is a tubular stator-based maintenance solution for large pumps, SCT relies on a two-part stator that allows the pump to be assembled and disassembled in a space-saving manner with just a few hand movements. SEEPEX is one of the world’s leading specialists in the field of pump technology. The product portfolio comprises progressive cavity pumps, pump systems and digital solutions. SEEPEX also offers innovative solutions for the conveyance of aggressive or abrasive media with low to high viscosities. The company was founded in 1972 and has more than 800 employees at locations in 70 countries, with 423 of them working at the company’s headquarters in the German city of Bottrop. https://www.youtube.com/watch?v=ShkAZrOahHQ https://www.seepex.com/en/home

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Loosening the Rotor with a Wrench “RJA and DJA will make things immensely easier for mechanics on site in the future. Even non-professionals can maintain the pumps. With a simple wrench, the rotating unit can be loosened to change the rotor and stator,” promises Jörg Brune, Head of Mechanical Development and Innovation Strategies at SEEPEX. For standard maintenance situations such as a rotor, stator or mechanical seal replacement, SEEPEX expects a drastic reduction of 80% in the time required. The reason for this is that flanges and joints can remain mounted. This increases the operating time, while the regular, simple inspection and maintenance of the wearing parts with standard tools ensures troublefree operation. Unique Patented Solution Previously, with standard pumps, the retaining straps of the sleeves had to be cut open and the joint dismantled for inspection and maintenance. During reassembly, the joint parts had to be reinserted, the sleeve pushed over the joint with a lot of force and the sleeve filled with grease again. 35 | Industry Asia Pacific | July 2021

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PROCESS

AFLEX HOSES PERFECTLY DESIGNED FOR THE TRANSFER OF DELICATE FLUIDS AT ORIL INDUSTRIE

Oril Industrie produces nearly 2,000 tons of active ingredients per year which are used in prescription medication in the fields of cardiology, oncology, neuropsychiatry, diabetes and venous insufficiency. The plant, located in Bolbec, Normandy, employs 800 people. The site’s equipment from various manufacturers is fitted with approximately 1,000 hoses, most of which are used for the transfer of solvents. Some provide anti-static protection while others located in non ATEX zones are simply made of PTFE.

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ril Industrie’s plant was experiencing breakage issues with some of its existing hoses. As it was already equipped with a number of hoses from Aflex Hose, part of Watson-Marlow Fluid Technology Group, the Company consulted Watson-Marlow regarding the installation of 30 new hoses.

Corrosion resistant even under heavy use Hoses were required for the transfer of highly concentrated hydrochloric and sulphuric acids, at a maximum pressure of 10 bar (145 psi). Anti-static protection was therefore essential. It was also imperative that all components comply with industry standard certifications, ATEX zone 2 as well as the materials 3.1 certificate. With temperatures likely to reach 50 °C (122 °F), Oril Industrie requested hoses with a thermal protection sheath. The hoses, which were to be subjected to intensive handling, had to be resistant.

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Watson-Marlow recommended the Corroflon hose from Aflex Hose as it is designed for the transfer of chemical and process fluids. Its internal shallow convoluted structure allows for a full flow rate while ensuring exceptional flexibility. The selected model has been tested at an operating pressure of 41 bar (595 psi), significantly higher than that required. Aflex is the only manufacturer of PTFE hoses guaranteeing a minimum liner thickness of 1.5 mm 35 | Industry Asia Pacific | July 2021

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NEWS

for hoses size 1 and above. This ensures that the tubing is sufficiently resistant to prevent its profile altering under internal pressure, removing the consequent risk of increased porosity and premature breakage.

Oril Industrie recognises the quality of Aflex Hose products, as well as the extended service life they provide at a comparable cost. The collaboration with Watson-Marlow is ongoing and Oril Industrie plans to order more products.

Corroflon met all the specificities of the application and is compliant with all required certifications including EN16643:2016, ATEX, FDA, 3-A 62-02, and the materials 3.1 certificate.

https://www.wmftg.com/

Recognised quality Oril Industrie selected an anti-static PTFE internal liner as well as a polypropylene external braid. This type of braid is often preferred over stainless steel braids in applications involving frequent handling as the hose is able to move and withstand temperatures from -30 °C to +100 °C. Polypropylene braids are also lighter, withstand chlorine corrosion and generally provide greater resistance to chemical products.

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Corroflon’s main advantage versus competitive products is its use of Hastelloy external braids and internal helix wires. Hastelloy C276 braids are used when chemicals, such as hydrochloric acid in the case of Oril Industrie, create severe corrosive conditions. The risk associated with this acid is the potential diffusion through the PTFE liner causing braid corrosion. With Hastelloy, both the bursting pressures and the maximum operating pressures are reduced by 80%, significantly reducing corrosion risk. 35 | Industry Asia Pacific | July 2021

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S M A R T FA C TO R Y

ENERGY, TWO CHOICES: REDUCE IT OR PAY FOR IT!

Among Mitsubishi Electric’s goals is to create a low-carbon society through the use of energy saving products and efforts to reduce CO2 emissions

The United Nations developed their 2030 Sustainable Development Goals to enhance everyone’s quality of life; they range from Poverty to Climate action. These things concern us all and make good sense. They make even more sense when they can also help us improve our manufacturing productivity, but how does that manifest itself in reality?

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n interesting but relatively unknown fact about Japan is that it has had to develop a culture of selfsufficiency as it no longer has any natural resources. In numbers it is only 6% self-sufficient in energy. That means other sources of energy have to be imported and that is expensive, so saving energy is embedded into every aspect of daily life. For industry that means Japan is a very difficult country to compete aggressively on the global stage from as nearly all resources from energy to labor are so expensive. So how do Japanese companies manage? In the case of Mitsubishi Electric energy saving and Kaizen (continuous improvement), through its e-F@ctory concept, have become part of its DNA. The successes in energy management have resulted in multiple CDP awards for Climate and Water and are the source of a drive to share its experience and knowhow.

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3 R’s of Sustainability Many people might not have heard of the “three R’s of sustainability,” but it is as important as Kaizen. The three R’s are; “Reduce” the use of unnecessary things; “Reuse” items whenever possible; and “Recycle” items when their useful life is over. This is practiced widely in Japan and Japanese manufacturing. And in the case of energy, especially from a corporate or manufacturer’s standpoint, it’s even more important. If you use it (sic. energy), you have two choices: Reduce it or Pay for it! It’s totally unavoidable … like paying taxes! And to make things worse, energy prices have been going up steadily over the past years. In fact, the US Energy Information Administration has demonstrated that the average retail price of electricity has increased 53% for home users and 42% for industrial users over the past 15 years … so it makes sense to treat energy as a precious resource and in some way use it ‘Just In Time’. Therefore, understanding when, where and how much energy is used is the first step to managing its consumption.


What goes up and down at the same time? It’s an innocent riddle which actually has a serious lesson behind. The see-saw is an interesting metaphor for the manufacturing context because it hits the bottom line; the actual answer is Energy and Productivity, i.e. as energy consumption increases productivity naturally decreases. Energy saving could be simply executed by turning off all your machines, but how does that help because you are now unable to produce? Therefore, if you focus on improving productivity, i.e. making more saleable products with less energy you have solved the real puzzle. And that’s why at Mitsubishi Electric energy saving is not about cutting costs but about improving productivity. Key concept There is one key concept which is fundamental to changing the perception of energy usage. Mitsubishi Electric calls this EPU; the Energy Per Unit produced. It is simply the amount of energy consumed to produce one product.

Typically, manufacturers have a very clear idea of the material costs, direct and indirect labor costs, logistics, depreciation, etc. related to their manufacturing processes. But very rarely do they actually know anything other than the headline energy consumption. By applying the e-F@ctory concept of ‘connect everything’ and measuring what’s important, customers are able to derive the EPU. The great thing is energy monitoring can be applied retrospectively to any existing site or machinery. Modules can be added to existing breakers directly or distributed measurement points can be installed without disrupting the existing production or cabling – simply clamp over the appropriate CT modules. Connecting these to local meters and monitoring stations makes it easy to pull all that data back to a central management point. The more visibility that is given to that data the more change effect can be created. Here are some real use cases.

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EPU has two powerful attributes; it allows the direct association of the energy cost to the manufacturing activity; it is also variable/dynamic. That does not sound so important until you have a line stoppage and the EPU starts to rapidly increase as energy is consumed but product is no longer being produced. The second attribute is that it makes it easy to compare production performance between lines, or even factories because the EPU is entirely driven by the efficiency

of production, i.e. productivity. And this is why Mitsubishi Electric uses it to benchmark themselves but also to drive energy saving activities.

Case #1: The circuit breaker line As noted, energy costs have been rising in Japan. This was compounded by the consequences of the Fukushima 35 | Industry Asia Pacific | July 2021

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For a low margin product like a breaker, coupled with fierce global competition, every cent saved counts.

earthquake which meant all nuclear power plants in the region were also shut down, leading to even more expensive energy and in some areas additional usage regulations. So, what was the countermeasure? In the case of a circuit breaker line, a typically price sensitive product, what did we learn? Firstly, the energy consumption needed to be visualized, that meant energy data needed to be collected from every part of the process. The result was a very clear picture which could be drilled down from production hall, to line, to individual machine. The other key aspect was the time base of the measurement frequency – this was critical to catch the root cause of problems. Looking for correlation between events even on different processes and machines quickly revealed where the real problems were. The last major learning point was that sadly technology does not solve everything. There has to be a strong commitment as a company, which filters down to every employee working towards the same goal and that’s why sharing the data on a wide basis makes everyone aware of the scale of the problem. Then it’s a case of going through the simple steps; visualize the issue, find the cause, take action – its pure PDCA! Case #2: The circuit board line In this example, the direct impact of EPU analysis was clearly the major contributing factor. The challenge for the production staff was that there were multiple machinery and production lines which experienced frequent line stoppages (micro-stops) making it hard to grasp the real energy usage in those lines.

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As in Case #1 the first step was to collect the data, but collection was not limited to energy only. Additional information such as the production schedule, equipment data, quality data and process error data were also collected. The critical point was this was collected in ‘real time’. That meant extensive line-side data processing, timedate stamping and filtering, so Edge Computing was an important element to make that possible. Initially the production staff were flooded with data, graphs and analysis – so much so they could not see what was happening. After applying EPU techniques they could start to pinpoint when production dropped and energy peaked, and cross reference that with error and quality information. This revealed several things; 35 | Industry Asia Pacific | July 2021

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• They were setting up/starting the machines too early in the morning before the main production commenced. • They saw frequent stops due to material shortages. • Equipment trouble and extended downtime occurred because maintenance members all took their break at the same time. The biggest energy consumer was identified as the curing oven. However, it could not easily be regulated as a constant temperature was needed and there was a time lag between taking action and its effect. So, from the EPU analysis the ovens utilization was the single most important issue; the production staff recognized they needed to keep it as busy as possible. To minimize the non-productive time during the “change over” for different products (when energy was still being consumed but nothing was produced) it was determined that a ‘Change Over’ support system was needed. The target was to reduce the downtime and the number of changes required so it needed to be fundamentally linked with the production planning system. The result was worth it, energy consumption was reduced by 30%. Case #3: Energy based predictive maintenance The title of this example is quite self-explanatory. When a machine fails it is no longer productive but may still be consuming resources. Therefore, understanding in advance when a machine is likely to fail can be a big help, and energy consumption can be a great indicator of when something is going wrong. A simple example is when a motor bearing is running dry or is damaged it encounters more friction and hence consumes more energy. So now the energy consumed can be an indicator of the health of the motor. In this case it really was a motor driving a vacuum pump which was failing. This critical part of an electronics production line should have had an expected life of 3-5 years, so no one had expected it to be a potential cause of production problems. The solution to this problem achieved improved OEE by monitoring the motor’s power consumption and using that as an indicator for predictive maintenance. This was a simple solution without any additional sensors – just using the existing data.


Sometimes the problem is a combination of events or things that happen infrequently, so capturing and analyzing the data are important steps to get right.

Case #4: Small changes, big results at Mitsubishi Electric Fukuyama Works In this last example elements from the three previous cases were deployed alongside efforts to change ‘human’ behavior. Before the COVID crisis over 10,000 visitors per year came to Fukuyama Works to hear how it managed to reduce its peak contract demand by around 1,700kW – that’s equivalent to a small solar power station covering 3.4 hectares or approximately 100m JPY (for simplicity let’s call that 1m USD per year … every year). The all-important EPU reduced from 14.3 JPY/ unit to just 5.5JPY/unit – that was a reduction of 62%.

The way forward Not everyone is an energy expert, so Mitsubishi Electric has packaged up a lot of its know-how into smart components, ready to use templates and solution packs. Additionally, a big effort to share experiences through discussions and regular fact-finding visits are also an important part of Mitsubishi Electric’s approach. For more insight into energy saving in manufacturing please feel free to watch the noted video: h t t p s : / / w w w . y o u t u b e . c o m / watch?v=jXNU3J3xtaY&list=PLz5P-EyPEYH1uKbSRl219l6_ ogJp1u82O&index=7

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To achieve this in a systematic way it is important to start on small projects where the expected ROI can be checked before scaling the work up for bigger projects. Another important aspect was that a lot of activities were simply to remind people to turn lights off, adjust the air conditioning temperature by 1 or 2 degrees, check for worn motors, identify root causes; perfect examples of the Kaizen approach.

Small incremental improvements are better than no improvements at all. Every solution does not have to be 100% correct but will move you closer to the goal.

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ANYBUS WIRELESS BOLT CAN – CAN COMMUNICATION VIA WI-FI OR BLUETOOTH

Since its launch five years ago, the Anybus® Wireless Bolt™ has provided thousands of industrial applications with wireless Ethernet access. With a rugged and unique form factor for bolt-on-machine mounting, it is today proven and trusted in the most demanding industrial applications. Use cases vary from warehouse installations and AGVs to manufacturing of food, underground mining or rough outdoor applications. Building on the success, HMS now launches the Anybus Wireless Bolt CAN, featuring CANbased communication to the host equipment. Industrial CAN goes wireless The new Anybus Wireless Bolt for CAN enables CAN-based, heavy-duty machinery and applications to transfer CAN data over a robust wireless link. Wireless communication is established either over a fast Wi-Fi connection or a reliable Bluetooth link. The CAN data is transported over a TCP/IP link which enables other standard Wi-Fi infrastructure to also connect to the wireless link if desired.

Wireless access to J1939 CAN-based vehicle data A typical use case is wireless access to CAN data from an industrial vehicle, such as a bulk material transport truck. For example, with the Anybus Wireless Bolt CAN, J1939 CAN data is easily communicated to a handheld tablet which gives the operator full control and visibility of the ongoing bulk material filling process.

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Wireless CANopen use case in manufacturing Anybus Wireless Bolt CAN is fully transparent when it comes to transporting CAN data, meaning that it works with any CAN-based protocol, including CANopen. This opens the possibility to create mobile automation islands in any manufacturing process – the Anybus Wireless Bolt CAN will bridge the CANopen line wirelessly.

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A wide range of wireless connectivity options for industrial networks and IoT applications In addition to the new Anybus Wireless Bolt CAN, the Wireless Bolt product family includes other versions which can connect to the host equipment using serial and industrial Ethernet connectivity. On the wireless side of the Wireless Bolt, the Wi-Fi and Bluetooth options were recently complemented with a version that supports the new LTE standards NB-IoT and CAT-M1, targeting IoT applications. More information regarding Anybus Wireless Bolt: https://www.anybus.com/products/wireless-solutions

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NEW GRAPHIC OPERATION TERMINALS FROM MITSUBISHI ELECTRIC PROVIDE “WIDER” CHOICES

Mitsubishi Electric have launched two new Graphic Operation Terminals which come in frame colors of smart silver (GT2512WXTSD) or cool black (GT2512-WXTBD).

Mitsubishi Electric has launched two new Graphic Operation Terminals (GOTs), which come as the latest addition to its GOT2000 Series Wide Model lineup. The 12.1-inch widescreen models, which feature narrow bezels and come in frame colors of smart silver (GT2512-WXTSD) or cool black (GT2512-WXTBD), will help meet customers’ needs for a wider screen to show more information in factory, process, utility and other automation applications.

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hese new widescreen GOTs are also ready to support remote connection in cases where user access may be restricted. Remote connection functions such as SoftGOT enable remote maintenance via access to the local GOT screen while operators can obtain live data using GOT Mobile. Learn more about the new GOT products at: https://www.mitsubishielectric.com/fa/products/hmi/got/ pmerit/watch/index.html#vol73

New Antibacterial, Antiviral Protection Sheets Available as Options for Standard GOTs In further enhancements to support safe-working practices, there are also new antibacterial, antiviral protection sheets as options for standard GT27 and GT25 GOTs in 12.1, 10.4 and 8.4 inch sizes. These sheets help reduce disinfection work by adopting “SIAA” certified sheets with anti-virus and anti-bacterial features. The sheets, which use RIKEN TECHNOS’ RIKEGUARD®, are proven to inactivate 99.99% of viruses and reduce bacterial growth to less than 1/100, with 10+ years of performance in typical environments.

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For details of the antibacterial, antiviral protection sheets visit: https://www.mitsubishielectric.com/fa/products/hmi/got/ pmerit/watch/got2000.html#vol_14

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N E W S ports, facilitating the The new models feature two Ethernet connection of Ethernet cables.

By using GOT Mobile, operators can monitor the screen from computers and tablets in a remote location.

Notes on antibacterial and antiviral properties: 1) This product uses RIKEGUARD ®, which is registered with SIAA. 2) The SIAA mark is displayed on products that have been evaluated in accordance with ISO 22196 and ISO 21702 standards and for which quality control and information has been disclosed in accordance with the Antimicrobial Product Technology Council guidelines. Inorganic Antibacterial Agent/Kneading/Surface Layer: JP0122310A0004O

This product uses antibacterial and antiviral materials that meet SIAA safety standards. This product complies with SIAA safety standards. This product is not a medicine. Antiviral processing is not intended to treat or prevent disease. This product does not inhibit the growth of all bacteria. This product does not inactivate all viruses.

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Inorganic Antiviral Agent/Kneading/Surface Layer: JP0612310A0003R

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The outstanding MAXXDRIVE® industrial gear unit portfolio based on the NORD modular system covers all industrial application fields up to 282 kNm.

MAXXDRIVE® INDUSTRIAL GEAR UNITS – NORD’S TOUGHEST FOR EVERY SITUATION

The overall portfolio of MAXXDRIVE® parallel and right-angle gear units from NORD DRIVESYSTEMS offers high output torques from 15 to 282 kNm across 11 sizes. In addition to this proven standard series, NORD DRIVESYSTEMS offers the new MAXXDRIVE® XT series with right-angle gear units having a thermally optimised design in seven sizes from 15 to 75 kNm. In combination with its comprehensive accessories and options programme, the modular system allows for the planning of perfectly matched drive systems for heavy-duty applications like conveyors or agitators.

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AXXDRIVE® industrial gear units are used when high output torques and powers are required. In combination with the suitable accessories, MAXXDRIVE® provides a technically and economically perfect drive solution for each customer project. MAXXDRIVE® industrial gear units are used when high output torques and powers are required. In combination with the suitable accessories, MAXXDRIVE® provides a technically and economically perfect drive solution for each customer project.

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The comprehensive configuration and mounting options of the MAXXDRIVE® industrial gear unit allow for standardised as well as tailor-made drive solutions. The combination of motor, gear unit, coupling and braking system, for example, results in precisely planned complete units that are supplied ready-to-install, mounted on a motor swing base or a base frame. As an alternative, the motor attachment can be realised via an IEC/NEMA adapter. A large variation of available flange and output shaft versions ensures that the customer’s application is ideally matched. The mechanical and thermal design of all NORD industrial gear units is always based on the existing operating data of the application and on the ambient conditions at the installation site. Thus, the MAXXDRIVE® portfolio ensures maximum individualisation, creating drive systems that


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fulfil the highest demands in terms of reliability and long service life.

https://www.nord.com/en/home-uk.jsp

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Variety of options for tailor-made application concepts Typical MAXXDRIVE® applications are drives for conveyor belts, consisting of an electric motor, a coupling solution and an industrial gear unit with axial fan. The primary focus here is on a sufficient heat dissipation to allow for ultimate thermal limit powers. The new MAXXDRIVE® XT industrial gear units with their heavily ribbed housings are ideally suited for this purpose. The power and speed ranges of the application-optimised two-stage right-angle gear units have been specially designed for applications in which low speed ranges are required in combination with high powers. MAXXDRIVE® XT series output torques range between 15 and 75 kNm with speed ratios of 6.3 to 22.4. MAXXDRIVE® XT industrial gear units are available in seven sizes for powers from 50 to 1,500 kW. Another typical application for this strong range of industrial gear units from NORD includes drives for mixing and agitation processes. By equipping the compact and robust MAXXDRIVE® industrial gear unit with reinforced bearing and flange versions (VL2/KL2 - VL6/KL6), the drive can be optimally adjusted to application loads. Sealless IEC/NEMA adapters (SAFOMI) and a TRUE DRYWELL sealing at the output shaft allow for highest possible operational reliability. The entire drive system – from NORD electric motors to flange connections – is delivered as a ready-to-install unit, which can easily be mounted vertically on the application.

Networked maintenance concepts NORD also offers innovative predictive maintenance concepts specially designed for MAXXDRIVE® industrial gear units. The NORD frequency inverter is an essential component here. The status data available in the inverter can be communicated to a higher-level control or directly to a safe cloud. The inverter can also directly record external sensor data for vibration monitoring or for measuring the gear unit’s oil sump temperature. Changes to the system condition can be detected at an early stage (condition monitoring) and predictive maintenance can be scheduled in good time.

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ICE CREAM MAKES CHEWY ENCOUNTER WITH DIGITAL MANUFACTURING

Lotte is a leading manufacturer of confectioneries, ice cream, general merchandise, and others. (Image Source: Mitsubishi Electric Corporation)

Since its launch in 1981, Lotte’s Yukimi Daifuku has been loved by people of all ages as a popular Japanese household favorite. Many have tried the unforgettable flavor and texture of the vanilla ice cream balls wrapped in soft, chewy mochi rice cake. “Delicious whenever eaten, regardless of the season,” however, to achieve that deceptively simple goal of consistent texture, quality and taste is actually more difficult than most people would have thought. To solve this challenge Lotte has introduced Mitsubishi Electric’s e-F@ctory to the production of Yukimi Daifuku.

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Before introducing e-F@ctory, there was an issue of inconsistency of the rice cake quality,” said Hiroshi Sugimoto, Manager of the Facilities Department, Urawa Plant, LOTTE Co., Ltd. “When wrapping the ice cream, the hardness of rice cake used to vary depending on the temperature and water content. Some operations were dependent on people, and losses arose out of the need to finely adjust the machine parameters.”

At each of the Yukimi Daifuku production lines the state of the product and the operating status of the machines is collected by PLCs installed in each process. Vast amounts of data, such as vibration data from the rice cake hopper to data from the conveying inverters is collected. All of the data can be understood in real-time not only through the overall SCADA monitoring system, which is installed in the control room, but also through on-site computer displays.

“The e-F@ctory system allows us to conduct improvement activities such as enhancing the operating rate, stabilizing quality, and optimizing staffing for production activities. The extendibility of the system, depending on what we want to do, was also appealing,” Hiroshi Sugimoto added.

“By introducing this system, data became centralized, making it possible to view and investigate conditions whenever we want,” remarked Hiroshi Akimoto, Section Manager of Facilities Department, Urawa Plant, LOTTE Co., Ltd. “Because the data volume is extremely high, having all the data centralized in one place has a positive effect. One big benefit is that we can now gather and analyze data and conduct data diagnostics using a real-time data analyzer. This system not only helps us stabilize the state of the

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The Real-time Data Analyzer (above) is running in the Mitsubishi Electric “MELIPC” industrial PC (below) where it gathers and analyzes data and conducts diagnostics. (Image Source: Mitsubishi Electric Corporation)

Rice cakes are made by steaming and kneading (left), then combined with cold ice cream (right). The rice cake temperature is key to Yukimi Daifuku’s soft and supple texture, which is the key feature of this popular ice cream. (Image Source: Mitsubishi Electric Corporation).

rice cakes used for the Yukimi Daifuku, but also promotes improvement activities within the plant.” “Another benefit is the adjustment of the blending ratio of rice cake and ice cream,” Hiroshi Akimoto continued. “This was usually done by experienced operators, who monitored the state of the rice cakes as they come out of the wrapping machine by kneading them with their fingers. We thought it would be great if we could automate this process. By automating such processes, which were conventionally performed based on human senses, and by capturing signs of any poor quality of the wrapped rice cakes beforehand, we can eliminate problems. That was our ultimate goal.”

“The use of IoT has only just been introduced to the production of Yukimi Daifuku, however, the Urawa Plant has many other lines making chocolates and ice creams, so Yukimi Daifuku is not our only challenge,” Takayuki Manako added. “We aim to horizontally deploy this system and construct a smart plant in which ‘symptom management’ and ‘operating rate improvement’ are implemented on numerous lines. Stable plant operation and manpower savings will eventually make a major contribution in terms of costs and so on. If we consider LOTTE as a whole, our goal is to further evolve this technology and extend it to other plants.”

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“As you know, ice cream is a cold material. This cold ice cream is combined with rice cake, which is warm when it is made,” said Takayuki Manako, Executive Director & Plant Manager of Urawa Plant, LOTTE Co., Ltd. “This technical aspect of combining a cold item with a warm one in a good balance is what makes Yukimi Daifuku a complex product. But I think this challenge is something that inspires us to find new ways to overcome it. The temperature in the manufacturing room varies all year round. We strive to maintain consistent conditions, but at the same time, we try to reliably create even better conditions. We introduced the e-F@ctory manufacturing concept with the expectation of realizing this in the future.”

“In the course of daily production, machines do not operate in the same condition every day. Previously experienced staff members checked and adjusted the settings of the machines,” Takayuki Manako continued, “but with e-F@ ctory we can visualize the condition of machines and the machines themselves can issue instructions to make adjustments. Another thing is that maintenance and failures are unavoidable with machines. We expect that these can also be better managed by using e-F@ctory’s symptom management features.”

https://eu3a.mitsubishielectric.com/

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THERMAL IMAGING TO BREAK THE CHAIN OF INFECTION

The corona pandemic has clearly demonstrated to the whole world just what a highly contagious virus can do. Tourists and travellers have unintentionally contributed to the spread of the disease. Detecting infected persons on arrival at airports is key in breaking a potential chain of infection. Here, thermal imaging cameras can make a decisive contribution. Motors from FAULHABER help these cameras capture precise images and measurement values in a fraction of a second.

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he idea of mass temperature monitoring is nothing new. Its introduction and increased use was prompted by the localised epidemics caused by the SARS, MERS and Ebola viruses. In view of the acute health risks that these viruses pose, some countries already began using thermal scans at airports and other points of arrival a number of years ago in order to at least hinder the spread of the diseases. As a result of COVID-19, this method is now increasingly being used all over the world.

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Fever is usually a symptom of an infectious disease. Even if the increased temperature is not necessarily caused by the coronavirus, it is an indication that closer examination is required. If a traveller is found to have a high temperature, targeted tests can then be carried out and further immediate measures taken.

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Fast and contact-free A major advantage of temperature measurement using thermal imaging cameras is its suitability for mass monitoring. The procedure is contact-free, takes just a few seconds and can be automated. This means it can be used at airports, at border controls or in other “sluice” situations without freedom of movement being significantly restricted or large numbers of people having to undergo cumbersome procedures. For example, South Korea also adopted the method during the parliamentary election on 15th April 2020: The body temperature of every voter was measured before they entered the polling station. This could be the reason why the country has managed to control the coronavirus particularly well compared to the rest of the world. The inner corner of the eyelid is the most suitable spot on a person’s face for fast and relatively reliable temperature measurement. Unlike the forehead, for example, which can cool down significantly as a result of perspiration, the


A less well known but widespread application for thermography is quality control. Whether metal, plastic or glass – a precisely set temperature during thermal processing steps is often a decisive factor in the quality of a product. This is why processes such as hot-rolling, lamination or glass hardening are frequently monitored using thermal imaging cameras. In the case of solar cells, thermography reveals structural damage by detecting energy-inefficient “hot spots”. Thermography also plays a key role in safety technology. A thermal scan can, for example, make overheated components visible long before they reach a critical condition. In atmospheric and space research, a completely different method is used: the quantum well infrared photodetector (QWIP). It consists of alternate layers of extremely thin semiconductor material and utilises a quantum effect. The layers limit the quantum-mechanical states that a particle can assume there. Incoming infrared waves influence the state and from this it is possible to obtain meaningful images. These images are characterised by extremely highresolution “colours”. There are also devices that do not use the available thermal radiation, but instead make use of active illumination. An infrared light source illuminates the observed scene in the same way as a standard photographic lamp – the thermal imaging camera becomes a night-vision device. This method is used in, for example, anti-terror operations in dark rooms. The infrared light remains invisible to the targeted individuals.

temperature at the corner of the eye is extremely constant. It can be determined using the infrared radiation emitted by the body’s surface. Most thermal imaging cameras capture this radiation in a similar way to normal digital cameras using an image sensor with up to one million pixels. Each pixel is a tiny bolometer, a thermal receiver measuring a few square micrometres. It takes less than 10 milliseconds for the thermal radiation to heat the bolometer, which is just 150 nanometres thin, by approximately one fifth of the temperature difference between the object temperature and the bolometer’s own temperature. The sum of these values is used to calculate the temperature profile on the captured surface. Represented visually, this produces a thermal image with the familiar colour shading – the brighter the colour, the higher the temperature.

To enable focusing and zooming, optical devices are often equipped with precious-metal commutated DCmicromotors of the 1524 … SR series. They achieve extremely high performance values with minimal space requirements. Motors measuring 8-10mm in diameter are used in cases where drives need to fit inside minute microlenses. For example, stepper motors of type ADM0620 in combination with an integrated lead screw are ideal for moving filters and shutters. FAULHABER also offers an extensive range of motors as well as matching gearheads, encoders and other accessories. They provide the optimum solution for almost every application. The drive components can be found in many conventional optical devices where they have been successfully tried and tested for many years. This also applies to the automatic, motorised alignment of the cameras on pan-tilt mounts. The FAULHABER compact and low-vibration stepper motors in particular are predestined for such applications.

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Thermal pixels and quantum well Apart from the bolometer, there are other methods of measuring temperature contact-free and “optically”. For example, certain sensor types detect the wavelength of the radiation and use it to determine the temperature. Bolometers and wavelength detection are not only used for clinical temperature measurement in humans. Another familiar application is searching for temperature leaks in the insulation of buildings. The coloured thermal image immediately indicates where heat – or cold in the case of air-conditioned buildings – is being lost.

Optics in motorised motion No matter which method is used, electromagnetic waves must always be “collected”, bundled and guided for measurement and imaging. This is essentially done in the same way as for conventional photography in visible light. The same optical elements are used: Lenses are moved for focusing and zooming; apertures are adjusted, filters brought into position and shutters operated. In the case of the widely used bolometer, the thermal pixels must additionally be recalibrated at short intervals so that points with the same temperature have the same brightness in the image. For this purpose, most devices have a black shutter which is automatically moved in front of the sensor in order to calibrate all pixels to the same value. The quicker the shutter moves, the shorter the time during which measurement cannot performed.

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MITSUBISHI ELECTRIC RENEWS SCADA LINEUP

GENESIS64 Basic SCADA

GENESIS64 Advanced Application Server

Supporting the increasing focus on digital manufacturing and IoT, Mitsubishi Electric has renewed its SCADA lineup, now offering two types of software for system monitoring and process control under the series name “GENESIS64”, replacing the existing “MC Works64” SCADA software. The new lineup will meet the diversifying IoT needs, covering a wide variety of purposes from small production line monitoring and control to multi-site monitoring and business intelligence (BI) of plant-wide systems, process automation as well as utility and building automation. The “GENESIS64 Basic SCADA” is an entry-level software with essential functions for small production lines, and the “GENESIS64 Advanced Application Server” is a full SCADA suite for large-scale monitoring of factories, buildings and utilities.

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he “GENESIS64 Basic SCADA” facilitates the visualization of data in small applications but can also be scaled up to medium applications with optional add-ons depending on requirements of the customer.

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For customers with bigger system needs, “GENESIS64 Advanced Application Server” will help to create a serverless system using cloud computing, which will facilitate the construction of redundant, multi-location or other highly secure, large-scale systems. This “top end” software can also connect to wearable devices such as smart glasses and smart watches, supporting customers interested in introducing remote monitoring or giving work instructions remotely. Furthermore, the software can be operated by voice commands with the use of AI smart assistant speakers, which helps operators avoid touching the monitoring screen – another function that supports the ‘new normal’ in the manufacturing world.

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With the renewal of the SCADA lineup, Mitsubishi Electric customers will have a unified one-stop access to SCADA solutions provided by the U.S.-based ICONICS, Inc., a SCADA and IoT analysis software company acquired by Mitsubishi Electric in 2019. Customers will be able to benefit from the combination of ICONICS’ software technology and Mitsubishi Electric’s FA technology spanning expanded software products and services from the edge to the cloud, all targeted at helping customers solve their automation and process control issues. This integration is initially demonstrated in the direct connection of Mitsubishi Electric PLCs to the GENESIS64 SCADA software, achieving automatic detection and smooth startup while eliminating the need for an OPC server. For more, visit Mitsubishi Electric FA Global Website at https://www.MitsubishiElectric.com/fa/products/hmi/ scada


The “GENESIS64 Advanced Application Server” will facilitate the construction of redundant, multilocation or other highly secure, largescale systems.

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Touchless monitor and control can be achieved with the use of AR devices; apps for mobile devices and smart watches facilitate remote monitoring.

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EMERSON’S SHANGHAI RESEARCH AND DEVELOPMENT CENTER RECOGNIZED FOR INNOVATION IN WELDING AND PRECISION CLEANING

Branson R&D Center receives designation for exceptional work delivering high-performance plastic and metal assembly technology to China and the world.

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he Shanghai municipal government recognized Emerson’s Branson Research and Development Center for its contributions to technical innovation in ultrasonic, laser, vibration, infrared and thermal plastic welding, as well as ultrasonic metal welding and precision cleaning.

In a Nov. 19 ceremony, Gong Zheng, mayor of Shanghai Municipal People’s Government, presented the designation “Shanghai Multinational Company R&D Center” to Emerson’s David Shen, general manager for Emerson’s Branson welding and assembly products. The Center, which employs a staff of more than 30 R&D personnel, was one of nine organizations recognized that day for meeting specific investment, employment, facility, and technology transfer and adoption benchmarks set by the government.

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“China’s industrial supply chain is undergoing a rapid economic recovery, a factor that has injected confidence into the global fight against COVID-19,” said Shen. “We will continue to adhere to the localized development strategy of ‘in China, for China,’ using innovative technologies and industry expertise, proactively focusing on new product development, and contributing to the transformation and upgrading of industry.”

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David Shen, general manager for Emerson’s Branson welding and assembly products in China, accepts the designation “Shanghai Multinational Company R&D Center” from local officials who recognized Emerson’s Branson Research and Development Center for achieving key investment, employment, facility, and technology transfer and adoption benchmarks.

As a large-scale, comprehensive ultrasonic equipment production and technology development enterprise, Emerson is committed to technological innovation in the fields of plastic welding, ultrasonic metal welding and precision cleaning. With advanced production technology, strict control of product quality, highly qualified technical personnel and rich industry experience, Emerson’s Branson R&D team in China has developed a variety of ultrasonic, laser, and vibration plastic welding products and has successfully introduced them to the market. These developments provide domestic customers with products and services that are on par with those around the world. In 2018, Emerson expanded the work of the Branson R&D Center in Shanghai, adding a new Global Metal Welding Research and Development Center that will lead Emerson’s worldwide metal welding product research and development work.

The plastic and metal welding experts at the multinational center in Shanghai have played a primary role in developing and introducing key Emerson technologies to China and to the world. These include the Branson GLX-Micro ultrasonic plastic welder, the Branson GL-300 laser welder, the Branson GMX-20 ultrasonic metal spot welding platform, and the Branson GCX ultrasonic generator for precision ultrasonic cleaning systems. https://www.emerson.cn/en-cn/news/automation/20-12shanghai-r-d

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Shen added that as a trusted welding expert for leading companies in various industries in China, Emerson will continue to advance welding technology, provide customers with professional and reliable customized welding application solutions, and help customers to succeed in light of new market trends. “The strength of our research and development expertise contributes to this effort,” he noted.

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EMERSON’S JOYSTICK SYSTEM SIMPLIFIES MARINE VESSEL MANEUVERS

AVENTICS™ Marex 3D provides intuitive control, dynamic positioning and easy installation.

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merson has modified its AVENTICS Marex 3D Joystick system for easy integration into existing vessels. Designed to enable single-handed operation of yachts, speedboats and pleasure craft, the joystick system provides the user with outstanding precision, for stress-free and safe maneuvers. Optional dynamic positioning features round off the convenience package.

Docking vessels can be challenging, even for experienced skippers. In narrow spaces, the steering wheel, main and auxiliary drives must be operated at the same time while the ship is drifting off with wind and current. Marex 3D allows for performing such maneuvers via one control element only – the Marex 3D Joystick – and steering the vessel intuitively and precisely. The captain can give the maneuver his full attention while Marex 3D takes control of the drives – a plus in safety. An integrated vector control intelligently manages engines and thrusters to ensure the vessel imitates the movement of the joystick exactly. The heading can be kept by implementing the yaw angle into the calculation.

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As an option, more comfort functions can be selected at the push of a button: “3D Hold’” keeps the ship at a defined spot, removing the need to steer manually while waiting at water gates or narrow port entries. Marex 3D intelligently controls the available drives in order to keep the ship’s heading and position. The virtual anchor mode allows the ship to drift around a defined point as if attached to an invisible anchor chain. The main engines will be operated economically in order to minimize fuel consumption and noise.

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The AVENTICS Marex 3D provides intuitive control, dynamic positioning and easy installation.

Marex 3D is a supplement to the AVENTICS ship controls Marex OS and Marex ECS by Emerson. It is suitable for use with most engines and thruster brands in conventional shaft line, fixed-pitch propeller applications in combination with ON/OFF and proportional thrusters. Marex 3D Joysticks can easily be retrofitted as the wiring effort is low if a Marex OS system is already on board. Compared to other offerings, the single-source solution of remote control and joystick system combined reduces installation and start-up time. “With the easy-to-use Marex 3D, maneuvering is very simple,” explained Norbert Volkmer, director of global business development, marine at Emerson’s Automation Solutions business. “Whether integrating into a new design or retrofitting to an existing vessel, the Marex 3D is quick and easy to install and provides vessel designers and owners a simple way of enhancing operational convenience and safety.”

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Further information about the AVENTICS range of marine solutions can be found at the recreational marine web page: https://www.emerson.com/en-us/automation/fluidcontrol-pneumatics/recreational-marine https://www.emerson.com

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TRACEABILIT Y

SELECTED AS A VENDOR FOR THEIR MARKING EQUIPMENT BY MORE THAN 150 MAJOR KEY ACCOUNTS, SIC MARKING ESTABLISHES ITSELF AS THE PREFERRED SUPPLIER FOR THAT KIND OF EQUIPMENT AROUND THE WORLD

After a dynamic year in 2019, both in terms of acquiring new customers and enriching its product range, SIC MARKING GROUP is continuing its momentum and multiplying its successes with key accounts in the automotive, medical, aeronautics and mechanical engineering sectors.

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Personalised support throughout the world “Thanks to a centralised sales team at headquarters, key accounts can rely on a single point of contact for the worldwide management of their marking machine requirements” says Eric BRECHENMACHER, Sales and Marketing Director of SIC MARKING GROUP. This personalised support is essential to the success of the French group and is reinforced by a worldwide presence, the result of a network of 10 subsidiaries and 45 distributors. In constant evolution, notably with the recent acquisition of a subsidiary in South Korea in 2018, SIC MARKING’s network enables it to provide local service and maintenance, at the best cost and with the greatest reactivity wherever customers have factories. In fact, Éric BRECHENMACHER confirms, “All the network members have trained technicians and a local stock of spare parts that enable them to intervene extremely quickly without costly travel by head office staff.”

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Perfect mastery of a wide range of marking technologies As the world leader in industrial traceability, SIC MARKING GROUP has 3 competence centres in Europe, America and Asia, enabling it to offer specific marking solutions, developed and studied locally for customer needs. In addition to this, a wide range of standard products has been developed throughout its 30 years of experience. Indeed, no less than 3 new products are launched every year in addition to the numerous evolutions of existing products. This longevity enables SIC MARKING GROUP to master a wide range of marking technologies from dotpeen to laser and scribing marking. “Thanks to our wide range of products and our expertise, we can offer the most suitable technology for every need,” concludes Eric B. Leading references in their field Proud of its know-how, SIC MARKING emphasises the clever combination of a wide choice of technologies, local service capability combined with the ability to make special machines anywhere in the world, which makes this company with its 300 employees so unique. “That’s what attracts these large groups,” says Laurent Bieth, Key Account Manager at


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SIC MARKING GROUP. “When we talk about Key Accounts we mean an international implantation and therefore a need to reproduce means of production in several locations while adapting to local local cultures.”Today, SIC MARKING is proud to be the supplier of major players in the automotive, aeronautical, medical and mechanical sectors such as SKF, TENNECO, MAGNA, BENTELER, SAFRAN and many others. www.sic-marking.co.uk

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