» Knowledge is Power: Overcoming 3D Printing Barriers to Adoption » The Future of Manufacturing: Impactful Tech on the Horizon » Scalable Quality Inspection and Collaborative Solutions
Manufacturing Showcase: IndustrialMachineryDigest.com
September 2020
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Table of Contents
COLUMNS
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BUSINESS 4.0 Survey: U.S. Manufacturers Look to Equipment-as-a-Service Business Models as Advantage in Current Crisis Relayr has released its new executive summary report, highlighting the current mood of the U.S. and German manufacturing industries.
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FEATURES
20
MANUFACTURING SHOWCASE
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ZOLLER Inc. By Russ Willcutt
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WORKFORCE DEVELOPMENT
Knowledge Is Power Overcoming 3D Printing Barriers to Adoption By: Greg Elfering, President of Ultimaker Americas
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Cloud Computing: Companies Love It, But So Do Hackers
DEPARTMENTS
NEW TECH The Future of Manufacturing: Impactful Tech on the Horizon
32 PROCESS
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SAFETY & MAINTENANCE By: Kevin Studley, President, The Network Pro
By: Rahav Madvil, Simulation Product Manager for Siemens Digital Industries Software, and Noam Ribon, Senior Business Consultant at Siemens Digital Industries Software
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TALKING SHOP Pat Boland Co-Founder and Managing Director, ANCA Group
Scalable Quality Inspection and Collaborative Solutions ABB’s new 3D inspection robot cell makes quality control testing ten times faster while their ground-breaking YuMi® robot has set new standards for collaborative robotics for five years
INDUSTRY INSIGHTS
A Drill for All Materials Korean automotive manufacturer sees 1,150% increased tool life with CoroDrill® 860-GM
6 EDITORIAL DIRECTIONS 8 INDUSTRY NEWS 40 NEW NORMAL MANUFACTURING 42 PRODUCT SHOWCASE 46 SURPLUS BUYING AND SELLING 49 CLASSIFIEDS 50 ADVERTISER INDEX
ON THE COVER
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Dynabrade has earned a reputation for excellence and a position of leadership in the innovative design and manufacturing of unique portable pneumatic abrasive power tools, related accessories, and dust collection. With their total systems solutions offerings, Dynabrade is able to meet the specific needs of many industries. For more information, visit www.dynabrade.com
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Editorial Directions SERVING AMERICAN MANUFACTURERS FOR OVER
One of the things I once loved most about my work was traveling, The farther away an assignment took me – China, Taiwan, Japan, Italy, Switzerland – the better. But I thoroughly enjoyed seeing as much of North America as I could, as well. A couple of days in Seattle, Los Angeles, Miami, or Chicago was always a welcome addition to my itinerary. No matter where I was headed, I enjoyed the preparation, and then the sheer anonymity of travel. Nobody knows who you are – you simply parachute in to the company you’re there to visit, get things done, and head back home. In my line of work, these visits would involve scheduling a site visit with a manufacturer for an interview and photography, conducting plenty of research in advance, and then showing up on time with a backpack full of all the gear I’d need. Then it was a matter of being curious and allowing my hosts to walk me through their world. I truly miss those encounters. I’d spend time with everyone from top executives to general managers, maintenance supervisors, machine tool operators… anybody who had a couple of minutes to tell me about themselves and their role within the company. What I learned is that everybody has a story: everybody. And I picked up a few handy insights along the way, too. For instance, I always record interviews, noise levels allowing, but you still need to take down notes. One reason is because it seems to be expected of you – you don’t seem like you’re doing the heavy lifting if you just sit there letting your digital recorder do all the work. Plus you can scribble down points you’d like to return to for clarification later without interrupting the flow of the conversation at that moment. And when it comes to photography, I always had a calisthenic approach, crouching down, reaching up, climbing ladders and being lifted on cherry pickers; anything to find that original angle for your shot. And I had a saying, too, about trying to get “skin in the picture” as often as possible. Shooting for trade publications can get awfully “metallic” at times, if you know what I mean,” so I'd work to get people in the background, or get someone to hold samples of the parts they make in the palm of their hands. Try to bring the image to life, in other words. These days I wonder if we’ll ever return to a time when we could travel so freely. It was such a rich experience to meet so many smart, entertaining, creative people. Same thing with tradeshows. As exhausting as they could be, you also felt an energy coming off an expo that simply can’t be matched, and you’d make friends you’d keep for your whole career. So without rushing our recovery, here’s to better days, when we can come back together as an industry again.
34 YEARS
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Industry News Jergens, Inc. Receives AS9100:2016 Rev D Single Site Certification, Expanding its Engineering and Design Capabilities in Aviation, Space & Defense The certification is designated for Jergens Specialty Fastener products, including Quick Release Pins, Threaded Inserts, Spring Plungers, Spring Loaded Devices, Handwheels, and Adjustable Handles & Knobs. The AS9100:2016 Certification is an invaluable component to the design and manufacturing of Specialty Fasteners, Lifting Solutions, and Workholding Solutions. The new certification will further enable Jergens Inc. to customize and design components offering rigid quality standards and mil-specs, with tight tolerances and high precision. “This certification is a game changer for Jergens and separates us from our competitors in terms of efficiency and service response time,” said Matt Schron, General Manager for Jergens, Inc. “Our many customers in the aerospace sector, both military and commercial, are seeking our heavily engineered expanded design services, customer solutions and standard and special configuration all while maintaining our shorter lead times. This certification will allow us to better serve our clients with premium products more quickly.”
Platinum Tooling Releases New Catalog Platinum Tooling Technologies, Inc., the exclusive North American importer of standard and custom Live Tools, Angle Heads, and Multiple Spindle Tools manufactured by heimatec GmbH, is excited to announce the release of their new catalog. The newly released catalog offers an updated look and features their high quality machine tool accessory lines, including: heimatec GmbH – Live Tools and Machining Center Angle Heads; Tecnicrafts Industries – Collets & Guide Bushings for Swiss Type CNC Lathes; Henninger GmbH u. Co. KG – Mechanical, Air & Motor Speeders, plus Custom Machining Center Angle Heads; Andreas Maier GmbH & Co. KG (AMF) – Cleaning & Marking Tools. Preben Hansen, President of Platinum Tooling, is known throughout the industry for his expertise and experience in the tooling industry. Hansen will continue to offer advice and welcomes the opportunity to discuss your application. Platinum Tooling Technologies, Inc., is located in Prospect Heights, Illinois (just outside of Chicago). They recently expanded their facility to provide increased inventory to better serve the marketplace.
BIG KAISER Celebrates 30 Years BIG KAISER Precision Tooling Inc., a global leader in premium high-precision tooling systems and solutions for the metalworking industries, is celebrating its 30th anniversary. On August 1, 1990,
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KPT Kaiser opened its doors and began its mission to make Kaiser CKB modular boring tools, developed in Switzerland, the leader in the North American market. When the company began in 1990, most shops used boring tool technology from the 1950s, where tool changes were a costly and a time-consuming process. Labeling themselves “The Tooling Problem Solvers,” the sales team set out to take on the industry’s toughest problems and prove the efficiency and time savings of modular boring tools. Today, the modular connections are still the same, meaning a tool built in 1969 can still be used on a machine today. “I started the company out of necessity,” BIG KAISER president and CEO, Chris Kaiser said. “I knew we needed to change how we were selling the boring tools manufactured by my father’s company in Switzerland, Heinz Kaiser AG.
Cincinnati Incorporated Partners with Multiax America for 3D Printing Turnkey Cincinnati Incorporated (CI) has partnered with Multiax America, a custom designer of CNC machining centers. The partnership will allow each company to offer needed products in the additive manufacturing space. In additive manufacturing, parts almost always have to be machined after they’re 3D printed. This secondary machining process gets the part to its final dimension and smooths the surface. Whether it’s a mold or a trim fixture, in the aerospace or automotive or marine industry, chances are the part requires follow-up machining. Multiax America now offers CI’s Big Area Additive Manufacturing (BAAM) machine, and CI in turn now offers the Multiax line of 5-axis routers. The result is a turnkey solution for customers that saves them time and opens them up to the service and support of two expert manufacturing companies. “Because an overwhelming majority of BAAM-printed parts require secondary machining, we’ve had a goal to partner with a leading CNC machine manufacturer for some time,” said Alex Riestenberg, Additive Manufacturing Product Manager at CI. “Multiax is that manufacturer. Our open-book relationship will make both of us stronger, and it will ultimately better serve the customer.”
RobotWorx Boosts Large Robot Parts Inventory Amidst COVID-19 Pandemic Amidst the COVID-19 pandemic business disruption, many businesses are learning to adapt and find strengths within their business that are capable of flourishing in the current economy. RobotWorx is well equipped to meet demand for parts and virtual service support in a shifting market. With state restrictions and social distancing orders, the industry has seen the typical July shutdown expectations take a 360. More businesses are taking advantage of the current “down time” to conduct their shutdowns while normal demand remains low. With staff cuts and attempts to save cash, many businesses are opting to conduct their own robot service in house, but still utilizing companies like RobotWorx to provide parts and long-distance support. To further meet demand, RobotWorx has launched a new campaign re-introducing their extensive parts inventory with up to 40 percent savings on reconditioned parts. You can find 100’s of
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thousands of parts in any of the following brands: FANUC, Yaskawa Motoman, ABB, KUKA, Lincoln Electric, Miller, Fronius, Abicor Binzel and Tregakiss. RobotWorx prides itself on fulfilling those hard to find items and their ability to expedite the ordering process to reduce downtime (even during a world pandemic). On their website you can find a number of parts categories including, cables, grease, mechanical components, PBCs, servo amplifiers, servo motors, teach pendants, welders and welding torches. All parts are backed by their full- replacement 30-day warranty. While most orders have same day shipment available depending on availability, their current special includes same day shipments guaranteed for part orders placed by 1pm EST.
HELLER Machine Tools - A New Partnership with Dynamic Machine of Detroit. Heller Machine Tools L.P. are very pleased to announce a new distribution partnership with Dynamic Machine who will cover the regions of Michigan, Western Pennsylvania and also Canada. Dynamic Machine is owned and operated by founders Greg Sandler and Vince Mileto. The company is now one of the largest machine tool distributors in America and they are a true provider of advanced machining solutions to the metal cutting industry and a trusted partner with several manufacturers and their global affiliates. The Dynamic Machine priority is to introduce technologies that can strengthen the customer`s ability to compete in the markets they serve. Whether the solution involves a single stand-alone machine,
multi-process equipment, or a fully integrated manufacturing system with automation, the goal remains the same - to optimize production methods and component quality at competitive prices. Heller Machine Tools have changed their business model in the North American market. For the first time ever Heller has moved to both direct and distribution sales and service - providing our customers with a more local interface that can provide sales, engineering and customer support via our new distribution network and still maintaining our existing direct Key Account business.
Industrial Magnetics, Inc. Appoints Aaron Evans as Western US Regional Manager Industrial Magnetics, Inc.(IMI) announced the appointment of Aaron Evans as regional manager for the company’s Western US territory, which includes the great states and regions of Arizona, Utah, central and southern California, and southern Nevada. Aaron comes to IMI with an extensive background in industrial distribution, including 15 years as an account manager with Kaman Distribution. He has also held management positions at various hydraulic and power transmission distributors and completed a number of factory training and certifications with companies such as, Baldor Electric Motor, Timken Bearings and Drives® Chain, and NIBA Belting Association.
WHAT WOULD YOU DO IF YOU COULD BUY TIME? What if you could be more productive? Imagine offloading work as if you gained an extra pair of hands in your shop. Cutting stock in-house is a great solution to reduce materials costs. But the act of cutting it has a price of its own.
The AF50 Autofeed Bandsaw from Tormach is designed to take on the chore of cutting stock. Set the length and number of cuts, then get focus on more profitable work. And with a list price of $3,995, the AF50 could pay for itself in as little as a few months.
Go to tormach.com/AF50/IMD for more information and to start your order.
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IMD 9
Business 4.0
Survey: U.S. Manufacturers Look to Equipment-as-aService Business Models as Advantage in Current Crisis Relayr has released its new executive summary report, highlighting the current mood of the U.S. and German manufacturing industries.
» Study describes the attitudes toward current developments in the industry and any short- and long-term impact the health crisis will have on their operations. » Most respondents say COVID-19 has affected existing customer groups and regions, and they’re looking for ways to adapt. » Almost all respondents say technological advantages such as industrial IoT (IIoT), big data, and artificial intelligence support their coping with uncertainty.
L
ike many other sectors, the U.S. manufacturing industry has been heavily impacted by the current health crisis. The global nature of the pandemic has led to bottlenecks in supply chains, turnover, and orders. To learn more about the current situation, relayr, a global industrial internet of things (IIoT) company, worked with the research firm, forsa, to survey over 200 leaders in the U.S. and Germany manufacturing industries. Topics ranged from how the crisis affects their operations and how they’re dealing with challenges presented by the pandemic to their assessment of future economic development. According to current estimates, the crisis will lead to economic setbacks across the board. Declining exports and difficulty in planning are leading to uncertainty in the manufacturing industry. Other key findings from U.S. manufacturers include:
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U.S. Companies Have Been Hit Hard by the Crisis Most respondents (67%) in the U.S. say the crisis has had a somewhat negative or very negative impact on their businesses. Their biggest challenges are a decline in new orders (58%), their employees' concerns about a possible COVID-19 infection (56%), and a decrease in sales (54%). However, only 11% of U.S. companies are seriously concerned about remaining in business.
Investment Behavior is Curtailed Half of the U.S. companies surveyed expect their investment behaviors to be lower than 2019, while 14% are unsure. In contrast, just over a third (36%) plan to make investments at the same level or higher than last year.
Flexibility is The New Mantra What measures have the surveyed companies taken to meet the challenges of the crisis? "Increased flexibility" was at the top of the list for U.S. manufacturers (59%). Other top measures include improving customer service and relying on technical innovations to counteract the crisis's effects.
Equipment-As-A-Service Business Models Are Becoming Increasingly Popular A complete business model overhaul was an option for only a few of the surveyed companies: 16% of U.S. companies are planning to transform at the moment. However, a majority of those surveyed recognize that new business models, such as pay-per-use models ("equipment-as-aservice"), represent an advantage for both the supply and demand sides in the current crisis. In the U.S., 34% said pay-per-use models represent a big or a very big advantage, while 29% consider it a slight advantage. Almost half of the companies surveyed also stated that they use a pay-per-use model themselves (18%), offer it (15%), or do both (9%).
in the current situation. Among the companies that use one or more of the listed technologies, 99% of the U.S. respondents believe technology will help their company in the crisis.
Easing of Lockdown Measures Shows Positive Effects The first loosening of lockdown measures is already leading to positive effects. Since restrictions have lifted, 14% of U.S. companies have felt a significant increase in demand for their products, and 45% have had a slight increase compared to the weeks before the easing. "These unprecedented times and developments cannot be compared to anything in the recent past,” says Josef Brunner, CEO, relayr. “Therefore, it’s encouraging that the manufacturing industry is fairly optimistic about the future. It clearly shows modern technology, flexibility, and customer focus are extremely critical factors for economic success in general and for building resilience as a business. Thus, even in these unusual times, companies can build the most solid basis for shaping and securing their future and the future of the industry." Access the full report at relayr.io/forsa/
ABOUT RELAYR Relayr is the Industrial Internet of Things (IIoT) powerhouse delivering the most complete solution for risk-free digital transformations. They unleash data insights from existing equipment, machines and production lines to improve our customers’ business outcomes. They enable industrial
Predictive Analytics Is on The Rise
companies to shift from CAPEX to OPEX-based offerings to their respective
The respondents are adopting various technologies to gain a competitive advantage. In the U.S., 38% of businesses are implementing predictive analytics, followed by big data (33%) and IIoT (32%). Of note, more German companies (47%) use IIoT and AI to gain a competitive advantage, while U.S. manufacturers have higher usage rates of predictive analytics. These innovative technologies not only represent a fundamental advantage for the respective businesses but are especially beneficial
markets, providing a unique combination of first class IIoT technology and
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its delivery with powerful financial and insurance offerings — all from a single source trusted by hundreds of companies worldwide. With relayr, manufacturers, operators, and service companies for industrial equipment are empowered to implement fully interoperable IIoT solutions guaranteed to achieve their target business outcomes. For more information, relayr.io
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Talking Shop
FEATURING:
TALKING SHOP WITH: Pat Boland — Co-Founder and Managing Director, ANCA Group Could you give us a brief overview of how you and Pat McCluskey came to found ANCA in 1974? We were working with minicomputers at the time and got the idea of modifying them to direct simple operations on the NC machine tools that were then available, effectively developing early versions of today’s CNC machines. We quickly realized that Australia, where we are headquartered, wasn’t the most productive place to market this technology, so we were lucky to have a colleague in the United States who introduced us to machine tool OEMs who incorporated
the controllers we were developing into their cutter/grinder machines in Indianapolis. This was in the early eighties, and by then we’d realized we wanted an end user product of our own, so we designed and manufactured a CNC cutter/grinder prototype that we took to IMTS in 1986. We sold that machine, learned out lessons from the experience, and began improving our product. We felt like our concept was sound, designing software to measure grinding cutting tools in process, if we could only streamline the technology and find the right markets.
When Pat McCluskey and Pat Boland founded ANCA over 40 years ago in 1974, they purchased a mini computer for $4,000. Their basic idea was to replace the hardwired controls of the time with a standard computer. Adding the computer to NC thus CNC resulted in a much more powerful and flexible technology than the hardwired logic designs that were current at the time.
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IMD – The Industry’s Most Extensive Industrial Publication
So the U.S. was your first target market? How did things evolve from there, in terms of your distribution model in North America and around the world. Yes, we definitely targeted the States initially, and we tried distributors and sales representatives at first, but that approach just didn’t seem right for us, or for them. So we decided to establish ANCA subsidiaries throughout the U.S. based on our existing location in Detroit, Michigan. That allowed us to build our strength and reputation, eventually spreading into areas around the world, including Europe, the U.K., Germany, China, Asia, and elsewhere. Primary manufacturing still takes place in Melbourne, Australia, but we also have facilities in Thailand and Taiwan.
Could you name some technological milestones along the way that have been particularly important to ANCA’s success? I would have to say that in-machine probing of grinding cutting tools was one of our first big game-changers. We really led the way in the area. And then, in 1991, when we began developing 5-axis controls that synched with robotics, the industry really took notice. It was an acknowledgment that machining systems and technologies were starting to merge, and that it was important to start thinking about them holistically instead of just as component and separate processes. Then I’d say 3D simulation of the complex geometries of various cutting tools brought design forward lightyears into the future, as did the shift from ball screws to tubular linear motors
in terms of increasing both accuracy and machine life. When you add to that servo-drives that monitor and control internal machine temperatures, long-term machine stability is increased significantly.
Looking back to those early years when you and your partner invested $4,000 on a minicomputer to get this whole enterprise off the ground, what surprises you the most? I suppose that ANCA is now a thriving business with more than 1,000 employees, and that we’re now a well-known manufacturer of CNC grinding machines, motion controls and sheet metal solutions around the world. We’ve managed to maintain our roots here in Melbourne, where it all started, even though we export 99-percent of our products to customers in 45 countries around the world. I think that's a pretty interesting business model, and one that neither Pat nor I could’ve imagined back when we first got started down this path. To learn more go to machines.anca.com.
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IMD 15
Safety & Maintenance
Cloud Computing: Companies Love It, But So Do Hackers By: Kevin Studley, President, The Network Pro
“It's everywhere and everyone's using it.” That's how one web-hosting resource describes cloud computing—and it is only a slight exaggeration. Upwards of 90 percent of business enterprises use cloud services for functions such as storing data, hosting email servers, integrating supply chains and managing workloads. The bad news: Cybercriminals also are big fans of cloud computing. Their activities appear to have tripled during the coronavirus pandemic as companies cope with the complexities of having employees work remotely. There's even greater risk for cybercrimes such as identity breaches, ransomware threats and the theft of company secrets. As the National Security Agency (NSA) has noted, companies may invest in cloud services that promise to enhance cybersecurity, only to find that the cloud poses hazards of its own. With apologies to the Rolling Stones, telling hackers to “get off of my cloud” isn't a workable strategy. But other tactics are worth
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considering to help safeguard functions and resources entrusted to the cloud—before cybercriminals succeed with strategies of their own.
Cloud Computing Basics As metaphors go, the cloud has been a tremendous success. It conjures up an image of a beautiful place in the sky, where valuable information is kept safe from earthly perils. Nice picture, though the cloud really refers to a collection of servers and networks spread among various geographical locations, promising constant, reliable support for companies' computing functions. It's not clear which entrepreneur or tech whiz came up with the term “cloud” to describe those functions. But it's clear that since cloud computing emerged as a technology in the late 1990s, and became a buzzy term around 2006, it has largely lived up to its
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promise. According to one estimate: » The cloud service market (worldwide) is estimated to exceed $623 billion by 2023. » Half of businesses spend more than $1.2 million a year on cloud services. » As of 2019, the manufacturing industry expected to spend more than $5 billion annually on cloud services. How does cloud computing figure into manufacturing? Extensively, because so many industrial operations are computerized. This affects not only office tasks like payroll and email, but plant functions such as alarms, sign-in systems, data sharing between machines, and sensors that boost efficiency on product lines. Cloud computing is a scalable resource that enhances innovation and competitiveness, according to the Information Technology & Innovation Foundation. In a 2017 report, the foundation underlined cloud computing's role in operations, supply chain integration, product design and fabrication, and even influencing how consumers use their products. With cloud resources, even small manufacturers can access new production systems including 3D printing, the internet of things (IoT) and industrial robots.
Great Potential, Rich Targets One reason managers welcomed the cloud is that they recalled what their data processing operations used to look like. For many industries, it was a gigantic room, cool and dimly lit, filled from floor to ceiling with shelves of humming servers. When something went wrong with the equipment in that room, people lost their internet, operations skidded to a halt and email went down. Then everyone had to wait until the I/S staff fixed the problem. Cloud computing providers like Microsoft—a major player in the industry with its Azure business—sold the cloud as a dependable alternative to all that. Local problems like a hardware glitch or severe weather matter much less when operations are backed by multiple off-site servers. Azure proclaims selling points ranging from cost-efficient storage of massive amounts of data, to machine learning and artificial intelligence to aid decision-making. Cloud computing providers also promise enhanced security. But it's a mistake to regard the cloud as an unassailable citadel protecting all your data 24/7. Cybercriminals, including malicious nation-state actors, use the same types of tactics with cloud systems as with
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other data systems, and for the same reasons: to steal money and secrets, disrupt operations, and glean information they can use or sell. Cloud systems are just another rich target. In one case, hackers were able to drill into the email of a CEO planning to make a major purchase of robotics equipment. Replicating the seller's credentials, they sent a phony invoice to the CEO and received a payment of $50,000. In two other cases, mentioned in an NSA report, publicly accessible cloud storage exposed sensitive data and authentication credentials from the National GeospatialIntelligence Agency (NGA), and data meant for the United States Central Command (CENTCOM). Hackers' tools allow automated efforts to repeatedly probe cloud-based data for passwords and other credentials. Eventually, some of these efforts will pay off. Withholding or freezing data for use in ransomware threats is more difficult with the cloud—but not impossible.
Precautions and the Pandemic Best practices can guide manufacturers in safeguarding their data. These strategies are prudent whether or not a company has vast resources in the cloud: » Schedule updates and take them seriously. Old passwords and outdated usernames have put out the welcome mat for many a hacker who discovers them. » Train employees to be aware of cybercrime threats. During the pandemic, they might even be encountering tactics such as phishing that are disguised as health information or offers of cool face masks. » Limit the number of people who have access to data systems. That means fewer chances for breaches that could imperil company data or halt operations.
A Partnership
The NIST Cybersecurity Framework is a helpful source of recommendations on cybersecurity best practices, as is the Center for Internet Security. Manufacturers also need to assess their security protocols regularly and stay on top of current threats, whether they have an internal I/S team or are working with an cybersecurity consultant. A Flexera survey found that companies planned to increase their spending on cloud computing services in 2020 because of significant pressures to support employees working remotely. It may be unavoidable, but that trend brings hazards including connection difficulties, missed system updates, viruses spread from interactions with home devices, and the distractions of working from home. Numerous tools are available to help cloud service providers bolster security, but that doesn't mean they're all being used effectively. For example, third-party software, which may be sourced from anywhere in the world, could pose backdoor threats to a company's supply chain, the NSA warns. The NSA report cited above suggests strategies to mitigate possible vulnerabilities in the cloud, including: » Monitoring the provider's responses to threat incidents that have occurred. » Checking that cloud services are configured to minimize threats—limiting shared access between cloud resources. » Enforcing data encryption when necessary for extra protection of sensitive data.
“The cloud” has always been a lofty metaphor for a very down-toearth set of challenges. Innumerable functions of business and industry have become computerized, and all that technology has to reside somewhere. Cloud computing offers an appealing alternative to maintaining a huge room full of banks of equipment that must be serviced by internal staff. The cloud is here to stay, but it is not an impenetrable fortress. Companies should view cloud computing as a process—and a partnership. Taking extra steps for cybersecurity can help safeguard data and operations from criminals who can't wait to use the cloud's extensive resources for their own sinister purposes.
ABOUT THE AUTHOR: Kevin Studley is the president of The Network Pro, Inc. a California-based Managed IT and Security company. The Network Pro is recognized as a growth company on the Inc. 5000 fastest growing companies list, a Great Place to Work by the OCBJ, and has placed on the Top 501 Managed Services Providers list for the last seven years. Kevin Studley is an active and long-standing member of Vistage and actively participates in events that promote the business community. For more information, visit www.thenetworkpro.net or call (714) 333-9620.
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Manufacturing Showcase
ZOLLER Inc. By Russ Willcutt
Z
OLLER was founded just outside of Stuttgart, Germany in 1945. Alfred Zoller realized that recovering from the devastation of World War II would require a great deal of remanufacturing, repairs, and re-engineering involving everything from household appliances to automotive parts. The company developed and manufactured its first presetter in 1963, which quickly gained market acceptance throughout Europe and soon accompanied the machine tools that were sold into the United States, paving the way for ZOLLER to establish its North American headquarter in Ann Arbor, Michigan, in 1997, led by Alexander Zoller. It is now a thirdgeneration family-owned global enterprise. Recognizing the need to be near its customers, wherever they are located, ZOLLER has 20 dedicated facilities providing service and stocking parts around the world. Along with a mix of authorized distributors and sales agents, it enjoys a global footprint, always sensitive to the societal expectations that might call for a locally based staff familiar with the surrounding dialect and customs. According to Dietmar Moll, director of business development, automation, and smart factory solutions, the company has four distinct product lines. “Tool Presetting is our number-one category, especially since it was really the basis of our original
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product lineup,” he says. “We offer both vertical and horizontal devices, and more than 45,000 have currently been sold around the world. Then there is Inspection and Measuring, with categories including universal measuring machines, process-oriented measurement, and Automation Solutions.” The fourth category, Tool Management, has existed for quite some time in the form of storage solutions for tool rooms, but the advent of automation, AI, and sophisticated software has ramped up advances within this area, making it ripe for R&D investments and industrial collaboration, particularly with machine too OEMs and cutting tool manufacturing. Tool Management systems have evolved to the point where manual loading can be held to an absolute minimum, with all tool monitoring, replacement, and mounting handled automatically by these precise, integrated systems. Automation has also been developed to handle other “non-valueadded” procedures such as tool delivery to a machine’s work area, providing ergonomic benefits, and process streamlining.
Describing ZOLLER as “a customer-centric” company, Rita Conroy-Martin, director of marketing, says educational resources are constantly in development, and while live events do still occur, the coronavirus has made the importance of digital interaction apparent. “The ZOLLER Training Academy, headed up by Michael Stepke, offers both live and virtual training seminars to current and potential customers, and we also host webinars that are then archived online. We collaborate with our sales team, who work on the front lines alongside our customers, to develop content for these webinars based on end-user comments. This allows us to address their concerns directly, to keep our content fresh, and also to pick up on pointers that we can utilize to improve our own technologies.” Conroy-Martin adds that, with the company marking its 75th anniversary, it will be kicking off the celebration by hosting a three-day online live event from September 15-17, 2020, that will be broadcast from its headquarters in Ann Arbor. The event will be rife with educational content and special promotions while also underlining an important message. “We want to emphasize that in addition to being the largest manufacturer of presetters in the world, we have evolved into a solutions-based company across the entire spectrum of cutting tools,” according to Moll. “Our upcoming celebration will be an opportunity for us to demonstrate how that has been achieved.” For more information go to zoller.info/us.
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IMD 21
Workforce Development
Knowledge Is Power Overcoming 3D Printing Barriers to Adoption By: Greg Elfering, President of Ultimaker Americas
O
ver the past six months, every industry in the world has been impacted in some capacity by the COVID-19 pandemic. Standard operating procedures and 2020 projections were quickly scrapped as companies realized they were operating on a new playing field that has never been traversed or even imagined. Through all the hardship and adaptation businesses faced, there was one clear lesson to be learned; organizations must accelerate their utilization and investment in their digital transformation plans. Specifically, those in manufacturing realized the previously stable global supply chains and operations could actually be overpowered by the unknown. Meanwhile, many other businesses and medical organizations were caught off guard, a beacon of support made its way to the forefront: 3D printing. While the world watched as the 3D printing community rushed to the aid of hospitals across the country to help supply them with essential personal protective equipment, other businesses realized the versatility of additive manufacturing. Not only were hospitals able to become more self-sufficient as they shortened supply
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chains, but they also saw flexibility in production and ease of access. As a result they were able they were able to print millions of copies of personal protective equipment during the pandemic to fix the shortages that were running rampant in healthcare organizations across the country. Due to the pandemic, Forbes predicts that over the next 18 months, manufacturing will experience five years’ worth of innovation. 3D printing technology is a key component of this trend, and as we move forward, companies will need to consider both hardware and software solutions as well as education of the technology to deliver tangible results in a shorter time than what they currently experience.
Knowledge Gap Remains a Key Barrier to Entry Although this technology is primed and ready to be widely adopted across a wide variety of industries, its biggest obstacle is a lack of knowledge. According to the 3D Printing Sentiment Index, a survey of professionals across industries, two-thirds of US businesses that could potentially benefit from 3D printing do not use the technology at all, while only one in ten believe that they have progressed to a
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mature stage in their implementation of the technology. In fact, 69 percent of the professionals surveyed cited knowledge as the most frequent barrier to enter the market. Of those professionals, 40 percent also brought up a lack of necessary skillsets to properly leverage 3D printing. Lastly, just 16 percent of professionals said they would describe their level of knowledge regarding this technology as advanced or expert - demonstrating that the greater majority think their understanding is basic or rudimentary.
The Role of Software In Bridging the Gap While those statistics might sound daunting, what they really demonstrate is a massive opportunity for growth. Businesses have already begun capitalizing on the opportunity but so many are still unsure of where to begin. The knowledge around 3D printing is attainable, but in general, most do not know where to go to seek information. Fortunately, companies in this sector are geared towards accelerating the world’s transition towards global digital manufacturing and making their resources accessible to those who would like to learn more. Software offerings for 3D printing provide an ecosystem that enables organizations to print the exact parts they need, when they need it, and where they need it, which allows them to capitalize on their return on investment. Any company that is considering 3D printing should be well equipped with the necessary information and tools. With software, hardware, and materials working together effectively, users can ramp up quickly and streamline processes efficiently.
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One of the key aspects of beginning a proper 3D printing operation is the software. For example, Ultimaker’s 3D printing software, Cura, can be utilized to prepare CAD for 3D printing. Cura is open-sourced, meaning that it is available to third-party users and individuals as well as those who already have an Ultimaker printer. Users can download free software like this to gain a better understanding of the technology behind 3D printing. Developed as easy to use software, both experienced and novice 3D printers can take advantage of the offerings to prepare 3D models for print within minutes. To help novice makers understand this technology better, the software has built-in tools and tips to assist with features that would usually require in-depth technical knowledge. While the open-sourced software is able to put the technology in the hands of the end-users allowing them to test the capabilities of themselves and the ability of the 3D printing technology, there are still other educational opportunities that can help close the knowledge gap. To help businesses uncover how 3D printing can benefit their business now and in the future, Ultimaker launched the 3D Printing Academy. These eLearning modules are designed to bring any level employee up to speed for any sort of role or responsibility in the growing 3D printing market. With role-specific courses, users will be able to train and develop deep knowledge and skillsets that immediately impact their day to day efforts. Additionally, all of the courses have remote learning capabilities so those who enroll do not need to physically be on-site to receive their education.
Recently released Ultimaker Essentials, an enterprise IT solution to overcome barriers in additive manufacturing, comes with three additional eLearning courses. Those who adopt 3D printing often learn to produce only one item and do not realize the full capabilities of the technology. The Academy lessons were launched in an effort to educate people and foster their development in the 3D printing space to the point where they can become a certified maker and scale up the technology in their own organizations. Users can collaborate, iterate, and innovate faster than ever before so their organizations can overcome real-time challenges faced every day. If companies did not already realize that global supply chains and manufacturing workflows could easily be disrupted, the pandemic surely made them recognize this potential issue. The transition to digital distribution and local manufacturing is imminentModex and 8in 3D xprinting companies on increasing 4.75in Ad Amanda.pdf are 1 focused 13/02/2020 17:33
education across potential users. Removing the final barriers and gaps of knowledge will help companies unlock the full potential that 3D printing provides. With both software that provides millions with the opportunity to openly work on projects and eLearning courses to strengthen the knowledge of users, the time for greater 3D adoption is now. For more information, visit www.ultimaker.com
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IMD 25
New Technology
The Future of Manufacturing: Impactful Tech on the Horizon By: Rahav Madvil, Simulation Product Manager for Siemens Digital Industries Software, and Noam Ribon, Senior Business Consultant at Siemens Digital Industries Software
I
ndustrial manufacturing as a sector has been an early adopter of robotics and other forms of technological improvements for decades. Robotics have been one of the best options to increase production efficiency for large and often highly repetitive manufacturing processes. But the era of producing large quantities of just a few products with low mix is coming to an end, giving way to increased product personalization requiring a more flexible production process with less waste than ever before. Fortunately, the future of manufacturing is brimming with opportunity. It is full of new technologies designed to reduce waste and maximize process efficiency and flexibility through software and hardware capabilities. Almost all of this promise is built upon a foundation of digital transformation – and the digital twin. Everything from raw material tracking to process optimizations to
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hardware selection stems from insights gained from the digital twin and a closed-loop optimization of entire facilities. The most difficult aspect of any change to operation are the inevitable changes to process, they are expensive twice over, because nothing is being produced and resources are still being consumed. An autonomous transport initiative squarely addresses this, relying on a few, key technologies to make it happen.
The Power of Virtual Commissioning Creating a comprehensive digital twin of your production process can greatly reduce downtime for new machines, new processes and new products. Let’s say you need to install a new CNC station. What if the processes for this new machine could be validated before it ever arrived on the production floor by using the digital twin of the production
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line? Less time could be spent integrating the new component into the overall production lines through line integration as a part of virtual commissioning. Available today, virtual commissioning is the critical underpinning to an efficient production environment enabling a closed-loop iterative optimization of the entire facility. Virtual commissioning is vital, not only for testing software controls, but for adding insight to the efficiency of the controls strategy. It is also essential for embarking on the advanced robotics journey, laying the groundwork for implementing greater process automation and flexibility needed to efficiently implement tomorrow’s manufacturing technologies today.
Simulate Everything Upfront One of the best options to minimize risk when updating an existing process or making a new one is to simulate the new operations. It nearly eliminates upfront investment in machinery before knowing whether the new process will operate as expected on the shop floor. For new digitalization efforts, this is where a digital twin should be established for the process. Without a comprehensive study of the actions within a plant new equipment could be under-utilized leading to lost investment. Just as important is the implementation of IoT devices, that serve to close the loop between the digital twin and the physical processes once the new processes have been initiated. Although these devices are often embedded in new production equipment, but it is important to consider how to best maximize
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Next Generation Programming Another route to maximizing production time even when supporting a high product mix is to expedite the reprogramming of the robotics in use on the factory floor. Without integrated robotic control, updating a robotic arm for a new task can be incredibly time-consuming. It needs to be taken offline, reprogrammed, validated and restarted, for each robot that will handle the new processes. All that changes by integrating the programmable logic controllers for these robots into the comprehensive digital twin. Much of this process can be streamlined. Does a bolt spacing on a phone need to be shifted slightly to accommodate the latest 5G wireless antenna? If the entire fleet of robots working on that production line could understand the change, that would save many hours across multiple engineering and production teams. Engineers simply need to let the robots know of the change and any differences in manufacturing tolerances can be accounted for with closed loop sensing through visual or force feedback. With force feedback within the robotic arm, any force exerted over a defined threshold can initiate a pause to the robotic arm’s actions and readjust positioning to address the perceived problem. Instead of shutting them down for reprogramming, all the robots working on the project can adjust independently to subtle changes.
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IMD 27
Figure 1 - Heatmap from simulating AGV and AMR activity on a manufacturing floor
Although this might sound like some futuristic scenario, task-based programming has already been tested in the real world. In a partnership between AtriMinds and B/S/H/, Siemens Digital Industries Software helped bring flexibility to robotic arms by enabling automation for flexible products. Previously, one of the largest hurdles to automating assembly was how to work with flexible components. Traditional robotics rigidly follow predefined movements, so if something were to inadvertently shift, the whole assembly could be destroyed. But by implementing force sensing on the robotic arms, there is an almost intuitive understanding of the parts and how the robot is interacting with the workpiece at its station. If a hole is slightly out of place on a panel, the input from force sensors can help the robot redirect its movement and thread a screw through without complex, preprogrammed instructions for misalignment scenarios.
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Optimizing Production with Autonomous Robotics Simulation, virtual commissioning and advanced robotics programming lay the foundation for a fully flexible production floor, but automated guided vehicles (AGVs) and autonomous mobile robots (AMRs) weave it all together and bring it to life.
Historically, conveyor belts acted as the material flow paths on a shop floor. They efficiently move product from point A to point B but require semi-static positioning. Even mobile conveyor systems, common in logistics work, take time to move and to ensure a safe path for product. In contrast, AGVs and AMRs can change their path during transit. This saves time that would have been spent readjusting existing features, this is critical for a flexible production environment. Imagine a production floor, making two distinct version of a product. For version one, the bolts need to be added before the secondary assembly is added, while in version two bolts cannot be added until after the sub-assembly has been mounted. In a static conveyor facility, this could be completed given enough conveyor length and a sorting mechanism. Beyond a couple variations to the production sequence the factory would fill up with conveyor loops that only transport a few products at a time, defeating one of the main goals of the technology But with a fleet of AGVs or AMRs moving materials and work pieces throughout the facility, products can be rerouted and the sequence reordered to another machine. Or, in the case of highly customized consumer products, components could be routed to the best machine for the task. It can account for how much time is required to switch over to the new process, how many units can it produce compared to other machines, and even the impact of a re-route on other processes on the shop floor.
Reaping the Benefits of Tomorrow’s Robotics Today Achieving all this requires a highly integrated production process. To guarantee a product is still made correctly during an automated process change, it needs to be simulated beforehand using a digital twin. To certify the product can be made in the new location, the production machine needs to be validated for the task using virtual commissioning. And to ensure the slightly different parts don’t produce errors in the process, the machines themselves need to be flexible to adapt to in real time to changing conditions with AGVs and AMRs. Properly managing all these variables can have an incredibly positive effect on process performance, in fact it can produce up to a 40 percent improvement in labor productivity, according to a 2020 McKinsey study. Understanding the shop floor is an invaluable proposition and will continue to net savings and improvements through the life of the facility, even making it last longer by reducing maintenance overhead and costs with the improved condition monitoring of extensive IoT and the comprehensive digital twin. For More Information Learn more of how Tecnomatix brings the tools of tomorrow’s factories to the factories of today with Siemens’ Xcelerator portfolio with free trials for the Process Simulate and Plant Simulate tools. Visit plm.automation.siemens.com/global/en/products/tecnomatix/
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IMD 29
Process
Scalable Quality Inspection and Collaborative Solutions
ABB’s new 3D inspection robot cell makes quality control testing ten times faster while their groundbreaking YuMi® robot has set new standards for collaborative robotics for five years
C
apable of detecting defects of less than half the width of a human hair and imperceptible to the naked eye, ABB’s new 3D quality inspection (3DQI) robot cell will dramatically accelerate production by providing fast, accurate testing to make metrology easier and less time consuming. The 3D Quality Inspection cell eliminates the need for time consuming manual inspection, while substantially reducing the likelihood of faults and errors. As well as increasing productivity, the solution also reduces costs by minimizing the risk of product defects that could lead to potential recalls. Key benefits of the 3DQI cell include its combined speed, accuracy to below 100 (micrometer) μm and flexibility provided by its modular design, with customers able to create a solution tailored to their exact requirements. The 3DQI is conceived for offline testing stations and its modularity allows customization or expansion to meet evolving business needs. Using a single 3D white light optical sensor to scan
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millions of 3D points per shot, a detailed digital model of the part being inspected can be created which can be compared to an original CAD drawing. All of this can be done 10 times faster than with traditional Coordinated Measuring Machines (CMM). The sensor can be carried by any robot with a handling capacity greater than 20 kg and is compatible with a range of robots, tracks and rotary tables, so there are no limits on the dimensions of the parts that can be inspected. The new 3DQI inspection cell is the latest cell introduced by ABB and joins FlexArc® and FlexLoader in ABB’s growing portfolio of smart, flexible solutions. “The ability to accurately measure and control quality is vital to ensure that products achieve consistency, comply with standards, and meet customer expectations. Traditional testing methods are slow and capture the potential quality mistakes often too late in the process,” said Tanja Vainio, Managing Director Auto Tier One Business Line for ABB Robotics. “Our 3DQI cell automates this process, far exceeding the capabilities of traditional inspection in
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speed, accuracy and repeatability. We’ve developed and piloted our 3DQI technology in automotive applications, including automotive supplier Benteler, and the 3DQI solution has been proven to improve product quality, throughput and safety, while freeing up skilled labor to be deployed on other tasks.” The solution also provides comprehensive data analysis processed in real time. Digital records support traceability, which is needed in several industries, as well as enabling customers to adapt their processes to prevent further failures to improve overall quality and productivity. All equipment is included in ABB’s powerful RobotStudio® Studio Planner Power Pack for easy and intuitive programming, enabling new users to quickly become familiar with using the 3DQI solution.
a range of safety features, including lightweight magnesium alloy arms with soft-padding to avoid pinch points, and advanced motion control with collision detection, YuMi is designed to be installed in workstations alongside people and increase flexibility by allowing humans and robots to work on tasks together that previously would have required safety barriers or cages. YuMi has set the standard for safety in collaborative applications where robots and manual workers need to work side by side. With its dexterity and dual-arm 14-axis design, YuMi has played a key role in enhancing productivity and quality on production lines worldwide,
ABB’s Dual-Arm Yumi Collaborative Robot Reaching Its Fifth Birthday This Year Originally launched in 2015 to assist workers in lightweight assembly tasks, ABB’s collaborative YuMi robot has gone on to blaze a trail in a raft of diverse applications and industries, opening new opportunities and helping to fire people’s imaginations about what can be achieved with robotic automation. With its ergonomic design and
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5:36 INDUSTRIAL MACHINERY DIGEST.COM3/22/20 PM
from assembling electronics and electrical components to sorting candy in confectionery factories. By removing the need for bulky and expensive safety measures such as fencing, YuMi has removed both the physical and psychological barriers separating people from robots. Key to YuMi’s popularity has been its friendly design that mimics the size and movements of a human operator, and its ultra-low weight soft padded arms, which allow it to safely move faster than other cobots. “Five years ago our vision for YuMi was to set a new standard for collaborative robotics, creating a robot able to work hand-in-hand with humans without further protective measures or barriers, while being simple to install and operate,” said Sami Atiya, President of ABB’s Robotics and Discrete Automation business area. “YuMi has proved to be incredibly popular, creating a new category for small, collaborative robots for material handling and assembly and inspection, while broadening the appeal of collaborative robots in an expanding range of applications, from manufacturing to healthcare and beyond.” Since its launch, YuMi has become a cornerstone in the broad portfolio of collaborative automation solutions of ABB Robotics and Discrete Automation. It has racked up an impressive employment history, delivering results in everything from producing electrical sockets, to helping to test the security, reliability and durability of ATM machines for Swiss-based payments software provider Abrantix AG. With the medical sector looking to improve efficiency, YuMi has branched out into healthcare and pharmaceutical applications, assisting with tasks in laboratories and medical facilities. Copan Diagnostics in the USA, for example, is using YuMi-based HEPA filtered bio-safety workstations to manage tissues, bone and sterile fluid samples, as well as transporting traditional swabs and blood cultures. YuMi has also had a big impact outside the workplace. Milestones include meeting world leaders Angela Merkel, Barack Obama and Naresh Modi, conducting an orchestra with Andrea Bocelli in Pisa, Italy and serving coffee to the public at Selfridges department store in London and Bloomingdales in New York. “YuMi has captured the imagination of the public, appearing in everything from music videos to popular TV shows, doing everything from making paper airplanes to performing card tricks,” added Atiya. “Underlying all of these fun applications is the serious message of how robots like YuMi are helping to change attitudes towards robotic automation. In helping to educate people about how robots can support our work, YuMi has paved the way for robots to be used in workplaces and factory floors worldwide.” To help continue the revolution started with the launch of YuMi, ABB unveiled its single-arm YuMi robot in 2017. ABB’s most agile and compact seven-axis collaborative robot can be mounted on tabletops, wall or ceilings, and is designed to offer flexibility in an expanding range of applications.
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“Over the past five years both our dual-arm and single-arm YuMi robots have tackled misconceptions that have hindered the adoption of robots, by demonstrating the wide range of benefits they can bring and by making them as easy as possible to use and apply to different types of processes,” said Andie Zhang, Global Product Manager - Collaborative Robots for ABB Robotics. “Customers tell us that the great thing about YuMi is that people don’t find it intimidating. Because it has human-like features, people feel comfortable next to a YuMi robot. We’ve also found that YuMi tends to be quickly accepted as part of the team when introduced into manual production lines as it tends to be used for boring and repetitive tasks, freeing the operator to perform more varied and interesting jobs.” YuMi has market-leading lead-through programming function built-in, making it easy for anyone to move the robot arms into required positions for their application. In addition, ABB’s new Wizard easy programming software helps to further simplify the process of creating a robot program, by offering an intuitive, graphical, drag-and-drop interface, which anyone can use without special training.
“With YuMi, users can start small, tackling the tasks that are the quickest and easiest to automate, and then use the experience and confidence they have gained to find ways to apply automation to other parts of their operations. Some customers have even purchased one without a specific application in mind,” added Andie Zhang. “They simply wanted to explore what is possible with collaborative automation with their production team.”
ABOUT ABB For more information, visit www.abb.com
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ABOUT ABB ROBOTICS & DISCRETE AUTOMATION
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IMD 33
Industry Insight
A Drill for All Materials Korean automotive manufacturer sees 1,150% increased tool life with CoroDrill® 860-GM
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t is said that life is a marathon, not a sprint. For automotive manufacturers, longer lasting tooling solutions are integral to more profitable production — but, often, manufacturers see little reason to change their existing tool set-up. Here, James Thorpe, global product manager at Sandvik Coromant, the global leader in metal cutting tools, explains why the benefits of longer-lasting tools — like the latest addition to its CoroDrill range — shouldn’t be underestimated, particularly for reducing costs-per-part or increasing overall output. Unpredictable tool life is one of the biggest threats in mass automotive production, particularly as its operations are so highly automated and use some of the world’s most advanced robotics and automation systems. Downtime is time-consuming, disrupts production and is also expensive, so it goes without saying that tool failures should be avoided at all costs. In some instances, manufacturers set the tool change interval to less than the maximum tool life. This approach is normally preferred because material variations in automotive components are minimal. It follows that the tool changes should be predictable, and safer, than trying to extend the tool life to manufacture a few more components.
Multi-Material Drilling For Sandvik Coromant’s specialists, the key to longer tool life is not limited to the amount of time a tool spends in use, but also the drill design itself. This approach led to the development of the CoroDrill 860 with enhanced -GM geometry, a new design solid carbide drill that’s optimized for a wide range of materials and applications, across all industry sectors. For the CoroDrill 860-GM, Sandvik Coromant applied its machine tooling and metal cutting expertise to develop a new grade, a unique fine-grained carbide substrate known as X1BM. The fine-grained carbide is imbued with increased hardness while maintaining toughness. Furthermore, the drill is tip-coated with a multi-layer physical vapor deposition (PVD) thin film coating. This is key to improving the drill’s productivity and delivering a consistent tool life across a variety of materials. The result is a tool with excellent stability, machining security and improved tool life when machining cast iron, steel, stainless steel, hardened steels and non-ferrous metals.
Assessing Tool Life A better way to assess tool life is by measuring the amount of material removed. To aid productivity, the CoroDrill 860-GM
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34 IMD SEPTEMBER 2020
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» Don’ t Fear Th e Robo tics How th e coming autom changin ation re g the wo volution rkforce, » Enab is for the ling On better -The-F The Ne ly Prod w Era of uct Expe Sales an Manuf rts: acturin d Marke g tin g in »
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» Surpassing Energy Savings Manufacturer in Oxnard, CA experiences the benefits of Green Hydraulic Power Units
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» Streamlining Control Siemens Offers Optimized Control Panel Construction to Machine Tool Builders
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has an innovative, polished flute design that improves the evacuation of chips and yields greater hole quality. This also helps to reduce heat build-up in the tool, and further benefits are high core strength and reduced cutting forces while drilling. The 860-GM forms part of Sandvik Coromant’s CoroDrill range of solid carbide drills. They are designed not only for optimized performance but also versatility, which means they can be deployed in a variety of applications and materials across multiple industries. This includes use with the following material groups: ISO-P, the largest material group in metal cutting that ranges from unalloyed to high-alloyed material; ISO-M that includes difficultto-cut stainless steels, austenitic steels and duplex steels; ISO-K grey, nodular and compacted graphite cast iron; ISO-H steels with a Rockwell hardness of between 45-65 HRc; and ISO-N for softer, non-ferrous materials such as aluminium, copper and brass.
Advanced Geometry As mentioned, the CoroDrill 860-GM has an enhanced design, but what exactly does this entail? Much of this relates to the design of the drill itself that includes an advanced optimized point and flute geometry, reinforced core and corner chamfers, edge preparation to remove cutting edge micro defects, and a double margin to enhance drilling stability. The drill’s point is also designed with refined clearance angles and improved surface quality. Overall, these design features stabilize the drill, reduce entry and exit burr and improve the hole tolerance, finish and straightness. The drill also gives stable wear progression and delivers excellent hole accuracy.
Improved Tool Life
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36 IMD SEPTEMBER 2020
For automotive manufacturers, the CoroDrill 860-GM has proven useful for drilling engine blocks, casings, flanges and manifolds. Beyond automotive and general engineering, the drill is also suitable for all applications where hole quality is critical — such as in aerospace, oil and gas, nuclear and renewable power. Among the most striking results achieved so far with the 860-GM was reported by an automotive manufacturer in Korea. The customer’s operation was to drill through holes in a production batch of automotive transmission connectors. Overall, eight 8.2 mm (0.32”) diameter through holes were drilled into each component that measured a depth of 10 mm (0.39”).
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The existing solution produced 200 components, 1600 holes in total, with a cutting speed (Vc) of 80m/min (3102 RPM) and cutting feed (Vf) of 381 mm/ min. In comparison, the CoroDrill 860-GM produced 2300 components (18400 holes) with a Vc of 100m/min (3878 RPM) and Vf of 814 mm/min. The result was a significantly improved tool life of 1150%, and a productivity increase that helped significantly lower the costs-per-part. Similar, impressive results have been reported by other Sandvik Coromant customers within the automotive segment, around the world.
Solid Choice The CoroDrill 860-GM’s abilities go beyond its machining security and improved tool life. Because the solution delivers one drill for all materials, stock holding can be reduced and greater machine flexibility is provided, which leads to reduced set-up times and cost reductions. These advantages show that automotive manufacturers should consider the positive impact of enhanced drills, like the 860-GM on their bottom line — particularly the longer-term benefits for when life is a marathon, rather than a sprint.
ABOUT SANDVIK COROMANT Part of global industrial engineering group Sandvik, Sandvik Coromant is at the forefront of manufacturing tools, machining solutions and knowledge that drive industry standards and innovations demanded by the metalworking industry now and into the next industrial era. Educational support, extensive R&D investment and strong customer partnerships ensure the development of machining technologies that change, lead and drive the future of manufacturing. Sandvik Coromant owns over 3100 patents worldwide, employs over 7,900 staff, and is represented in 150 countries. For more information visit www.sandvik.coromant.com
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Product Showcase
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IMD's Monthly Product Showcase features the latest from some of the manufacturing industry's top suppliers.
Coxreels® Offers Custom Products for Any Application
Suhner Offers Economaster® Drilling Units for Value-Priced Production Use All the features and reliability of Suhner technology at an affordable price, whether OEM or end user, and made in America! Suhner introduces the EconoMaster® line of drilling units, affordably priced at under $3000 for the basic unit, in stock for immediate delivery or customizable to suit the particular operation. This economical solution is ideal for multiple materials such as light metal, wood, composite, plastic and foam. Because these units are entirely produced at the Suhner factory in Rome, Georgia, response times for delivery and customized construction are very fast, according to Sales Manager Lee Coleman. “We recognized the need to bring our global technology to a local level, here in America, and the EconoMaster® is a key step in that process.” Suhner is based in Brugg, Switzerland with plants and distribution centers worldwide. The EconoMaster® drilling unit features low power and air consumption, adjustable motor housing, adjustable total stroke up to 4”, hydraulic feed control cylinder, J33 taper spindle end, 0-1/2” drill chuck, electric front & rear position limit switches, belt tensioner and chrome-plated quill. Basic unit weight is 45 lbs. Other key features include adjustable feed stroke of ½-3”, 400 lb. thrust at 85 psi, operating pressures to 110 psi, TEFC/IP56 protection, standard 230V/460V, concentricity of .002” TIR, speed ranges to 9600 RPM and an air connection retract/advance of ¼” to 27 NPT. EconoMaster® drilling units can be supplied with an adjustable stand, inline vertical configuration and multiple spindle heads for medium-duty production drilling, with many other spindle options and toolholders available. Please consult the factory. » For more information, visit www.suhner-machining.com
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Coxreels is pleased to offer their customers thousands of standard products to choose from; however, in the event that a customer cannot locate the perfect reel for a specific application, Coxreels has the capability to custom build any product to your exact specification. Coxreels custom built products offer a complete solution to any of your hose, cord, and cable reel needs. Coxreels offers custom design expertise and manufacturing flexibility that is unique in the industry. Coxreels® takes great pride in designing, building, and supporting all of their products right here in the U.S.A. » For more information, visit www.coxreels.com
Get Noticed! To have your product considered for our Product Showcase please submit your product description and images to our editorial staff. editor@industrialmachinerydigest.com
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IMD 39 8/13/19 11:31 PM
Epson Announces Availability of New 3kg & 20kg LSB-Series SCARA Robots
ESAB Introduces GCE Specialty Gas and Valve Product Lines In North America
Notable, new and improved features include batteryless encoder, a lower cable duct profile that is ideal for hard to reach work cell layouts, built-in camera cable for easy vision system setup, and new top-of-arm layout for enhanced usability. Epson’s LS3-B SCARA robots are perfect for factories looking for maximum value without giving up performance. They are ideally suited for applications such as assembly, pick and place, kitting, dispensing, and more. The LS20-B SCARA robots are perfect for higher payload applications such as large component pick and place, machine load/unload, palletizing, mechanical assembly, industrial part transfer, and more.
Since completing the acquisition of Gas Control Equipment (GCE) in October 2018, ESAB Welding & Cutting Products has focused on aligning its global product offerings and innovations into four focus areas: cutting and welding, healthcare, specialty gas equipment and cylinder valves. Furthering the global integration, ESAB today announced that North American distributors and end-users now have full access to the GCE Druva® specialty gas equipment and GCE Valves product lines. The GCE Druva product line focuses on products for the control and distribution of high-purity and specialty gases used in research and manufacturing processes.
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New EasySwitch Vac Simplifies the Process of Vacuuming Wet and Dry Materials EXAIR’s new EasySwitch® Wet-Dry Vac simplifies the filter change process when switching from vacuuming a dry material to a liquid or vice versa. Utilizing minimal compressed air, the EasySwitch is a powerful pneumatic vacuum that is ideal for any application - wet, dry, light and heavy. The fast and tool-less conversion to vacuuming liquids is done by releasing one latch, removing the filter element and securing the latch. The EasySwitch is designed to handle the toughest of industrial cleanup jobs with ease. With EXAIR’s patent pending design, the EasySwitch vacuum uses a standard or HEPA certified filter when vacuuming dry material. » For more information, visit www.exair.com
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GROB Systems Announces Linear Pallet Storage System for Numerous Machine Types GROB Systems announces its newly developed linear pallet storage system (PSS-L) – a highly automated, flexible manufacturing line that complements a wide variety of part types. The PSS-L is ideally suited as a modular system for individual machines or for interlinking the same machining systems. With it, up to five machine tools – including the G550a, G552 and G552T – can be connected to a pallet storage racking with a maximum of 87 pallet positions. The PSS-L can also operate “locked out” of a system, as an independent machine. Additionally, with the PSS-L, a significant increase in machine utilization and economic production can be achieved. » For more information, visit www.grobgroup.com/en/
New TURNPWR Control by ACU-RITE Makes Debut The new TURNPWR control is a workshop-oriented turning control that enables the user to program conventional machining operations right at the machine in an easy-to-use conversational programming language. It is designed for turning machine tools with up to two axes. TURNPWR was developed to satisfy the wants and needs of lathe machinists where manual and automated operation are both useful and needed. TURNPWR promises to enable the user to maximize throughput by significantly reducing set-up time, scrap and other non-productive operations, thereby increasing efficiency, productivity and profitability. » For more information, visit www.heidenhain.us
Dual Force Precision Vise from Palmgren The Dual Force Precision vises from Palmgren combine quality, high precision and wide clamping capacities—all at an affordable price. These premium vises are ideally suited for everyday use from high production environments to rapid prototyping machine shops. The vises are equipped with the Dual Force anti-lifting mechanism. This design provides a 1/2 pound of downward force for every pound of horizontal force. The vises feature a sealed friction reducing needle thrust bearing to help clamping pressure and reduce drag. Palmgren, now in its second century, is a C.H. Hanson brand. » For more information, visit www.palmgren.com
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IMD 41
Renishaw Launches A New Version of Fixturebuilder 3D-Modelling Software The software allows users to design metrology fixturing set-ups without having to use co-ordinate measuring machines (CMM) and other inspection devices. This reduces the amount of set-up time and increases productivity. It can be used with a CAD model of the part, which is imported into FixtureBuilder. The entire fixturing set-up, along with the part, can then be exported into inspection programming software. In FixtureBuilder 8.0, users can now model fixtures that use the innovative Renishaw QuickLoad™ rail system, which is used on CMMs and provides a secure workholding position when used in conjunction with QuickLoad base plates.
Platinum Tooling Named North American Distributor for Technicrafts
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Effective immediately, Platinum Tooling Technologies, Inc., will be selling products from Tecnicrafts Industries, a manufacturer of collets and guide bushings for Swiss Type CNC Lathes. Tecnicrafts is an ISO 9001:2015 Certified company, with its manufacturing plant in South India with state-of-the-art machine tools and 115 technicians. Tecnicrafts collets and guide bushings are exclusively used for Swiss Turning applications on Citizen-Cincom, Tsugami, Star, Tornos, Hanwha, Traub, Hardinge, Manurhin-Kmx, Miyano, Nomura and other popular machine brands and are widely recognized and accepted by customers in Europe and Asia. » For more information, visit www.platinumtooling.com
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Rockford Systems Redefines Metalworking Machine Safeguarding with Launch of PROTECTOR™ Series Shields
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PROTECTOR Series Shields are constructed of 14-gauge powdercoated steel and thick 3/16" shock-proof, scratch-resistant polycarbonate, creating an extremely tough, rigid and durable safety shield that protects operators from flying debris, lubricants, coolants and swarf. They incorporate cool, bright LED lighting into the shield frame to yield superior visibility of the work area, thereby improving the safety and satisfaction of the operator. Further, PROTECTOR shields are modular in design and easily configurable to tailor a custom fit for any machine application, thereby optimizing employee safety and generating a positive ROI. » For more information, visit www.rockfordsystems.com
Siemens Announces Solid Edge 2021
Siemens Introduces New Servo Drive System Simplifying Motion Control for Machine Builders With its Sinamics S210 converter designed specifically for use with the newly developed Simotics S-1FK2 motors, Siemens is offering a new and innovative servo drive system in an initial offering from 50–750 watts. The converters come with integrated safety functions and enable rapid engineering via motion technology objects in Simatic S7-1500 controllers. They are connected to higher-level controllers via Profinet and are quickly and easily programmed by automatic motor parameterization and one-button tuning. Typical uses for this new drive system include packaging machines, handling applications such as pick-and-place, wood and plastics processing, as well as life sciences and digital printing.
Siemens Digital Industries Software announces the 2021 version of Solid Edge® software, which includes design capability enhancements such as new subdivision modeling and improved reverse engineering performance with new deviation analysis. A new artificial intelligence-powered adaptive user interface to predict next steps, and a seamless integration with 3dfind.it, an intelligent 3D model search engine powered by CADENAS, can be used to save valuable time in the upfront design phase. Enhancements have been made across the Solid Edge portfolio including fast, accurate 2D layout of industrial control panels with new cabinet panel design capabilities, and an optimized integration between flow and structural simulation. » For more information, visit siemens.com/whats-new-in-solid-edge-2021
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HC10XP Robot Facilitates Collaborative Welding for Increased Productivity Specifically designed to add robotic welding capacity to current production, the six-axis HC10XP humancollaborative robot enables operation with or in close proximity to human workers. Ideal for supplementing manual welding or for rolling up to large, heavy workpieces with its 1,200 mm reach, the 10-kg payload HC10XP can be easily repurposed depending on production needs. Meeting established safety standards, the HC10XP features Power and Force Limiting (PFL), where dual channel torque sensors in all joints constantly monitor force to quickly react. The HC10XP also offers precision hand-guiding, facilitating easy programming for fast implementation of a robot system. » For more information, visit www.motoman.com
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SERVING AMERICAN MANUFACTURERS FOR OVER
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» Don’t Fear
IndustrialMachineryDigest.com
Industria lMachineryD igest.com
IMPACTING DROP ZONE
9 July 201
June 201 9
Featur ed Supp » 2019 liers Annual Supplie rs Guid e Listin gs
the
igest.com lMachineryD Industria
March 2019
The Ro botics How the coming autom changin ation rev g the wo olution rkforce » Enab is , for the ling On better -The-Fl The Ne y Produc w Er t Experts Manufac a of Sales an : d Mark turing eti ng in » 2019
INGE GOB IL
Wildeck Provides Increased Safety for Moving Palletized Loads » Empowering Employees
MO
ESAB ies on obile ens Rel d the M g Kitch Cruisin elders to Fee W Mobile Boom g Vendin rts Long Pa Large or hining » Mac Set-up le ng Si s with a Benefit ers aining k Belt Tr d Their Custom » Blac nies an g rin Compa tu ac Manuf an ic er rong » An Am Still Going St , Legacy
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THIS IS SOME TEST HERE
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ilt fo KENNED ose, Bu th Purp Built wi
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Betenbender Manufacturing, Inc — www.betenbender.com ....................................................... 13
YEARS
Burr King Mfg Co. — www.burrking.com ......................................................................................... BC Carell Corporation — www.carellcorp.com ...................................................................................... 19 COLE-TUVE Inc. — www.coletuve.com ............................................................................................49 Combilift, USA — www.combilift.com ............................................................................................... 25 Cosen Saws, USA — www.cosensaws.com ...................................................................................... 15 Denver Breaker & Supply — www.denverbreaker.com ..................................................................45 DHM Associates, Inc. — www.dhmassociates.com ........................................................................49 Dynabrade, Inc. — www.dynabrade.com ..........................................................................................FC Eagle Bending Machines — www.eaglebendingmachines.com ................................................... 19 ENM Co — www.enmco.com ..............................................................................................................49 Essex Structural Steel Co. — www.essexstructuralsteel.com ........................................................48 Formdrill USA Inc. — www.formdrill-usa.com ................................................................................. 33 Heritage Global Partners — www.hgpauction.com ........................................................................ 47 H&K Equipment, Inc. — www.hkequipment.com ............................................................................48 HMI div of Betenbender Manufacturing — www.betenbender.com ...........................................43 IMDauctions.com — www.IMDauctions.com ..................................................................................45 Iverson & Company — www.iversonandco.com .............................................................................48 Kanetec USA Corp — www.kanetec.com ..........................................................................................48 Lenzkes Clamping Tools, Inc. — www.lenzkesusa.com ................................................................... 3
ARE YOU LISTED?
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L&L Special Furnace Co., Inc. — www.llfurnace.com .....................................................................49 MacMillin Hydraulic Engineering Corporation — www.macmhydraulic.com ........................... 41 MSC Mediterranean Shipping Company S.A. — www.msc.com/usa ........................................ IBC Pro-Line — www.1proline.com ............................................................................................................49 Radwell International, Inc. — www.Radwell.com .......................................................................... IFC RAS Machine Tool Technologies Inc. — www.rasmachinetool.com ........................................... 31 Royal Products — www.mistcollectors.com .....................................................................................49 Schweiss Doors — www.schweissdoors.com ..................................................................................49 Scotchman Industries, Inc. — www.scotchman.com ....................................................................... 7 Select Equipment Company — www.selectequipment.net ..........................................................44 Standard Direct.com — www.Standard-Direct.com .......................................................................45 Stor-Loc — www.storloc.com ............................................................................................................. 23 Suhner Industrial Products — www.suhner.com ............................................................................. 27 Tap Associates, Inc — www.tapextension.com ................................................................................40 Tormach — www.tormach.com ............................................................................................................ 9 Trim-Lok — www.trimlok.com ............................................................................................................. 37 US Shop Tools — www.usshoptools.com ..........................................................................................11
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SEPTEMBER 2020 IMDdirectory-TV-042020.indd 1
3/23/20 4:36 PM
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