Industrial Machinery Digest - October 2023

IndustrialMachineryDigest.com | October 2023

North America’s Manufacturing Resource for Industry Professionals Since 1986

Talking Shop with: Bob Sutphen — Founder & CEO, LD Systems Closed-loop Quality improves manufacturing The Positive Impacts of Destratification on Energy Consumption, Building Performance, and Workplace Comfort Cobots boost production 200% on TIG and MIG welding and 600% on machine tending for metal fabricator Choosing a Robotic Spindle for Deburring Manufacturing Challenges and Solutions Series: Labor Shortage Ergonomic welding—a contradiction in terms?

Advanced meters deliver powerful data, graphs and energy insights

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Table of Contents

October 2023 8 10 16

EDITORIAL DIRECTIONS INDUSTRY NEWS BUSINESS 4.0 Closed-loop Quality improves manufacturing By: Rahul Garg, Vice President for Industrial Machinery & SMB Program, Siemens Digital Industries Software

22

TALKING SHOP

26

SAFETY & MAINTENANCE

28

MANUFACTURING SHOWCASE

32

INDUSTRIAL AUTOMATION

Bob Sutphen — Founder & CEO, LD Systems The Positive Impacts of Destratification on Energy Consumption, Building Performance, and Workplace Comfort Cobots boost production 200% on TIG and MIG welding and 600% on machine tending for metal fabricator

16 22

Choosing a Robotic Spindle for Deburring

By Mark Fairchild

34

WORKFORCE DEVELOPMENT Manufacturing Challenges and Solutions Series: Labor Shortage By: Emmet Cole, A3 Contributing Editor

36

PROCESS

40

INDUSTRY INSIGHT

Ergonomic welding—a contradiction in terms?

26

Advanced meters deliver powerful data, graphs and energy insights Getting to the root cause of power problems and taking corrective action By: Karen Cheung, Product Manager, Eaton

44 47 49 50

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Welcome to the October edition of Industrial Machinery Digest, where we delve deep into the realm of advanced manufacturing. The recent FABTECH Chicago trade show was a captivating spectacle, drawing an impressive crowd and presenting a suite of exciting products from over 1,500 global exhibiting suppliers, marking an increase of just over 18% in exhibitors. The event sprawled across three halls and occupied a staggering 825,325 square feet of the convention space at the iconic McCormick Center.

The air at FABTECH 2023 was charged with overwhelmingly positive responses from both attendees and exhibitors, emphasizing the energetic and flourishing ambiance of the event. FABTECH has consistently been a pivotal platform for unveiling groundbreaking innovations, beckoning industry stalwarts and decision-makers to immerse themselves in the latest technologies.

This edition was particularly educational, featuring over 180 enriching sessions and workshops spread across 15 specialized technology tracks. A cohort of seasoned industry pioneers and experts steered more than 1,000 conference attendees through a myriad of pivotal topics, including automation, smart manufacturing, welding, cutting, lasers, lean methodologies, workforce development, and proficient business management strategies.

In this edition, our features include a thoughtful piece on Business 4.0, titled "Closed-loop Quality Improves Manufacturing," contributed by Rahul Garg, Vice President for Industrial Machinery & SMB Program at Siemens Digital Industries Software. We also bring you an engaging "Talking Shop" conversation with Bob Sutphen of LD Systems, shedding light on "Revolutionizing Industrial Spaces."

Our section on Safety & Maintenance elucidates the substantial impacts of destratification on energy consumption, building performance, and workplace comfort, offering insights into optimizing industrial spaces for enhanced productivity and well-being. The Manufacturing Showcase highlights the role of Cobots, illustrating how they augment production by 200% on TIG and MIG welding and by a staggering 600% on machine tending for metal fabricators.

We hope this issue provides you with invaluable insights and stimulates thought-provoking discussions on the advancements shaping the manufacturing landscape. We are excited to journey with you through the evolving tapestry of industrial innovation, exploring the multifaceted developments sculpting the future of manufacturing.

Warm Regards,

William Strickland Publisher, Industrial Machinery Digest

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Industry News

INDUSTRY NEWS Industrial Machinery Digest's Industry News features the latest news and press releases from some of the industry's top companies.

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A3D Manufacturing Receives Distinguished HP Digital Manufacturing Partner Certification A3D Manufacturing, previously known as Athena 3D Manufacturing, has achieved recognition as a certified HP Digital Manufacturing Partner (DMP), a noteworthy qualification from HP, highlighting its proficiency in 3D manufacturing. This certification attests to A3D Manufacturing’s compliance with HP's stringent standards for state-of-the-art additive manufacturing processes, established industry certifications, robust quality management, and volume job production, establishing it as a leader in 3D manufacturing.

The distinguished certification followed a rigorous assessment by HP and signifies A3D Manufacturing’s capacity to meet the high-quality demands of customers, rendering it a valued partner in HP’s Digital Manufacturing Network (DMN). Gregory Elfering, the Head of Americas, 3D Printing at HP, expressed excitement about incorporating A3D Manufacturing as the newest partner in their esteemed community.

A3D Manufacturing, specializing in the production of custom plastic and metal components since 2019, has been serving high-tech sectors such as aerospace, military and defense, life science, transportation, and consumer products as a trusted manufacturing partner. Now, with the certification, the company has added the HP 5420W printer, capable of printing white, functional parts, to its product line.

Jon Toews, Senior Vice President of A3D Manufacturing, assures continuous delivery of high-quality products and expressed pride in partnering with HP, anticipating sustained excellence as a DMN supplier.

In collaboration with HP 3D Printing, A3D Manufacturing is organizing a webinar focusing on

www.IndustrialMachineryDigest.com 10 | IMD October 2023

the innovative intersection of 3D printing and medical devices, aiming to unlock medical device innovations through 3D printing.

For further details on additive manufacturing or to register for the webinar, contact A3D Manufacturing via email at info@a3dmfg.com or visit www.a3dmfg.com.

2024 AMUG Conference Registration to Open September 1 The Additive Manufacturing Users Group (AMUG) is set to open registration on September 1, 2023, for its 2024 AMUG Conference in Chicago from March 10-14. This user-centric event, unique in its focus on user experiences and insights, provides a collaborative platform for professional users of industrial additive manufacturing technologies. The conference features over 50 hours of peer interaction, enabling discussions of best practices, challenges, and application developments.

The conference will retain its foundational networking and collaborative elements while introducing modifications like extended AMUGexpo hours, adjustments to sponsor programs, and enhanced technical content. The AMUGexpo is expected to host over 140 companies, responding to members' requests for more exploration time for additive manufacturing solutions. Keynotes, panel discussions, educational sessions, and hands-on workshops are included in the agenda to optimize user experiences with additive manufacturing solutions. The conference will again feature the Innovators Showcase and will recognize contributions to the industry through various awards. Registration is available at $1,295.00 until January 5, 2024, with details and access provided at www.amug.com.

In another development highlighting rapid advancements in part production, a new integration

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of machining and metrology is emerging. This integration allows for in-theater measurements of machined or additive parts, streamlining the validation process against CAD files and significantly reducing time and labor. The cutting parameters are instantly compared to CAD specs, enabling real-time adjustments, marking significant progress towards digitalization and machine learning in manufacturing processes.

This innovation is already being implemented by several forwardthinking clients, showcasing the ongoing, lightning-speed developments in part production across various industries. The fusion of machining and metrology is a pivotal step in the advancement of digitalization and machine learning in industrial processes, and it seems AI is not just on the horizon but already arriving.

ANCA Inc Expands Presence in Canada with New Hire ANCA Inc, renowned for its precision grinders, is augmenting its Canadian presence with the strategic hiring of Brady Roarke, a new applications engineer and technical sales expert, based near Toronto, Canada. This move aligns with ANCA's strategy to fortify its operations and service capabilities across the Canadian market, showcasing its commitment to addressing the dynamic needs of its clients in the region.

Brady brings a wealth of experience to ANCA, with nine productive years in grinding machines and a successful stint as an applications engineer. He is well-versed in milling and grinding, poised to leverage his insights to explore new opportunities and strengthen existing relationships, reinforcing ANCA’s presence in Canada’s grinding industry.

Russell Riddiford, President of ANCA Inc, expressed excitement about Brady joining the team, anticipating significant contributions to ANCA's growth trajectory in Canada due to Brady’s comprehensive industry

12 | IMD October 2023

knowledge. Brady, echoing the sentiment, is eager to collaborate and contribute to ANCA’s sustained success, providing top-notch grinding solutions in Canada.

The incorporation of Brady is a pivotal part of ANCA’s overarching strategy, marking a relentless pursuit to elevate its service offerings and solutions in the Canadian market, ensuring the fulfillment of the evolving demands of its clientele in the region.

ANCA CNC Machines to Exhibit at Motion + Power Technology Expo 2023 ANCA Inc, a global leader in CNC Grinding Machines and technologies, will be exhibiting at the upcoming Motion + Power Technology Expo from October 17 – 19, 2023, at Huntington Place, Detroit, Michigan.

The Expo is a pivotal event for the mechanical, electric, and fluid power industries, serving as a platform for innovation and networking, drawing in professionals and experts from across the United States.

ANCA is excited to showcase its innovative products, services, and industry solutions at the Expo, particularly as it's located close to its American headquarters in Wixom, Michigan. Attendees visiting ANCA at Booth 3232 will have the opportunity to witness the capabilities of the GCX linear machine, demonstrating advanced processes for gear power skiving. Additionally, visitors can engage with ANCA’s experts to discuss individual grinding needs and goals and explore how ANCA’s tailored solutions can meet them.

Russell Riddiford, President at ANCA Inc, emphasized the importance of the Expo as a venue to present their latest innovations and to interact with industry leaders and potential clients, exploring avenues for addressing their grinding requirements through ANCA’s offerings.

The Motion + Power Technology Expo in Detroit is anticipated to be a convergence point for top-tier companies and professionals in the field, leveraging Michigan’s legacy

as a significant manufacturing hub. ANCA is eager to connect with existing and potential clients to delve into collaborative discussions on the future of grinding needs and solutions.

Buy Your Favorite Tools, Support Your Local Schools BIG DAISHOWA is once again running its innovative "Tools for Schools" program, where customers purchasing the company’s top-notch cutting tools, tool holders, and workholding products between October 1 and December 29, 2023, will simultaneously be supporting local manufacturing training programs. A tooling certificate, valued at 20% of every qualifying order, will be donated to the buyer’s selected school, which can redeem it for any BIG DAISHOWA products.

This initiative had remarkable success last year, with nearly $30,000 in tooling certificates issued to various educational institutions, ranging from high schools to universities. The program aligns with BIG DAISHOWA’s mission to foster the development of a new, skilled generation of workers in the manufacturing sector.

To participate, customers need to place a minimum order of $5,000 through their local distributor, earning them a $1,000 tooling certificate, and mention “PROMO-BD-SCHOOLS” as a line item on their order. Jack Burley, President/COO of BIG DAISHOWA, emphasizes the program’s role in workforce development and in helping students gain practical experience with tools they will use in their future roles as engineers and machinists.

BIG DAISHOWA, renowned for its product lines of precision tooling, workholding, and tool management systems, aims to optimize process time and cost per part. The company is the officially licensed provider of BIG-PLUS tool holders in North America, offering a variety of popular and high-performance products and systems. This program enables customers to invest in quality tools while contributing to the

development of skills and expertise in their future workforce.

Magnet Solution Provider Bunting-DuBois Increases Sales Staff Bunting-DuBois, a prominent magnet solution provider, is gearing up for substantial growth with the appointment of Steve Slack as the New Business Development Manager for the Midwest Region. Steve embarks on this new role with a wealth of experience in sales and business development, having previously showcased his adept sales skills as an account executive at Dunn Allen Design & Advertising and as a senior account executive at Digital Marketing provider Hibu. Before joining BuntingDuBois, he served as the Sales Leader at LS Industries in Wichita, Kansas.

Steve's desire for a role requiring more sophisticated product knowledge and his ambition to leverage his sales expertise to elevate an organization’s growth led him

to Bunting-DuBois. In his new role, Steve is eager to utilize his extensive knowledge to design unique, tailored solutions to address the challenges faced by prospective customers. He expressed his enthusiasm to help the organization in crafting solutions that are customized to the individual needs of the customers.

Steve’s multifaceted experience in industries such as automotive, agriculture, and oil & gas rendered him the ideal candidate for spearheading business development initiatives in the Midwest region, as noted by Don Lindstrom, General Manager for Bunting-DuBois.

Lindstrom praised Steve's proficiency in product development and his ability to forge and sustain customer relationships, highlighting his positive and energetic approach.

In his pursuit to be a meticulous, proactive, and motivated team player at Bunting-DuBois, Steve aligns himself with the company's vision to ascend to unprecedented heights as the

singular North American manufacturer specializing in compression bonded, injection molded, and hybrid magnets.

His inclusion in the team is anticipated to bring a new wave of innovation and growth to Bunting-DuBois, enhancing its stature in the magnet solution sector.

Partnership between BuntingDuBois and the Critical Materials Institute, AMES National Laboratory leads to Cerium Gap Magnets Bunting-DuBois, in collaboration with the Critical Materials Institute (CMI) at Ames National Laboratory, has innovatively developed a new magnet material, named “Cerium Gap Magnet,” by compression bonding the abundant rare earth element, Cerium (Ce). This noteworthy achievement earned the collaborative team the esteemed 2023 R&D100 award, an accolade synonymous with the “Oscars of Innovation” and the “Nobel Prize of Engineering.”

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Traditional ceramic magnets are crafted by amalgamating iron oxide with strontium or barium carbonate, involving high energy consumption and generating relatively weak magnets. Conversely, high-strength neodymium magnets are developed by melting and blending neodymium, iron, and boron, followed by intricate processes of casting, crushing, pressing, and sintering. While ceramic magnets lack the strength for significant utilization in clean energy, neodymium magnets have propelled advancements in the sector despite their limited supply and high, fluctuating costs.

Don Lindstrom, General Manager of BuntingDuBois, highlighted that the “Gap” in Cerium Gap Magnets represents the strength void between weaker ceramic magnets and robust neodymium magnets. The advent of Cerium Gap Magnets offers the industry a valuable alternative—magnets that surpass the strength of ceramics without relying on neodymium iron boron elements, potentially mitigating the demand and cost for neodymium.

The unique construction of Cerium Gap Magnets eliminates the need for sintering, involving a domain pinning mechanism at an intragranular level. While it remains to be seen whether Cerium Gap Magnets will replace neodymium magnets, their potential applications in automobile sensors may significantly reduce the dependence on neodymium.

Bunting-DuBois’s longstanding partnership with CMI and Ames National Laboratory spans nearly a decade, focusing on the development of innovative processes and critical materials in the magnetic field, yielding several groundbreaking advancements.

For more in-depth information on Bunting-DuBois and their innovations, visit www.bunting-dubois.com. Any editorial coverage can be shared by sending links to online articles to mwilks@buntingmagnetics.com.

John Fritz Joins Carlisle Fluid Technologies as Account Manager.

Carlisle Fluid Technologies is pleased to announce that John Fritz has joined Carlisle Fluid Technologies as Account Manager for the New England territory. John has two years of experience with our powder group as field service technician and product demonstration specialist.

John’s product knowledge and channel partner experience will allow him to develop valued relationships to help grow the business in the New England territory.

His background as demonstration specialist will help him support our channel partners and end users.

Carlisle Fluid Technologies Regional Manager – East Region, Matthew Reilly believes "John's experience will help drive new opportunities to grow the New England territory." Matthew adds, "I am excited about the new insights and experience John brings to his territory."

Carlisle Fluid Technologies is excited to welcome John Fritz to the team.

14 | IMD October 2023

CERATIZIT Enhances Upper Midwest Sales Presence CERATIZIT has welcomed Steve Smith to the company as a Technical Sales Engineer. With 42 years of industry experience, Smith serves the company’s customers in North Dakota and Minnesota.

Smith specializes in short-hole and deep-hole drilling, turning, milling and advanced tool materials, including ceramic, Cubic Boron Nitride (CBN) and Polycrystalline Diamond (PCD). Along with studies in machining and plastic injection mold making, he attended Anoka Technical College and has completed a variety of factory training programs. Further, Smith’s professional leadership is anchored by Kaizen lean strategies that empower production teams to excel.

"Our industry continues to evolve and putting what I know to work for others is when I am at my best," Smith noted. "Helping improve productivity is an investment in my territories’ companies, people and communities and I am proud to be part of that investment.”

An Army veteran, Smith also volunteered as a Special Olympics coach in several sports.

Detroit Manufacturing Systems Donated Backpacks to Detroit Area Children Detroit Manufacturing Systems (DMS), a Detroit-based contract manufacturing and assembly company, has donated 300 filled backpacks to The Children’s Center in Detroit as a part of their community service initiatives.

This marks the second year of collaboration between DMS and The Children’s Center, which provides holistic, evidence-based care to over 3,500 children annually, helping them overcome various challenges, including mental, behavioral, and physical issues.

This donation aligns with the seventh annual Back-to-School Bazaar hosted by The Children’s Center, aiming to collect 1,500 filled backpacks for their program's children. The backpacks, equipped with essential school supplies tailored to different age groups, will be distributed in mid-August, right before the commencement of the new school year.

Bruce Smith, the CEO, and Chairman of DMS emphasized the company's commitment to giving back to the community and highlighted the significance of providing necessary tools to help children succeed academically. The continual support and active participation of DMS in such initiatives signify its dedication to fostering community welfare and enhancing the lives of children and their families in Detroit.

FANUC Announces Production of its One Millionth Robot FANUC CORPORATION, a pioneer in automation technology and a global leader in Factory Automation and robotics, has marked the production of its one millionth industrial robot, reinforcing its stronghold as a leader in

the field of automation. Having developed its first robot in 1974, FANUC has a rich history and extensive experience in robotic technologies. The company entered the North American market in 1982 and initially served as a prime supplier to the automotive industry.

FANUC's extensive range, comprising over 200 robot and cobot models, caters to various industries such as aerospace, agriculture, electric vehicles, food and beverage, consumer goods, medical, pharmaceutical, and warehousing, to name a few. The robots are utilized globally to execute a wide range of tasks including assembly, handling, packaging, painting, and welding.

Mike Cicco, President and CEO of FANUC America, emphasized the rising demand for easy-to-use automated solutions due to an increasing labor shortage, and he positioned FANUC as well-equipped to address such market needs with its cutting-edge, reliable solutions. He highlighted FANUC's innovative approach of utilizing its own robots to manufacture other robots, controllers, and machine tools.

FANUC America is expanding its operational capabilities, with its new West Campus under construction and set to open in spring 2024 in Oakland County, MI. The new addition will bolster FANUC’s footprint in the region, spanning nearly two million square feet across its different campuses.

The company’s continual commitment to innovation, coupled with its pledge to provide lifetime support for its products, solidifies FANUC’s role as a front-runner in developing automation solutions designed to tackle modern production challenges.

Flow Software Engages With CESMII To Help Democratize the Adoption of Smart Manufacturing Flow Software, a company specializing in converting organizational data into actionable knowledge and intelligence, has collaborated with CESMII, the Smart Manufacturing Institute, in an endeavor to democratize the implementation of smart manufacturing. Flow Software is renowned for its proficient method of extracting, purifying, and converting data into analyticsready information, and it offers a seamless, no-code framework to accumulate, integrate, and standardize data from various OT and IT sources.

Jeff Knepper, Managing Partner at Flow, emphasized the prevalent partial visibility companies usually have regarding the data and insights produced by their equipment and processes. Flow addresses this by creating a comprehensive model, connecting all data sources to this model, and transforming isolated data points into actionable KPIs and analytics. This approach facilitates enhanced communication and decision-making across different levels of an organization.

The company's initiative is driven by CEO Graeme Welton's perception of a substantial intelligence gap in the industry. He highlighted Flow’s contribution as a “single source of truth,” a centralized hub that enriches

and provides access to operational data to enable efficient, sustainable, and profitable performance across organizations.

Flow's alignment with CESMII is strategic and complements the institute's vision of broadening the accessibility of smart manufacturing solutions across the U.S. John Dyck, CESMII CEO, expressed enthusiasm over the partnership with Flow Software, anticipating that the collaboration will significantly hasten the adoption of Smart Manufacturing by addressing the existing challenges related to cost and complexity in today’s varied manufacturing solutions.

Global Shop Solutions Achieves 15-Year Milestone with Friday Features High-Level ERP Training Global Shop Solutions, a premier provider of ERP software for manufacturers, celebrates a 15-year milestone for its Friday Features, a series of free high-level ERP training webinars. The initiative, open to all of its customers, focuses on advancing ERP skills to simplify manufacturing processes. The live webinars are conducted by seasoned ERP consultants and trainers and delve into specific topics each week, covering core software features like job costing, inventory management, and scheduling, alongside various enhancements and integrations to augment shop floor efficiency.

The inception of Friday Features was by Langley Melendres, a Senior Consultant at Global Shop Solutions, intending to offer “bite-sized continuous improvement” to both new and long-standing users of the company’s software. It quickly gained traction, becoming one of the company’s most attended training programs in its over 45-year history. The program’s value is evident from consistent user attendance and its utility as a training resource for new hires, available for viewing for a week post the live session.

Dusty Alexander, President and CEO of Global Shop Solutions, expressed his enthusiasm for the program, emphasizing the unique approach of involving the company’s top executives in direct interactions with hundreds of customers weekly, allowing reciprocal learning. The series has not only fostered enhanced ERP skills and confidence among manufacturers but has also provided substantial value back to Global Shop Solutions, keeping them attuned to customer needs and feedback.

The company, through this initiative, continues to aid manufacturers in staying abreast of essential software developments, vital for their business operations.

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Business 4.0

Photo credit: Siemens

Closed-loop Quality improves manufacturing By: Rahul Garg, Vice President for Industrial Machinery & SMB Program, Siemens Digital Industries Software

Q

uality has been a well-defined term in manufacturing for decades. Quality is when the product created meets the original expectations for product performance and features. Traditionally, quality control has been delegated to specialists and often relegated to specific, isolated steps in the overall manufacturing flow. All that is changing due to the adoption of digitalization, which has led to a paradigm shift for the emergence of an innovative approach called closed-loop quality (CLQ).

Due to digitalization, today’s smart manufacturing can now provide crucial, real-time, quality data that enables manufacturers to continually adjust their processes to optimize quality in real time. When real-time process adjustments are impossible, CLQ identifies parameter trends and their sources to allow adjustment at the first available downtime. With the help of CLQ, when a product's quality or the manufacturing process becomes subpar, the manufacturer can quickly identify and correct nonconformance when practical. This leads

16 | IMD October 2023

to overall improved product quality while minimizing scrap and rework.

With CLQ, quality-related concerns become a shared responsibility instead of a disconnected or isolated process occurring at the end. The CLQ process involves everyone from the design and engineering process to the manufacturing personnel and quality team.

Pursuing a quality culture CLQ provides complete visibility of quality-related metrics from planning through delivery of the completed product.

It also can improve the overall product quality over time, but where do manufacturers start? There are the key stages to implementing CLQ: » First, it is crucial to start in the machine design stage with a quality mindset by listening to the voice of the customer to detail all the requirements, including the one for quality, and carefully defining all the capabilities and expectations of the product in a virtual environment

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before building the first prototype. This includes detailing quality procedures and identifying best practices to follow from the standards. » Then, it is fundamental to write a plan for quality upfront and use the recommendation of standards to apply risk analysis for expected failure modes or creating procedures for mitigating those issues.

These requirements could be as design specific as defining vibrations, temperature A shift in the quality culture is the foundation of a new paradigm. (credit: Hero Images/Getty Images) tolerances, or process definition oriented to set machine conditions, even » An essential stage is to implement ongoing quality looking at environmental and machinery conditions checks throughout the production process that that may impact quality and the overall production monitor the specifications described in the quality processes. The plan also should describe how and plan. This involves capturing the output parameters where to monitor these requirements to guide the final and comparing the as-built conditions against the product to meet the predefined quality goals. requirements. It enables the manufacturing team to

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quickly resolve any disturbing parameter trends or deviations from the quality plan. » Nevertheless, it is crucial to continuously improve the overall quality level, not only in case of a major issue, but also to pursue a real path to quality excellence. The continuous monitoring and assessment of quality core processes and improvement projects will lead to a continuous cooperation across departments to constantly deliver great products.

It is all about the culture and data A shift in the quality culture is the foundation of a new paradigm. And quality analysis can be increasingly consistent by using reliable data.

Quality information is collected and shared in repository with the engineering domain by leveraging a common collaborative platform.

In the production environment, to ensure sufficient data is captured, most manufacturers must augment older machines and key areas in their facilities with IoT devices.

These devices need to be carefully positioned to supply the uninterrupted and unhindered data collection

The continuous monitoring and assessment of quality core processes and improvement projects will lead to a continuous cooperation across departments to constantly deliver great products. (credit: Siemens)

necessary to transfer closed-loop feedback to the manufacturing process. Alternatively, where possible, manufacturers can leverage smart machines – cognitive computing systems – to seamlessly collect and deliver this invaluable data.

To facilitate the collection and analysis of this data, information technology (IT) is converging with manufacturing operational technology (OT) to analyze large,

complex data sets, making it possible to look at the OT world holistically rather than just at the individual, siloed units of a single machine or production line.

With IT/OT convergence, new patterns emerge, and new insights are revealed, allowing data-driven decisions in near real-time. This in turn makes it possible to apply machine learning and data analytics to the operations, increasing

CLQ provides complete visibility of quality-related metrics from planning through delivery of the completed product. (credit: Siemens)

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manufacturing adaptability and making the manufacturing process easier to scale.

Ongoing benefit: Continuous quality improvements With a quality plan in place and sufficient data collection across the factory, manufacturers can verify the product quality produced against the engineering requirements throughout the development and manufacturing process. This scenario creates an environment of continual optimization of critical quality characteristics throughout the product's lifetime. It is possible to broaden this closed-loop quality process to supplier quality management to ensure the availability of high-quality materials even when experiencing unforeseen supply chain disruptions.

In my discussions with customers, companies implementing closed-loop quality processes

typically see a median product compliance rate of 99 percent, with most performing in the 97 to 100 percent range. Organizations that have not implemented closed-loop quality experience greater variations in quality, with most performing in the 90 to 98 percent range. These improvements in quality outcomes might seem small, but they can provide a significant competitive advantage. It can be the difference between being first or second to market, avoiding a costly product recall, or giving a manufacturer the crucial edge for winning future contracts.

Smart machines ideal for closed-loop quality While in many brownfield facilities IoT devices are used to supply uninterrupted data collection and IT/ OT convergence to analyze complex data sets comprehensively, in new factories or on new production

lines, smart machines, or cognitive computing systems, they can also be implemented to provide ideal quality on the factory floor.

Today's smart machines create more value for the manufacturing customer by supplying better quality data and higher reliability—all suited to supporting a CLQ approach.

Other benefits of using smart, networked machines are lower costs, improved safety, less waste, and better serviceability. Smart machines inherently improve overall quality by preemptively detecting problems, enabling the manufacturer to respond in real time before any nonconformance becomes a major issue. This helps minimize significant downtimes, boosting the overall factory productivity without compromising optimal quality.

A notable example of using smart machines to create value in a CLQ process is a customer in Germany that collects and analyzes machine data and provides users

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Traditionally, quality control has been delegated to specialists and often relegated to specific, isolated steps in the overall manufacturing flow. (credit: Siemens)

with recommendations on how to optimize their smart machine operations. The company relies on lasers to continuously measure the tooth width of the gear production machine, evaluate the measurements in real time and adjust if necessary. It is exact in delivering the correct product and, if needed, stopping the production process if it detects a potential issue with product quality. This process has helped reduce maintenance costs by 10 to 40 percent and energy consumption by 40 percent. The result is a highly agile and adaptable production environment for creating customized, personalized goods.

Developing a manufacturing digital twin With CLQ in place, a digital twin of the manufacturing environment can be created and enriched with real-time data. The digital twin is a virtual, digital replica of the entire manufacturing environment that combines the virtual and physical worlds to provide new insights and efficiencies for product manufacturing through data analytics and AI. With a comprehensive digital twin in place, the virtual representation can be used to analyze any threats to quality, providing a crucial feedback loop between manufacturing operations and quality.

In addition, it provides manufacturers with a mechanism to understand what could happen in the future. They can confidently use the digital twin for exploring scenarios for optimizing operations, predicting maintenance, enabling more efficient commissioning, better changeovers, and faster production line changes.

20 | IMD October 2023

All this encourages managers to examine a broader range of feasible approaches for quality enhancements before committing to physical implementation on the production floor.

Looking to the future With a robust CLQ approach and a digital twin of the production environment, manufacturers can evaluate and adopt more advanced technological capabilities.

For example, they can efficiently determine how to deploy robots and cobots for optimal interaction with skilled workers.

As reshoring and localization for production become more pervasive, hyper-automation—that relies on highly flexible machines to provide next-generation performance—can be intelligently applied where it will have the most impact. It is even possible to have fully integrated product lifecycle management (PLM) systems with a native quality management system (QMS) extending down the supply chain to suppliers and customers to ensure customer requirements to the design and the production shop floor are connected and working effectively.

By taking the above-mentioned steps, manufacturers can improve product and manufacturing quality and performance continuously to realize the immediate benefits of CLQ, today. And in the long term, this approach opens a host of possibilities that will have a tangible impact on the manufacturing bottom line and, ultimately, customer satisfaction.

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Talking Shop

Revolutionizing Industrial Spaces: A Conversation with Bob Sutphen of LD Systems FEATURING:

TALKING SHOP WITH: Bob Sutphen — Founder & CEO, LD Systems

I

n the ever-evolving sphere of industrial machinery, leaders in the sector continually innovate and adapt to deliver top-tier solutions that redefine operational norms. Bob Sutphen, the CEO of LD Systems, is at the forefront of such evolution, driving transformative change within the industry. In our latest 'Talking Shop' session, we delve deep with Bob, exploring the intricate processes and diligent approaches employed by LD Systems to assist businesses in achieving optimized automation solutions.

LD Systems, renowned for its meticulous strategies and cutting-edge solutions, emphasizes sustainable models with significant returns on investments within 24 months.

are aligned meticulously with the client’s requirements.

"We present at least one or more options for a design for automation, with a 24-month or less ROI," Sutphen states, underscoring the emphasis on delivering financially viable solutions.

The process does not cease with the creation of robust designs. Clients are endowed with multiple design options, enabling them to sift through and select one that resonates with their vision. It is this collaborative spirit, imbued with a commitment to meticulous fine-tuning of the chosen design, that ensures the resultant implementation is precisely congruent with the client's expectations.

Pioneering the Path to Automation

Implementation – A Journey of Precision

Bob Sutphen's leadership has seen LD Systems carve a niche, delivering meticulous, client-centric solutions, aiming to create state-of-the-art facilities that propel businesses forward. LD Systems specializes in studying client facilities, processes, and equipment in-depth, analyzing each element intricately to present tailor-made automation solutions. These strategies revolve around enhancing productivity, fostering a safer working environment, and fortifying employee retention by implementing pioneering technology, thereby promoting a harmonious blend of efficacy and workplace morale.

Once the design is ingrained with the client's vision, LD Systems plunges into the implementation phase, with a dedicated project manager steering the ship. The process is underlined by regular, robust communication with the client, culminating in weekly meetings as the implementation phase dawns. This methodological approach sees LD Systems managing all the contractors essential for the project, orchestrating the shipping and delivery of equipment, and overseeing the seamless installation process.

The implementation journey is marked by stringent adherence to project schedules, a testament to the impeccable planning and execution espoused by LD Systems. "It's extremely unusual for a project to finish beyond its planned completion date," Sutphen remarks, highlighting the unrelenting commitment to timelines. This unwavering dedication ensures that every project concludes with a satisfied client, relishing the transformation of their facility into a technologically advanced space.

The Multi-Faceted Approach Embarking on the journey to automation with LD Systems is marked by a transparent, comprehensive process, a signature approach meticulously crafted under Bob Sutphen's aegis. The journey commences with a profound study of the client’s facility, where the team scrutinizes processes, layouts, and equipment, ensuring the strategies

22 | IMD October 2023

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Creating a Symphony of Technologies LD Systems, being technologically agnostic, prides itself on presenting solutions that are unbound by any allegiance to specific brands or types of machinery. "We can look at any technology that's available and analyze if it addresses the customer's needs and does it give them a 24-month ROI," Sutphen remarks. This independence grants LD Systems the flexibility to engineer solutions that are inherently the best fit for the client’s unique needs, devoid of any predispositions towards particular brands or models. It’s this approach that propels LD Systems ahead, allowing them to scout and amalgamate the best available technologies, ensuring clients receive solutions that are not only innovative but also the most appropriate for their distinctive requirements.

The Impact – Beyond Financial Returns Bob Sutphen’s vision transcends beyond mere financial gains. The implementation of automation, under the stewardship of LD Systems, is aimed at holistically enhancing the operational ecosystem of a facility.

Employees revel in a safer working environment, heightened productivity, and a state-of-the-art workspace, fostering a sense of pride and belonging. This holistic approach aids in bolstering employee retention, as the workforce feels valued, working in sync with avant-garde technologies.

The managerial strata too experience a palpable ease in their responsibilities, witnessing enhanced productivity

and reduced errors. "We've improved productivity, we've reduced errors; there are so many benefits from doing this," Sutphen points out, emphasizing the multifaceted benefits reaped by the client’s team.

A Global Footprint With Bob Sutphen at the helm, LD Systems has stretched its transformative touch globally, impacting businesses across diverse geographies. The company has embarked on projects as far-flung as the Philippines and Peru. It's not about the locales or the complexities they bring; it’s about the confidence and trust that clients worldwide repose in LD Systems to deliver. “It’s just people that knew us and reached out to us and said, ‘Hey, I’ve got an opportunity over here. Would you be willing to go take a look at it?’”

Sutphen shares, reflecting on the global outreach of LD Systems. It’s this universal appeal and trust that have paved the way for LD Systems to imprint its innovative solutions across borders, a testament to their unmatched capability to deliver.

A Testament to Consistency and Trust The reputation that LD Systems enjoys is not built on transient successes but on a consistent delivery of excellence. “About 80% of our business is repeat customers or someone who’s referred us to a customer,” Sutphen proudly states. This high degree of customer retention and

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referrals is not merely a business metric; it is a tangible manifestation of the trust and satisfaction that clients have experienced. It is a holistic testament to the seamless integration of innovative solutions and meticulous project management that has left clients unequivocally satisfied.

The Evolution of the Market The market landscape is continually evolving, a reality that LD Systems acknowledges and embraces. Bob and his team recently analyzed their project history, studying the trajectories of their customers over the last 15 years. The findings were revelatory. “60% of those customers are no longer available as a customer to us because they didn’t stay competitive and they went out of business,” Sutphen reveals. Others evolved, becoming more competitive, leading to acquisitions, while some shifted to having their distribution managed by 3PLs. This study underscored the relentless transformations within the industry, shedding light on the myriad ways businesses can evolve or dissolve. It’s a stark reminder of the importance of staying competitive, innovative, and adaptive in the ever-changing industrial landscape.

A Passionate Visionary Bob Sutphen’s passion for excellence and his visionary leadership are the cornerstones of LD Systems’ unwavering commitment to delivering outstanding value. For Bob, every project is akin to an offspring, reflecting his personal commitment and the meticulous standards he sets for every endeavor. When he walks into a building post-completion and thinks, “Wow, if this was my facility, I would be thrilled with this,” it’s not just about client satisfaction; it’s about his personal contentment, ensuring that each project bears the stamp of his dedicated vision and unparalleled commitment to excellence.

24 | IMD October 2023

Weaving Impact Beyond Balance Sheets LD Systems, under the discerning eye of Bob Sutphen, is not just a provider of industrial machinery solutions; it’s a transformative force, redefining the realms of what’s possible in industrial spaces. The impact of their work is not confined to the balance sheets; it resonates in the enhanced morale of the employees, the ease in managerial operations, and the fortified trust of their clients. The meticulous approach, the emphasis on collaboration, and the relentless pursuit of excellence make LD Systems a beacon of transformative change in the industrial sector.

The Road Ahead As the industry pivots towards uncharted territories, the role of visionary leaders like Bob Sutphen and pioneering companies like LD Systems becomes pivotal. The intricate blend of innovative technologies, meticulous strategies, and an unwavering commitment to delivering excellence positions them as architects of the future industrial landscape, crafting solutions that are not just efficient but are also harbingers of holistic growth and employee satisfaction. The journey of LD Systems is not just about creating state-of-the-art facilities; it’s about sculpting experiences, fostering growth, and above all, about reimagining the future of industrial spaces.

Bob Sutphen’s commitment to excellence, his profound understanding of the intricacies of the sector, and his visionary approach make him a true industrial maestro, orchestrating symphonies of transformative change, one project at a time.

For more information: For a deeper dive into the innovative solutions offered by LD Systems, you can visit their official website www.ldslc.com.

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Safety & Maintenance

The Positive Impacts of Destratification on Energy Consumption, Building Performance, and Workplace Comfort

W

hen it comes to optimizing indoor environments in manufacturing facilities and storage warehouses, one often overlooked yet incredibly effective strategy is air destratification. Air destratification is a simple but powerful tool for reducing energy costs, improving building performance, and boosting workforce comfort, safety, and productivity. By addressing temperature stratification, businesses can create healthier, more efficient, and more pleasant indoor environments that benefit their bottom lines and workforces. In a world where sustainability and workforce well-being are becoming increasingly important, air destratification stands as an invisible ally, helping to create better work spaces for all. This article explores the concept of air destratification and investigates its impact on several important aspects, including energy costs, building performance, storage resilience, and workforce comfort.

DESTRATIFICATION DEFINED Stratification occurs when warm air rises to the ceiling in an enclosed space and forms uneven temperature layers, or strata, in the space below. This causes thermostats located at the ground level and HVAC units to over-deliver warm air in order to maintain a desired temperature at the floor level, which creates a vicious cycle of inefficient and ineffective heating.

Destratification occurs when a powerful, purposebuilt destratification solution gently forces this warm air downward, consistently circulating and mixing the air to more evenly distribute it; and to create a more uniform temperature from ceiling to floor and wall to wall.

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One of the most significant benefits of air destratification is its impact on energy consumption. In most buildings with tall ceilings, warm air naturally accumulates near the ceiling, while cool air stays near the floor. This temperature

26 | IMD October 2023

stratification makes heating a space more challenging as thermostats typically measure air temperature at the ground level. As a result, heating systems work harder and consume more energy to maintain comfortable temperatures throughout the space.

Air destratification systems disrupt this stratification by gently mixing air layers and promoting more uniform temperatures from ceiling to floor and wall to wall.

Consequently, HVAC systems run more efficiently and energy costs decrease by as much as 30%. These savings translate into reduced operational expenses and a shorter payback period for the installation of a destratification system.

JOURNAL ARTICLE Impact Of HVLS Fans On Airplane Hangar Air Destratificaiton | ASHRAE JOURNAL | April 20, 2020 In this study, the authors attempted to quantify the effects of destratification on energy cost and consumption from use of an HVLS fan in an airport hangar. Why HVLS fans? Because at lower speeds, large diameter HVLS fans can effectively mix warm air at the ceiling with cooler air at the floor without creating perceived cooling across occupants’ skin.

With temperature loggers placed on the back wall of the facility at 5, 15, and 35 feet above the floor and single gas heaters installed in all four corners of the building, the authors evaluated several parameters with the fan on and off, including average temperature gradient from floor to

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ceiling, time to destratification (when the fan was turned on) and stratification (when the fan was turned off), and normalized gas consumption (and extrapolated cost).

Average Temperature Gradient from Floor to Ceiling During the first week of the study, when the HVLS fan was not in use, the average recorded temperature gradient from floor to ceiling was 6° F (3.3° C). The following week, while the fan was in use, an average floor-to-ceiling temperature difference of 0.7° F (0.4° C) was observed. The highest recorded temperature gradient was over 8° F. The HVLS fan effectively mixed the stratified air to produce more uniform temperature conditions despite the size of the hangar.

Normalized Gas Consumption The HVLS fan also reduced the normalized gas use by 29%, which consequently translated to significantly lower winter heating costs.

Conclusion Time To Destratification and Stratification When the fan was turned on, it reduced stratification and achieved near-uniform temperature conditions within 10 minutes of operation. Once the fan was turned off, stratification of the air started to reappear in as little as 15 minutes, which indicates that continuous or nearly continuous operation of the fan may be required to minimize heat loss through the envelope.

Using HVLS fans in airplane hangars is an energy-efficient method of creating a more uniform thermal environment due to the fan’s low power requirements and high potential for utility savings in the cold weather season.

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Manufacturing Showcase

Cobots boost production 200% on TIG and MIG welding and 600% on machine tending for metal fabricator

O

hio-based Raymath turns to user-friendly Universal Robots to automate complex TIG welding, as well as MIG welding and machine tending applications, driving revenue from $15M to $50M in three years.

“I’m always one who wants to try things myself—that’s what’s going to show me whether it’s going to work,” says Greg LeFevre, CEO and president of Ohio-based sheet metal fabricator Raymath. While researching automation

28 | IMD October 2023

options, LeFevre had discovered Universal Robots (UR), and when he found a UR certified systems integrator, THG Automation, close by, THG’s CEO Matt Hendey invited LeFevre to bring parts with him to get hands-on with the company’s UR cobot-based MIG welding system.

“Within the four hours that I was there, we programmed 20 weld points,” says LeFevre. “I was actually practicing and sampling on the parts that I was going to make. It

IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986

proved to me without a doubt: if I can program this in four hours and actually have my parts running, there’s no doubt this can work in our shop. I wrote the purchase order that same night.”

Raymath started with a cobot-based MIG welding application and expanded its automation strategy to include complex TIG welding applications. The company has grown from $15M in revenue to $50M in about three years, and LeFevre attributes the growth to the fast adoption of technology. “The learning curve isn’t as steep as what people think it is. The cost to get into it isn’t as much as people think,” he states. “Don’t be afraid to take that step.

You’re going to find out that even if it doesn’t go perfect, that ROI is going to be there in a pretty short time, and you’re going to find a new way and better ways, that will spur ideas from other people in the plant.”

Cobots bring automation advantages to high-mix, low-volume manufacturing Raymath welds, presses, brakes, lasers, and machines metals of all sorts, for almost any industry. The company produces parts that go into conveyors for large warehouses, construction equipment used worldwide, transportation and parking automation systems, food equipment, and more. LeFevre and his business partner, Jay Woeste bought the 40-year-old tool-and-die shop in May 2019 and quickly expanded the company, despite the immediate challenges of the Covid-19 pandemic.

“Customers want to have fewer suppliers,” says LeFevre, “So instead of having a hundred suppliers, they would like to have ten that can do more. We wanted to satisfy those needs.” With a background in automation, LeFevre knew automation would be key to meeting their goals, but his experience was in high-volume, low-mix manufacturing.

“It was very easy to automate when you make millions of a specific part. Moving into the fab-shop, sheet metal-type business, we’re now looking at a large number of different parts, but much smaller volumes of those parts.” Because traditional automation doesn’t lend itself to high-mix, low-volume, the company needed a much more flexible approach. “For us, robotics, and especially Universal Robots, has been who we turned to for a wide breadth of different parts with the same equipment,” he explains.

Automated MIG welding yields 4X productivity improvement and “invaluable” customer relationship Raymath, like most manufacturers, struggled to fill manufacturing and welding positions, especially during Covid. Raymath robotics specialist Nick Ogle says: “The THG robot units weld almost 50 percent faster than manual weld, sometimes more.” That lets Raymath produce parts more quickly with its existing staff, but also allows the company to support higher-volume orders.

With robotic welding, fixtures, push angles, speed, and heat are the same every time, which leads to faster, more consistent, and higher-quality welds than manual welding.

Cobot arms can also reach all the way around a part in ways

a human welder can’t, so almost all welds can be done without rotating the part. And with fewer starts and stops, robotic welding produces a cleaner weld that also reduces required grinding time.

As a high-mix shop, Raymath started with about twenty different parts on the THG welding system, but LeFevre quickly saw new opportunities to add more parts. He says, “Within two months, we decided to buy a second robot because we had filled the first one up, and the guys—Nick especially, who is our leader in that area—was picking up on the programming as fast as we could add parts. We had people now coming to us saying, ‘This would be a good part to put on the THG unit.’” Some of these requests came from operators who didn’t want to manually weld difficult parts; some came from the plant manager who saw the ability to fill larger orders; others came from supervisors who needed additional manpower to fill orders.

Gratifying to see all four cells run At Raymath, two robot operators typically run two THG welding cells each, depending on workload and cycle times. “The operators will typically run one robot, hit start, and while that one’s running, they’ll be loading the other one, and then will just jump back and forth,” Ogle explains.

“Seeing all four cells run at the same time is pretty gratifying, knowing you’re pushing that much product out the door that much faster.”

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For one aluminum part, the UR-based THG welding system has reduced weld times from 15 minutes per part manually to five to six minutes per part; for another, weld times shrunk from three to four minutes each to 30 to 40 seconds.

Cobots handle hard-to-staff processes with half the number of operators, and weld at twice the speed, resulting in 4X productivity improvement. But LeFevre says, “Really, it’s the opportunity cost that I view as the most invaluable.

There was business that we were able to take on that we would have never had the manpower and the ability to do.” Now that Raymath can satisfy all of customers’ needs, customers are less like to go to a competitor who might also gain future business. “It builds a better relationship with our customer, and how you measure that is hard to tell, but I know that it’s extremely valuable.”

Automated TIG welding system addresses both stainless and aluminum parts up to 6X faster than manual welding Complex aluminum welding was one of Raymath’s biggest challenges for growth, as it was all TIG welded by hand with precise welds on top and underneath, with difficult angles and heat settings, and multiple moving parts. After seeing success in MIG welding, LeFevre approached THG for a TIG solution. “It was an extension of what we were doing with our MIG welding, so adding TIG to our package with the Universal Robot was pretty seamless,” says Hendey. “Once you get the precision and everything down, the THG unit can make a very, very good TIG weld, and can do it anywhere from two to six times faster than doing it by hand.”

Hendey notes that while automated MIG welding can be applied to many different materials and applications, it may be difficult for manufacturers to justify both a MIG system for aluminum parts and a TIG system for stainless parts, especially at low volumes. With the THG cold wire feed push/pull TIG system, Raymath can weld both stainless and aluminum parts with the same system. The UR cobots in the THG system can also work around fixtured parts in one process. Some parts are much larger than the table they’re being welded on, so those parts are fixtured so the TIG weld occurs on the table and the rest of the part hangs off the edge.

Easy programming for both TIG and MIG welding LeFevre says, “I’m always looking at ease of use, and I found that the Universal Robot’s programming method was probably better than anyone’s out there. I really wanted to find a solution, knowing that we were going to change parts all the time, that had the programming and the implementation as easy as possible, and Universal Robots just fit the bill.”

THG’s Hendey adds, “With UR, unlike other robot brands, you get an open platform. There’s a lot of templates, there’s a lot of functionality that’s already built into the software, and the capabilities through the load-sensing that they offer

30 | IMD October 2023

and the intrinsic safety that allows it to be collaborative.”

This open platform allowed THG to create a customized robotic welding system with their own software to address customer needs.

THG created URCaps (software handshakes between the UR cobot and peripherals) that made the welding system easy to use, even for operators without previous robotics experience. Ogle, a manual welder by trade, simply moved the robot arm where it needed to be for the weld, and at the correct angle, and used the teach pendant to save the point. “UR and THG is the first time I’ve ever used collaborative robots, and I was very surprised at the ease of use,” says Ogle.

This ease of use is a key element of the THG design.

While THG provides one to three days of training for new systems, “A lot of times our customers will already have an application running in the welding before we even show up,” says Hendey. “When they call us down the road, it’s not about, ‘How do we make this thing still work?’ It’s about ‘Now I know how to do all this stuff, I want to get into the more advanced functionality of it.’”

UR cobots manage CNC machine tending with Hurco and Easy Robotics ProFeeder Beyond welding, Raymath also turned to UR for its machine tending automation needs, adding the UR cobot-based ProFeeder machining cells from ProCobots to its two 3- and 5-axis Hurco CNC machines. LeFevre says, “Using the ProCobots Hurco solution seemed like a very natural fit for us. We already had Hurco units, and we loved the conversational programming that goes on there.” Larry Dare, CNC machining supervisor at Raymath, had never

worked with robots and according to LeFevre, quickly became efficient at making the system work well. LeFevre says, “Now, not only can Larry be sitting at his desk attending to his paperwork, he’ll have two Hurcos running right in the background for him, that he can attend to only when they need parts, setting them up so that they can run parts when he is gone.” That allows the second shift to simply monitor the automated systems while running other machines, and the systems are still running when the first shift arrives the next morning, without having someone on third shift attending to them.

“We get 24 hours of machining time where we’ve never been able to get that before,” LeFevre states. That lights-out processing gives Raymath more than a 600% productivity boost in machining, getting double the hours with the same number of workers. This is especially important when workers—especially for third shift work—are in short supply.

ProCobots provided training and has simplified the systems over time with software updates. Dare says, “I’ve managed CNC areas for probably 15 years now. But the robot portion of it—we don’t have a whole lot of people that have their hands in that. It’s really just me and one guy on second shift. With the training that we’ve had, we’re usually able to get in and troubleshoot any problems we might have, and work through them ourselves and do all the programming of any new parts.”

The programming itself is straightforward. “The robot has a general path that it follows to take the part into the machine,” Dare explains. “Really, all you’re teaching it is from that point to the vise and where to place the part in the vise.”

ROI is easy to measure from a laborsaving standpoint, he emphasizes the ongoing return from additional opportunities and growth that technology has provided.

And as the company grows, LeFevre expects to continue to grow Raymath’s workforce who will be employed in more interesting, valuable jobs. “We are hoping to use the robots to attract talent,” he says. “We want to be known as a technology company that happens to do metal parts.

Because then we can attract the talent to allow us to take us the next step.”

LeFevre is adamant about the role of robots and jobs. “People believe robots take away jobs. I will always say robots add jobs. The more you can do for your customer, the more jobs you’re going to end up having. For every robot that I’ve put in, I’ve probably added four people,” he says adding that he sees manufacturing as the basis for many countries’ economies.

“And it’s going to take things like collaborative robots to allow not only the United States—but a lot of industrialized countries—to stay strong in manufacturing. UR has been the leader in collaborative, and they’re a good partner to try to make that happen.”

quality matters. every time.

Future cobot uses, from grinding to press brakes Raymath expects to continue its growth-throughautomation strategy, likely beginning with grinding—a dirty, dusty job that is perfect for robotics—as well as press brake tending.

And if business needs change, UR cobots can be easily redeployed into other applications, from material handling to screw driving or any other manufacturing process.

When customers ask how difficult that is, THG’s Hendey tells them, “Well, it’s a couple settings and re-bolting the equipment to the tables, and they can be off and running again within a day or so.”

Cobot-based systems deliver ROI and workforce advantages In terms of ROI, LeFevre says, “Any time you’re investing in a new technology, you’re going in with the belief that it’s the right investment, that the ROI is going to be right.

With these units, there’s no doubt that we’re getting about a one-year ROI at this point in time.” But while immediate

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IMD | 31

Industrial Automation

Choosing a Robotic Spindle for Deburring

By Mark Fairchild

R

obotics integrators are finding an increasing need for robotic deburring systems, and for good reasons.

Deburring is necessary for various fabricating operations, but attracting and retaining employees to perform the work is difficult. Labor shortages are ongoing, and the National Association of Manufacturers reported that in 2022 there were 800,000 unfilled manufacturing jobs in the U.S., with 2.1 million predicted by 2030. The nature of the deburring task is highly repetitive, dirty, and carries a risk of injury. Retaining personnel for such a strenuous, messy, and uninteresting job is challenging. Robotic deburring is an appealing option for these reasons, plus the results are more precise and repeatable.

Choosing the appropriate spindle for deburring applications carries a number of different considerations than for a milling assignment. In this article, we examine various aspects of spindle choice for deburring. We also examine polishing and sanding, which have slightly different requirements yet again.

From Where Is the Compliant Pressure Controlled?

Kenny Wilson, a Precision Drive Systems Engineering Manager with more than 25 years of experience, pointed out that the first thing to determine is whether the pressure applied to the workpiece will be controlled by the robot arm or the spindle itself.

32 | IMD October 2023

A variety of active force compliant spindles are available that are closed-loop systems capable of maintaining a constant pressure regardless of orientation. That is, the spindle will compensate for the force of gravity to maintain the same pressure in all positions. Less expensive passive systems can be appropriate in applications where gravity is not a factor.

If the spindle is not controlling the pressure, then the robot arm must do it. Either way, knowing this is the first step in choosing your spindle.

Bring the Part to the Spindle - or the Spindle to the Part Wilson said that he's seen more and more cases in which the robotic deburring operation will be performed by keeping the spindle in a fixed position, and having the robot arm bring the part to the spindle. The advantages to this approach are several.

With a stationary spindle, the deburring system designer or specifying engineer can choose a large and powerful spindle without having to worry about a robot arm strong enough to carry it. Since the robot only needs to bring the relatively lightweight part to the spindle, the arm needn't be as robust as it would be if it had to manipulate a heavy spindle. The result is a less expensive system and potentially a lower maintenance solution.

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However, some part geometries do not lend themselves well to being deburred using a stationary spindle. If the robot arm must carry the spindle, then it's important to choose a spindle that is powerful enough. The extra weight of the spindle will require a larger and stronger robot arm, thus adding cost to the system.

In a sanding application, Wilson said the angle at which the sanding wheel will contact the workpiece - and the percentage of the wheel that will make contact - need to be known. Combining these factors with the force applied enables one to calculate the torque requirements of the spindle.

What are the Speed and Torque Requirements?

Conclusion

Wilson described a variety of considerations relating to speed and torque when choosing a spindle for deburring, buffing, and sanding.

"For a deburring application, you need a spindle that can handle both radial and axial loads," Wilson said. Usually, a standard set of bearings in the spindle will suffice, unlike in a milling application, in which a triplex or quad set of bearings may be needed. "For deburring, it's more about the speed and torque of the spindle than it is the bearings," Wilson explained. He went on to say that the spindle for a deburring task will probably need a higher speed and torque than a milling application. Whereas a milling application will need a lot of torque at a relatively low speed, a deburring application will require a substantial torque at a higher speed.

Sanding, deburring, and buffing each have unique requirements as it relates to the physics of the spindle.

Deburring is usually high-speed while buffing will use a little lower speed. Polishing will often need more torque at a lower speed than deburring.

Choosing a spindle for a deburring application should be done carefully to achieve a system that is both cost-effective and will produce the desired results.

Calculating the speed and torque requirements of the spindle requires knowledge of many different aspects of the application. A robotic integrator can take advantage of the expertise and experience of spindle experts to help in making the best choice.

ABOUT PRECISION DRIVE SYSTEMS Since 1996, PDS has been the global leader in providing new spindles, design and engineering, customer support, and repairs for spindle applications in fabricating metal, wood, plastics, stone, marble, glass, and robotics manufacturing industries. The PDS corporate office is located near Charlotte in Bessemer City, NC. European customers are provided local solutions by the PDS service facility in Herford, Germany, with affiliated offices located worldwide. For more information, visit www.SpindleRepair.com or call 704-922-1206.

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IMD | 33

Workforce Development

Manufacturing Challenges and Solutions Series: Labor Shortage By: Emmet Cole, A3 Contributing Editor

T

here is no way to sugar coat the scale of the labor crisis in manufacturing: The latest National Association of Manufacturers (NAM) Outlook Survey reveals that 75.7% of manufacturing leaders in the U.S. consider attracting and retaining a quality workforce to be the number one business challenge.

Statistics from the U.S. Bureau of Labor & Statistics show that around 750,000 jobs are unfilled Boston Dynamics’ Stretch replaces manual unloading of packaging from trucks -a role that’s almost impossible to fill in today’s in the manufacturing manufacturing labor climate. Credit: DHL sector –even though unemployment is at historically low levels. And Deloitte both, but the current labor crisis has intensified the sense Insights predicts that 2.1 million manufacturing jobs will of urgency and is a major driver of automation adoption. remain unfilled in the U.S. alone by 2030.

“The situation is quite dire,” says Lian Jye Su, Cometh the hour, Cometh the robot research director at market analyst firm ABI Research, Analysts are saying it. Manufacturers are saying it. noting that the problem isn’t confined to North The industrial automation sector has always known it: American manufacturing.

Automation enables manufacturing companies of all “China also faces similar issues in keeping its factory sizes to address labor shortages while providing the workers. One report stated that more than 60% of Chinese traditional benefits and enhancements of automation from manufacturing workers were born between 1975-1985 and 24/7 availability and improved product quality through that very few young adults are interested in manufacturing increased production and throughput. jobs due to higher salary expectations and education levels.”

A shortage of workers for manual unloading of If demographics are a guide, then the labor crisis isn’t packages from trucks led DHL to invest millions in a going away anytime soon. collaboration with Boston Dynamics on the development “The manufacturing sector will always be of Stretch –a mobile platform for automated case handling expected to produce goods in a highly competitive, that comes with a 7 degrees of freedom robot arm, an time-sensitive, cost-effective, and safe manner. Coupled adaptive gripper, advanced vision capabilities, and a set of with the ever-declining birth rate, the labor shortage in high-capacity batteries to see Stretch through full shifts on manufacturing will likely remain, and automation is the a single charge. DHL plans to roll the robot out in several only way out,” says Su. facilities in 2023 and across many more locations over The latest NAM Outlook Survey also asked the coming years. manufacturers about their plans and the number one The manufacturing sector is experiencing a critical response –at 65.3%-- was “capital spending on new shortage of machine operators too. Solving this particular equipment and technological investments.” problem led Rapid Robotics’ to develop the Rapid The synergies between the industrial automation and Machine Operator (RMO)—an affordable, automated manufacturing sectors have always been important to machine tending system that the company says takes

34 | IMD October 2023

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The Rapid Machine Operator is a flexible automation system designed for speedy deployment. Credit: Rapid Robotics

just hours to set up and can be quickly switched between different tasks.

3D LiDAR sensor multiScan 100 “Traditional automation has many barriers that have kept manufacturers, especially in the small to medium category, from getting started. Lengthy deployment lead times, hidden integration costs, hefty upfront capital investment, lack of task flexibility –the list goes on.

New robotics-as-a-service (RaaS) models can provide a holistic robotic workforce solution that circumvents these barriers,” says Jordan Kretchmer, CEO & co-founder of Rapid Robotics.

As “a true RaaS company,” Rapid Robotics offers manufacturers the opportunity to lease pre-trained, fully operable robots on a monthly basis, with 24/7 remote support, and regular updates from the cloud designed to improve robot performance, says Kretchmer.

“This shifts the burden of cost from a large capital expense to a manageable operational one. Put differently, rather than pay a massive upfront charge for the machine, plus the additional cost of service and a systems integrator to program the machine, RaaS presents a low-risk pathway to automation.”

According to a recent study of 300 manufacturing decision makers conducted by Rapid Robotics, more than 92% are actively hiring machine operators, and more than 60% need to hire at least six. Echoing the results of the NAM survey, Rapid Robotics’ study also found that two thirds of manufacturers increased their number of automated processes in the past year, and that almost 80% plan to increase their automation in the next 12 months.

Automation doesn’t just help to address labor challenges, it also gives companies the bandwidth to take on more business, says Kretchmer, citing the case of a Rapid Robotics customer that automated pad stamping

and heat stamping applications, freeing human operators to focus on higher value tasks –a deployment that resulted in $60,000 in savings per year and $600,000 of additional business.

Looking to the long term Facing ongoing labor shortages, a machine shop in Texas deployed automation on tasks from CNC machinetending, sanding and deburring to part inspection and laser marking. Credit: Universal Robots There is no quick fix for the deeper issues driving the labor crisis in manufacturing, says Joe Campbell, senior manager of applications development at Universal Robots.

“We’re seeing unemployment hit its lowest level since 1969, but more than half of young people today just aren’t attracted to jobs in manufacturing. At the same time boomers are retiring. As a result, we’re seeing hundreds of thousands of manufacturing jobs remain unfilled,” says Campbell.

Long term efforts that will take “years to put in place and produce significant results” are nevertheless crucial to the survival of U.S. manufacturing.

“For a generation that is sometimes said to ‘live’ on their electronic devices, the opportunity to program a cobot from a smartphone or tablet can be very appealing and an extension of what they are already familiar with,” says Campbell.

“We need to increase interest in STEM topics in schools to introduce students to the core technologies, and to build awareness of exciting, technology-rich career opportunities in the manufacturing sector. State and local governments see the value in reshoring U.S. manufacturing, part of that has to include the introduction of more training opportunities, including 2-year manufacturing technology programs, to shrink the skills gap and expand the manufacturing workforce.”

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IMD | 35

Process

Ergonomic welding— a contradiction in terms?

W

henever series production is not a consideration, welding is frequently carried out by hand.

Welders often work in positions that strain the joints and muscles, for example when welding while forced to adopt awkward postures. This results in complaints such as sprains of the lower back or arms, which not only affect the health of welding professionals, but also come at the expense of the company’s productivity. Companies are therefore increasingly focusing on ergonomics during welding.

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What is meant by ergonomics?

Ergonomics has several meanings, one of which is quite literal: the term is derived from the Greek words “ergon” and “nomos”. “Ergon” means work and “nomos” translates as law. The word ergonomics can therefore be translated as “law of work”. Another significant (and practical) definition of the term “ergonomics” is the mutual adaptation of people and their working conditions. Ergonomists try to design the workplace in such a way that it does not impair the physical or mental health of workers.

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The same applies to welding workplaces. “These should be designed to meet the physical requirements of welders and enable predominantly focused work that does not cause fatigue,” emphasizes Peter Fronius, Head of Strategic Product Management Professional Welding Tools. “For example, by taking the height or arm reach of the welders into account. If workplaces do not satisfy ergonomic standards, the likelihood of sickness, injury, and absence through illness increases.” Of course, ergonomic risk factors cannot be eliminated every time and everywhere.

This is the case for out-of-position welding, for example, whereby the aim must be to limit the time that the individual spends in the situation insofar as possible.

stretching the body, twisting the spine, being supported by or kneeling on hard surfaces, maintaining the same posture over a longer period of time, or a lack of rest. If such risk factors occur repeatedly (individually or in combination) they can lead to work-related musculoskeletal disorders (MSDs), in other words injuries and diseases that affect muscles, nerves, tendons, ligaments, joints, intervertebral discs, skin, subcutaneous tissue, blood vessels, or bones. In addition to the causes previously mentioned, unfavorable environmental conditions such as extreme temperatures can also contribute to the development of MSDs, while personal risk factors such as physical condition, pre-existing illnesses, or age also come into play.

Risk factors when welding

Work-related musculoskeletal

Most causes of injury are not restricted disorders in welders to specific industries, but result from These disorders usually develop as a the movement and behavior patterns result of micro-traumas acting on the 2022 IMD AD final 11-21-2.pdf 1 11/22/22 12:16 AM of welders. Typical here are repeatedly body over time and causing conditions

such as lumbar slipped discs—the most common herniated discs due to the overall weight of the spine sitting most heavily on the two lower discs.

These intervertebral discs consist of flexible, annular cartilage that contains semi-liquid gel. If a welder repeatedly lifts heavy components while adopting

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an unfavorable posture, this cartilage can degrade and tear over time. This results in the intervertebral disc bulging, pressing on a spinal nerve, and causing severe pain.

The most common musculoskeletal disorders include back injuries, bursitis, inflammation of the tendon and tendon sheath, carpal tunnel syndrome, and thoracic outlet syndrome. This disorder, which can occur due to compression of nerves, arteries, or large veins in the neck and chest area, is very painful and can be caused by frequent overhead welding.

Ergonomics and welding are not contradictory Time and again, welders are forced to adopt unfavorable postures for a variety of tasks—frequently over long periods of time. It is often easier for the welder to move around large, heavy components themselves than to move the component into the optimum welding position.

Is it therefore paradoxical to talk about ergonomics and welding in the same sentence? Absolutely not. Because despite all the hindrances, there are plenty of ways in which welding companies can design workplaces and work equipment ergonomically. Effort that is generally rewarded by a healthier workforce, better morale, higher productivity, and enhanced product quality. For example, height-adjustable welding tables and stools are tried and tested means of adapting the welding height to the physical requirements of welders.

Ideal for long seams: welding carriages “Rather than welding meters of welds by hand in the overhead position, rail-guided welding carriages can often be used. The same applies to longitudinal seams and circumferential welds of large dimensions, which can be

38 | IMD October 2023

joined either with rail-guided carriages or with magnetic welding carriages. If mechanized systems like these are used, professional welders essentially only have to operate the remote control, while standing upright and with no physical exertion required,” explains Christian Neuhofer, Product Manager Fronius Welding Automation.

The compact Fronius FlexTrack 45 Pro can be used in a wide range of applications. Three different rail types are available to suit different requirements. In industries where surface geometries vary, such as shipbuilding or container construction, FlexTrack 45 Pro welding carriages are perfect for all-round use.

Welding 24/7 without physical effort Nowadays, cobot welding cells mean that the automated welding even of small batch sizes is cost-effective. Thanks to its enormous flexibility for joining different components, the compact CWC-S from Fronius is the ideal tool for this. “It

is easy to use, even without programming knowledge, and there is no physical effort required,” Neuhofer continues: “Your software remembers the welding sequences of the individual components, which are mounted either on a welding table or turn-tilt positioner. The components are welded fully autonomously in a protective cabin with an automatically closing and opening glare protection screen, which protects the welder from arc radiation—around the clock if necessary. If desired, the CWC-S can also be equipped with a fume extraction system.”

Heavy components should be lifted while fastened to lifting aids, such as indoor cranes, in order to protect the muscles and spine. This rule essentially applies to all lifting activities related to welding, because overloading the musculoskeletal system not only endangers health in the long term, but can also result in instant injuries such as lumbar syndrome, also commonly referred to as lumbago.

Orbital welding systems relieve the spine Pipelines that are often used in the food industry or in power plant construction are produced using orbital welding, whereby the welding torch is guided around the pipe. They often have to be joined at unfavorable heights and positions, which can have an adverse effect on the welder’s back. Orbital systems, such as the open and closed welding heads from Fronius, provide a solution. If the pipe to be joined is clamped, the welding torch automatically moves around the component and welds the seam with consistently high quality.

Ergonomics at Fronius The products of the Austrian technology pioneer have made a name for themselves not only for their technological finesse, but also for their user-friendliness. All welding torches, for example, are characterized by their low weight, comfortable handles, and user interfaces adapted to the tasks at hand. The ergonomic handles with non-slip components fit comfortably in the hand during welding and allow for safe and simple welding torch guidance, with ball joints facilitating optimum torch adjustment. Furthermore, the weight distribution of all torch components is well balanced, which promotes fatigue-free welding. With options such as a pistol grip, button extension, and heat shield available, our welding torches can be adapted to the personal use and safety needs of the welder.

Fronius also keeps usability in mind at all times when it comes to welding systems. In all compact systems, for example, the wirefeeder is integrated directly into the welding system housing, making them easier to use, especially when it comes to manual welding tasks.

Modularity combined with personal configuration and intuitive operating procedures are the keywords that we always focus on with our welding systems. The easier they are to use, the better professional welders can concentrate on the welding task at hand and keep their risk of injury low.

Examples here include the systems in the TPS/i, TransSteel, and iWave series, whose touch-sensitive displays and dials

are not only intuitive, but also easy to operate while wearing welding gloves.

Of course, the worker’s muscles and spine must also be protected, which is why Fronius welding systems have customized transport trolleys that accommodate the welding system, cooling unit, wirefeeder, and gas cylinder.

Easy to move around, they are better pushed than pulled, because constant pulling has a negative effect on the skeletal muscles.

Learning to weld without risking injury With the Fronius Welducation Simulator, trainees can familiarize themselves with welding without any risk of injury. They create different welds without putting themselves at risk due to arc radiation and welding fume, using ergonomically shaped welding torches and while adopting different welding positions, including out-ofposition welding postures. The components used for the different simulations are not only handy, they are also made of lightweight plastic, which protects the muscles and spine of future welding experts.

In summing up, there are many ways in which to make the working environment of professional welders as safe and ergonomic as possible, and in doing so positively influence the working conditions and motivation of employees. This in turn enhances not only cost effectiveness for the company but also public perception.

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IMD | 39

Industry Insight

Advanced meters deliver powerful data, graphs and energy insights Getting to the root cause of power problems and taking corrective action By: Karen Cheung, Product Manager, Eaton

P

ower quality events occur for ordinary and extraordinary reasons. Whether your power is coming from the utility grid or onsite resources, maintaining a reliable supply of electrical power is critical for aroundthe-clock uptime.

Metering data is imperative for managing energy wisely, but most organizations are already buried in data. And ever more is coming. So how do you zero in where problems are developing without spending all day looking at “normal” electrical circuits?

Metering with root cause analysis provides essential data and first-step insights to remedy power quality (PQ) problems, so you can ensure they don’t impact your business, without requiring inspection of every individual circuit.

Powerful trends are at work Already, 77% of companies expect to transition away from their current energy sources (source: The Intersection of Digital Transformation and the Energy Transition, July 2022). Businesses need new, intelligent tools to manage a changing mix of energy sources. Especially as electricity consumption soars, renewables are being added to businesses’ energy mix and electric vehicle (EV) adoption surges. This energy transition will generate new and far more data that businesses need to make use of and act on.

At the same time, power outages are increasing.

Large-scale power outages in the U.S. have increased 64% since 2000, largely due to weather-related events (Source: Climate Central, September 2022).

No matter how energy is sourced, power-critical businesses need to keep energy flowing. Yet, one in five data centers experienced a “serious” or “severe” outage in the last three years (Source: Uptime Institute’s Outage Analysis Report, June 2022). The cost of outages is soaring, with more than 60% of failures resulting in

40 | IMD October 2023

at minimum $100,000 in total losses (up from 39% in 2019).

And power-related problems make up 43% of significant outages that cause downtime and financial losses.

Focusing investments on electrical infrastructure continues to be a critical differentiator. Powerful metering and root cause analysis tools are providing critical insights, which make it possible to spot problems that would have otherwise gone unnoticed.

Standards apply – automate reporting for IEEE 519 If your local utility is enforcing the Institute of Electrical and Electronics Engineers (IEEE) 519 guideline, advanced meters can help you meet those requirements. Beyond the utility penalty costs, excessive harmonics can have wide-ranging and long-term implications for industrial, data center, commercial and other environments. Harmonics

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can overheat, damage and shorten the lifespan of motors, transformers, power conductors, sensitive electronics and other equipment.

The IEEE 519 Standard deals with harmonics, which introduce inefficiencies and wasteful heat into your power system and can result in fees from your local power company. IEEE 519 establishes the goals for the design of electrical systems that include both linear and nonlinear loads or harmonic producing loads.

Managing the harmonics in a power system is a joint responsibility shared between power consumers and their utility company. While some level of distortion is acceptable, how much that impacts voltage depends on the impedances in the system. Both you and your utility need to work cooperatively to keep voltage distortion below levels that cause problems.

The standard provides guidance and recommendations on harmonics limits, so your neighbors do not cause problems for your electrical system. And it establishes your local utility as the mediator for when things do go wrong.

In other words, your utility will determine whether it will enforce the standard.

Meters with sophisticated reporting functionality can help you meet your utility’s requirements by analyzing each cycle and comparing harmonic content across the spectrum over time to the IEEE 519 established limits. It takes a lot of processing to determine that you stay within those limits

95% of the time (which is the threshold established in the guidelines) at the point of common coupling.

Advanced metering delivers on more than data—get actionable reporting In today’s increasingly digital world, most organizations are buried in data. How can you make better sense of it all to establish a competitive advantage? When you have hundreds or thousands of individual circuits to monitor, you need a simpler and robust way to see what’s happening on your system. Actionable data analytics are essential to provide accurate information on where problems are developing. You cannot waste resources on looking at circuits that are operating normally.

When you suspect a problem with your electrical system, you shouldn’t need to be an expert to know what to look for to prevent or avert it. Yet power quality events often happen so quickly that they are over and done faster than an alarm. You need your meters to help demystify these power quality events and today’s advanced technology makes it a lot easier to spot problems in advance and take corrective action.

"In a world where power quality events arise from both the ordinary and extraordinary, the key to uninterrupted operations lies in the wisdom of metering data and root cause analysis. As businesses navigate a changing energy landscape and battle increasing power outages, these

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IMD | 41

tools shine a light on the hidden issues, safeguarding against downtime and financial losses,” said Tony Trim, Gulf Region Lead Solution Architect, Eaton. “In the midst of powerful trends, investing in electrical infrastructure becomes the critical differentiator that ensures the relentless flow of energy, securing the future of powercritical enterprises.”

7 tips on how you can get to the root cause of power problems faster

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Tip one: Leverage aggregated metrics to speed up analysis.

Meters are essential to informing a broad view of what’s happening on your system. Yet looking at information from individual meters is insufficient, especially when you have dozens or hundreds of meters. To help you take action that improves power reliability and efficiency, advanced meters provide a robust bird’s-eye view with interactive data, so you can look at events and toggle between information.

Simple to understand tools like a PQ index can identify circuits with Power Quality problems. To dig deeper into the root cause of PQ problems, users can compare statistical gauges, trend plots, waveforms and cycle-by cycle RMS plots. For example, you can see voltage levels and whether they impact load currents, and you can see the correlation between current and voltage. And by plotting current and voltage into the same graph, you can make more sense of what’s happing in your power system. To dig even deeper into the root cause of PQ problems, you can compare statistical gauges, trend plots, waveforms and cycle-by-cycle root mean square (RMS) plots.

Tip two: See what’s happening over the duration of multiple events.

When you your lights flicker, it’s hard to say whether the cause is internal or external. Yet, these power quality events can be a challenge for hospitals, data centers and anywhere that power reliability is mission critical. Knowledge of what’s driving power events enables you to address and rectify them while minimizing downtime.

Today, you can see what’s happening and put multiple events in context through your meter. That gives you the data to better protect your infrastructure and talk with your utility (if the events are a regular occurrence). For example, if there’s a fault on the line, reclosers open and close, creating an inrush, which has adverse impact on motors. Armed with a documented Power Quality event history, you can discuss what your Utility Company can do to reduce the occurrence of these events.

Tip three: Spot patterns with a calendar view.

When power quality events occur regularly or seasonally, you can identify the patterns in a calendar view and determine if an issue coincides with a regular process, like testing of standby generators. In the meter’s calendar view, you can see the timeline of what occurred and see patterns of power quality events impacting equipment.

Tip four: Benchmark energy usage and see how energysaving measures are working.

Your meter can help you trend your energy demand over time, accumulated energy savings, peak demand and the amount of energy you use. You can also see energy flows in either direction, whether you’re taking power in from the grid or shedding excess power generated. And you’re able to understand when your onsite solar or energy storage resources are kicking in to support your facility and offset power from the grid.

Tip five: Track phase balance.

Phases can become unbalanced. In order to predict and rectify phase imbalances, you need to see the trends, not just the trigger point. With this graph you can see how phase data drifts apart before it reaches a trigger point.

Tip six: Determine if power sags are impacting your business.

Identifying power sags has historically been somewhat of a guessing game. Previously, RMS plots would typically offer too little information; available data provided a microscopic view (with the waveform) and broad five-minute interval, which would shed some light but make it difficult to determine when and why a power sag occurred.

With the newest meters, you have a lot more information on what occurred during a power sag and can set alarms and triggers to help avoid future events. You can see anomalies in voltage, current, frequency and power through plots featuring 5-minute interval readings. A newly available two-minute cycle-by-cycle RMS view at a high resolution, with one-cycle readings can help you understand what led up to or resulted from an event. While there is still detective work involved in identifying and preventing power sags, there is a lot more information at hand.

Tip seven: Take the guess work out of your analysis Traditionally, your meter would provide individual waveform analysis for each power quality event. The information can be disjointed and even the RMS plots would have limited utility by themselves because they did not provide much context. Now, you can get a much fuller picture from your meter and see how events relate to each other.

For example, when the lights flickered in a stadium during a big game years ago, a two-minute recording of what was happening could have helped get the lights back on faster by understanding the root cause of the event. The graph would have shown why there was an event, and that turning everything on simultaneously would cause an inrush that would overload the generators. The bottom line is that you need information to make decisions on how and when things need to run, and you need visibility into potentially developing problems.

Meters can help you both see the forest and the trees with relatively easy-to-digest information even if events happen on different days. And you can see the full picture of what occurred with longer capture information at a lower

resolution, so you can see what happened and how different waveforms relate to each other with the RMS plot.

Move beyond simple metering to advance uptime, productivity With energy sources changing and everything electrifying, focused investments in your power systems can be a critical differentiator. And robust, advanced metering capabilities are setting a new standard for power distribution system event diagnostics.

Powerful metering and root cause analysis tools are providing the critical insights you need to spot problems that would have otherwise gone unnoticed and prevent them from happening again. These capabilities can transform your day-to-day operations from simple measurement to intelligent insights – so you can focus on your business mission instead of analyzing metering data for your critical systems.

When it comes to power quality, it’s not just about the amount of data you can capture, it’s about capturing the right data exactly how and when you need to.

For more information: To find out how advanced metering can help you improve power quality monitoring and event analysis for your critical systems, visit Eaton.com/PXQ.

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IMD |8/23/18 43 9:33 AM 8/23/18 9:33 AM

Product Showcase

PRODUCT SHOWCASE Industrial Machinery Digest's Monthly Product Showcase features the latest from some of the manufacturing industry's top suppliers.

WANT TO BE FEATURED? Send your latest product information to editorial@indmacdig.com

New electronic bore gage makes in-process gaging fast, easy and affordable Sunnen’s new PGE-6000 Electronic Bore Gage combines advanced computer control and color touch screen operation with the proven mechanical design of the legendary PG-800 series gages.

Unique design makes piece-by-piece production monitoring practical, with easy setup and operation.

Onboard computer collects and stores data for downloading into a PC for Statistical Process Control (SPC) analysis.

The new PGE-6000 Electronic Bore Gage from Sunnen Products Company allows precise control of final bore size and quality of purchased or semi-finished parts, with an instant digital or numerical readout for 100 percent inspection. The electronically amplified comparative bore gage is ideal for quick, simple, economical process control in almost any manufacturing environment, combining lab-precise accuracy with a robust design built for everyday shop use. An easy-to-follow setup menu handles all pertinent information required for fast, easy part inspection. An onboard computer can store serialized part measurement data for use in Statistical Process Control (SPC) analysis. Data is downloaded directly into a PC via a cable or USB drive, which also is used for software updates.

A viable alternative to air gaging in many instances, the PGE-6000 gages bring reliable, flexible ID gaging to the manufacturing floor with no need for probes or master rings. A single gage can measure a wide range of part sizes, offering greater versatility at a lower cost than a comparable air gaging system. The standard unit handles bore diameters from 0.370 to 1.50 in (9.40 to 38.10 mm) utilizing adjustable gaging fingers on both sides of the gage (the proven

44 | IMD October 2023

PG-800 gaging system). Installing the optional gage finger extensions increases the bore diameter range to 1.50 to 3.00 in (38.10 to 76.20 mm) to accommodate even larger parts.

The upper control/display unit is easily rotated to utilize either side of the mechanical measuring system.

The PGE-6000 Bore Gage removes complexity, skill and "feel" from the measurement process, and allows machine operators to precisely confirm part size with confidence after only brief training. A large 7-in diagonal (178 mm) color touch screen, with easy-to-use setup and measurement displays, allows the operator to tailor the gage to the application.

Compact and easily portable, the gage can be mounted right at a machining station or in a QC or lab setting. The optional PG-400 or PG-500 adjustable setting fixtures simplify setup, while eliminating the need and expense for plug gages, jo blocks, master rings or micrometers. The selectable screen displays measurements in Radial Arc or Linear format with selectable resolution down to 0.0000010 in. or 0.0001 mm for 100 percent inspection of machining operations or fast sampling of large vendor lots. Data can be displayed graphically or numerically. Measurement units are easily changed between inch and metric.

PGE-6000 Bore Gages can be used to examine the entire bore length for diameter, taper, barrel, bell mouth, out-of-round and lobing, and it is accurate right up to the edge of ports, lands or the ends of blind bores.

Standard internal functions include the average, median, standard deviation, minimum, and maximum of a series of measurements.

PGE-6000 Bore Gage combines a proven mechanical design with modern electronics to "lock in" accuracy, performance and reliability. An exclusive system of floating reeds locks the gage fingers at the desired diameter size, protecting against drift or lag. Accuracy is not affected by temperature, moisture, air pressure, or vibration. The floating reed system eliminates friction and wear to maintain repeatability. An optional foot pedal is available to allow hands free data entry.

Additional information on the PGE-6000 Bore Gage is available from Sunnen Products Company, 7910 Manchester Rd., St. Louis, MO 63143. Phone 1-800-325-3670; fax 314-781-2268 or e-mail sales@sunnen.com.

IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986

Arnold Highlights L Type Magnets for Industrial Market Arnold Magnetic Technologies Corporation, a subsidiary of Compass Diversified and a prominent manufacturer of high-performance magnets and thin metals, is offering innovative L-Type Laminated magnets designed for high efficiency in industrial applications such as high-speed motors, power generation, and magnetic bearings. These magnets are proven to minimize eddy current losses, ensuring optimal efficiency and less heat production in high-power motors.

The L-Type magnets use the market's thinnest insulating materials, with layers measuring fewer than 20 micromoles, and guarantee premium performance quality at temperatures exceeding 200ºC. They are available in Samarium Cobalt or Neodymium Iron Boron, with the choice depending on the application’s highest temperature potential, required magnetic output at the typical use temperature, and the overall target cost.

Particularly noteworthy is Arnold’s RECOMA 35E, a power-dense samarium cobalt magnet designed for demanding applications involving high speed (100,000 RPM+), high temperature (above 200°C), and corrosive environments, making it ideal for various industrial applications. Arnold ensures compliance with ITAR and adherence to DFAR clauses throughout the RECOMA supply chain.

Arnold’s laminated L-Type magnets, juxtaposed with non-laminated ones, vividly illustrate the reduction of eddy current losses and subsequent heat distribution, with lamination effectively ensuring heat reduction and enhanced efficiency.

The company provides these custom-made permanent magnets based on client specifications and project needs, with engineers assisting in selecting suitable materials and lamination thickness according to application requirements.

Arnold is globally recognized for collaborating with clients in delivering high-efficiency motor designs, custom magnetic assemblies, and complete rotors by leveraging laminated Rare Earth magnets, precision thin metals, carbon fiber sleeving, and RECOMA samarium cobalt for holistic system performance. The firm’s global presence and engineering expertise position it uniquely to work with diverse design teams to elevate motor performance in the industrial market.

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IMD | 45

Big Ass Fans Introduces Hornet Fan Big Ass Fans, a pioneer in the industrial and commercial fan sector, has unveiled its newest product, the Hornet, marking its first-ever industrial-focused destratification fan.

The Hornet is engineered to optimize energy efficiency, enhance air mixing, and ensure supreme comfort in demanding applications, particularly in obstructed environments like racking aisles and workstations where traditional high-volume low-speed (HVLS) fans aren't feasible.

The Hornet stands out with its impressive ability to produce up to 6000 CFM per unit, making it a market leader in power, efficiency, and versatility.

This equates to lower energy, upfront, and installation costs as fewer units are needed to achieve desired results.

It features an IP55-rated motor and a robust steel frame, ensuring durability in extreme industrial conditions.

The fan offers industry-leading safety features, versatile control options for easy integration into existing systems, and the capability to operate multiple units from a single controller. Additionally, its elevated speed capacity provides a cooling effect in warmer months.

According to David Rose, Global Product Manager, the Hornet, when paired with HVLS fans, provides an ultimate solution for air mixing and destratification in manufacturing and warehousing environments, potentially reducing HVAC costs by up to 30% while avoiding extensive capital expenditure on HVAC. The Hornet is available for purchase, with more details on the company’s website: www.bigassfans.com/hornet

Dormer Pramet adds a new option to their high-end threading options Dormer Pramet, a global leader in tool manufacturing, has expanded its high-end threading options with the introduction of the Dormer Shark E894. This high-performance HSS-E thread forming tap is designed to suit both through and blind holes across a diverse range of workpiece materials. The taps are crafted using premium materials, ensuring an optimal balance of toughness, hardness, and heat resistance throughout the entire tap.

The Dormer Shark E894 is available in DIN/ANSI standard and offers UNC, UNF, and Metric thread forms, catering to global operations with varied requirements.

It features innovative forming lobe geometry, optimized post-treatment, TiN coating, and oil grooves ensuring lubrication up to a 3.5xD depth, making these taps the preferred choice for rigorous mass production threading applications.

This new addition reaffirms Dormer Pramet's

46 | IMD October 2023

commitment to reliability and quality in their product offerings. For additional information regarding Dormer Pramet and their products, please visit www.dormerpramet. com or get in touch with the local sales office.

EMUGE-FRANKEN USA Introduces MultiTOOL Program for a Complete Threadmaking Solution EMUGE-FRANKEN USA has unveiled its innovative MultiTOOL program, a collection of high-performance threadmaking solutions meticulously designed to meet the diverse needs of various job shop applications. This program integrates versatile and high-quality tapping solutions, thread mills, and drills, making it an ideal option for applications involving a wide range of materials.

The MultiTOOL program consists of the MultiTAP™, a versatile tapping solution available in different coatings and extended lengths. It is expertly designed to cut through various materials, including carbon steel, steel alloys, stainless steel, and aluminum, making it a practical choice for multiple applications.

Its distinctive geometric design and special base material and surface treatment allow it to produce threads within both 2B and 3B classes of fit, enhancing thread quality and output while optimizing production costs.

Additionally, the program includes the new MultiTHREAD™ MILL, a general-purpose thread milling solution, noteworthy for its efficiency and cost-effectiveness, especially when materials and part applications are frequently changed in job shops. It's coated with EMUGE's proprietary TIN T21, designed to cut a wide range of standard materials proficiently. This tool is versatile, reducing the number of tools needed and consequently, the costs.

The MultiDRILL™ component of the program brings forward high-quality solid carbide drills, designed for environments with many materials and limited quantity production runs. These drills are made of a unique sub-micro grain carbide grade, harder than conventional carbide grades, and feature advanced TIALN-T63 coating with nano-layer technology, providing reduced friction at high temperatures and longer tool life.

These solutions collectively aim to address the varying needs of manufacturers and job shops, offering a balance of quality, versatility, and cost-efficiency, allowing for optimal productivity and performance in diverse industrial settings. The MultiTOOL program exemplifies EMUGE-FRANKEN USA's commitment to providing comprehensive, state-of-the-art threading solutions to the manufacturing sector.

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Advertiser Index Actek Manufacturing and Engineering Inc. — www.actekmfg.com ...............................................................6 ATTCO, Inc. DBA Syclone ATTCO Service — www.skyhookmfr.com ............................................................9 Attica Hydraulic Exchange — www.hydraulex.com .........................................................................................27 Betenbender Manufacturing, Inc — www.betenbender.com ........................................................................ 11 Burr King Mfg Co. — www.burrking.com .............................................................................................................5 Carell Corporation — www.carellcorp.com ....................................................................................................... 13

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