Industrial Machinery Digest - December 2020 by Industrial Machinery Digest

» New Welding Processes, Technologies and Retraining Help Address Labor Shortage » Machining Large Components for Wind Turbines » Cleaning – the Key to Successful Surface Preparation

Manufacturing Showcase: Custom Industrial Products, Inc. IndustrialMachineryDigest.com

December 2020

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Table of Contents

COLUMNS

BUSINESS 4.0 Why Positioning Is More Important Than Ever By: Andrea Belk Olson, MSC CEO of Pragmadik

TALKING SHOP Tom Kelly Senior Vice President, Mitsubishi Heavy Industries America, Inc. Machine Tool Division

20 FEATURES

20 22

MANUFACTURING SHOWCASE Custom Industrial Products, Inc.

WORKFORCE DEVELOPMENT

New Welding Processes, Technologies and Retraining Help Address Labor Shortage Learn how to increase productivity of the welding operation through new technology and advanced processes.

NEW TECH

DEPARTMENTS

Machining Large Components for Wind Turbines Starrag’s Machine Engineering Helps Harness the Wind to Help Provide Cleaner Energy

30 PROCESS 34

SAFETY & MAINTENANCE The Art of Mobilization: Ensuring the Continuity of Industrial Production By: Del Williams

Cleaning – the Key to Successful Surface Preparation

By: Venesia Hurtubise,Technical Chemist at MicroCare, LLC

INDUSTRY INSIGHTS

The Path Towards Digitalization — Bring Your Running Shoes! By: Brian McMinn, Head of The Machine Tool Business, Siemens Industry, Inc.

6 EDITORIAL DIRECTIONS 8 INDUSTRY NEWS 36 PRODUCT SHOWCASE 46 SURPLUS BUYING AND SELLING 49 CLASSIFIEDS 50 ADVERTISER INDEX

ON THE COVER

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Editorial Directions SERVING AMERICAN MANUFACTURERS FOR OVER

Long before I began working in trade publishing, I sold industrial safety supplies; respirators, protective clothing, and the like. My specialty was companies working with hazardous materials, like removing asbestos or PCBs, so I sold a lot of Tyvek suits and rolls of polyethylene sheeting. We were a busy little company, so most days I’d find myself in the warehouse on a forklift, loading my own orders into delivery trucks on the loading dock. I couldn’t help thinking back to those days while writing this month’s company profile of a leader in material handling technology. Boy, I sure could’ve used some of their expertise back then! But that can be said for so much of what we have at our fingertips these days that we didn’t have not so long ago. Not to sound like too much of a codger, but some of you will recall what it was like to be in sales before the internet or websites were in the public domain; when sales involved catalogs, phone calls, closely-guarded contacts, and shoe leather. I like to imagine what my younger self would’ve done had he been handed a tool like a well-built website with pages of product specs and resources to aid in prospecting new clients. These thoughts also resulted from a question I asked an old friend during a conversation for another feature in this issue: what advance has surprised you most over the years? Maybe it’s because I grew up reading science fiction, but the answer for me will always be robotics. I will never forget visiting an OEM in Japan and watching a cluster of robots building themselves, or an automaker in Italy with massive floor-mounted welding arms flipping car chassis around like so many Matchbox cars. Will wonders never cease? What a gift it is to work in manufacturing. To know the secrets of how so many things are actually made, and especially at a time when so many fascinating new technologies and processes are being introduced. While it can definitely be a challenge to battle your way up the learning curve at times, the payoff for the effort is more than worthwhile. So, to answer my question… no, in manufacturing, wonders will never cease.

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6 IMD DECEMBER 2020

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Industry News Universal Robots Launches First Accredited Collaborative Robot Certifications for Schools and Industry “With the Education Program we’re addressing a tremendous need to provide cobot training as part of an integrated, accredited course,” says Joe Campbell, senior manager of applications development at Universal Robots (UR). “This hands-on learning initiative will be instrumental in addressing the skills gap and get state-of-the-art cobots into classrooms, offering students instant employability and manufacturers access to an upskilled workforce.” Universal Robots has been accredited by the International Association for Continuing Education and Training (IACET) and is now authorized to issue the IACET CEU (Continuing Education Units). The Education Program provides a clearly defined pathway for students to master cobot programming and deployment as part of an Industry 4.0 career in robotics and advanced manufacturing. Schools can now purchase the ready-to-go package that includes the complete curriculum, a UR cobot arm, and the hardware and software required to build actual industrial applications.

Chris Kaiser, BIG KAISER president and CEO of 30 years, will take on the role of Executive Advisor. “Jack has been my right hand in this company from the very beginning,” said Kaiser. “He’s shown his leadership in managing the sales and (Left) Jack Burley to president/COO as of January 1, 2021. (Right) Chris Kaiser, BIG engineering teams and KAISER President and CEO of 30 years, will has made many significant take on the role of Executive Advisor. contributions to BIG KAISER including new product designs and development. He’s more than ready and deserving of this promotion.” Burley began his career with BIG KAISER more than 30 years ago and is currently Vice President, Sales, and Engineering. Burley is a U.S. Marine veteran and earned his degree in mechanical engineering from the State University of New York at Alfred. As president/COO of the North American operations for BIG KAISER, Burley will continue to hold his seat on the board of directors for BIG KAISER.

FANUC Named Top Workplace in 2020 FANUC was named a top workplace in Michigan by the Detroit Free Press for the ninth consecutive year. FANUC ranks 15 out of 30 companies in the large employer category in Michigan. In addition, the Chicago Tribune named FANUC’s Hoffman Estate, IL regional office a top workplace in Illinois for the third year in a row. “I’m so honored that even during these challenging and unprecedented times of a global pandemic we’ve been named a top workplace,” said Mike Cicco, President, and CEO, FANUC America. "This recognition is based on our employees’ feedback, and I’m proud they feel that FANUC is an ideal place to work.” “Our team of talented professionals is our greatest asset – integral to our company’s mission and key to FANUC’s competitive advantage,” added Cicco. FANUC America’s Achievements in 2020 include a number of new CNC and robotics products, a new facility in Alabama, national recognition for helping close the manufacturing skills gap, and a first-ever virtual event.

BIG KAISER Announces Promotion of Jack Burley to President/Chief Operating Officer BIG KAISER Precision Tooling announces the promotion of Jack Burley to president/chief operating officer as of January 1, 2021.

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Siemens Expands Xcelerator Portfolio with Enhanced Model-Based Definition In Latest Version Of NX Software Siemens Digital Industries Software announces the availability of the latest version of NX™ software, including capabilities that allow companies to use rules and a knowledge-based approach to Model-Based Definition, which builds in best practices and leverages artificial intelligence to dramatically improve productivity. NX Model-Based Definition provides a rich set of data that defines a variety of characteristics beyond size and shape to enable a truly comprehensive digital twin. By including non-geometric data within the CAD model, engineers can now produce a complete digital definition of a product in an annotated and organized manner, creating alignment throughout the production process, from design to production through validation. “I've been in the CAD/PLM game my entire career, over 35 years. Rarely have I been as impressed by a big leap forward as we saw today,” said Tom Gill, Senior Consultant at CIMData, after reviewing the technology. “Siemens continues to innovate and reimagine CAD design in a way that truly looks to the future of design.” A first to the industry, patented technology, NX Model-Based Definition answers many of the challenges companies face when digitalizing the design process and transitioning from 2D to 3D

Mitsubishi Hires New Vice President of Sales J. Scott Knoy Mitsubishi Heavy Industries America is pleased to announce and welcome J. Scott Knoy as the new vice president of sales for the Wixom, Michigan based Machine Tool Division. Scott will be J. Scott Knoy, vice responsible for sales team leadership, driving president of sales, revenue, strategic planning and marketing, Mitsubishi Tool Division

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as well as management responsibilities. Scott brings 26 years of experience in the gear machine and tooling industry. His career includes 12 years with the Gleason-Pfauter organization working as a Regional Sales Manager in both the tooling and machinery sales groups and 14 years with GMTA (American-Wera) where he served as the Vice President of Sales, Vice President, and President. “Scott has an impressive background in sales and executive management within the gear machine industry”, says Atsuhiro Kawaguchi, General Manager of the Mitsubishi Machine Tool Division. “Scott will aggressively lead our sales team and I believe with his leadership we will overcome this unforeseen market condition.” Scott who resides in Howell, MI is married (Holly) and has 2 adult children (Kelsey, Karlyn). His education includes an MBA from Lawrence Technological University as well as a Bachelor’s Degree from the University of Michigan in Ann Arbor. Additionally, Scott served as a combat engineering officer in the U.S. Army Reserve for 10 years.

Helen Blomqvist New President at Sandvik Coromant As president, Helen will be responsible for enhancing Sandvik Coromant’s leading position in manufacturing tools and machining solutions and sharing the knowledge that drives the manufacturing industry forward. Helen will report to the newly appointed President of Sandvik Machining Solutions, Nadine

Crauwels, and will be a member of the Sandvik Machining Solutions Management Team. She starts her new position on 1 December 2020. Blomqvist has a solid background with Sandvik Coromant and joined the company in 2003 as a research engineer. In her 17 years, she has held various managerial positions in Product Management and R&D, as well as in sales — having been the General Manager for Sales Area North Europe. She holds two patents Helen Blomqvist new president at Sandvik Coromant and in 2018, she was awarded Sandvik Coromant Leader of the Year. Blomqvist is a Swedish national and holds a Ph.D. in Structural Chemistry from Stockholm University. “I am pleased and honored to have the opportunity to lead Sandvik Coromant, a company with a fantastic position for products and solutions that are adding value to our customers. I look forward to working with Sandvik Coromant's management team, employees, and partners to continue to develop our offering, our innovation power and to implement our strategy to lead the industry forward and shape the future of the manufacturing industry. My focus will be to strengthen our role as a market leader,” says Blomqvist.

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Business 4.0

Why Positioning Is More Important Than Ever By: Andrea Belk Olson, MSC - CEO of Pragmadik

Andrea writes original articles across a spectrum of topics, providing unique insights to leadership, culture change, organizational engagement, behavioral insights, and communications.

here was a great book published back in 2001 called "Positioning" by Al Ries and Jack Trout. It emphasized the importance and impact of companies taking a unique position in the market, albeit through now outdated examples. However, the principles of this idea have gotten lost over the years, and the time is ripe to bring the concept back. Now, positioning isn't lost at a product level, where product management teams are perpetually seeking new ways to differentiate their offering with new features. But positioning at a company-level is much less prevalent. Take, for example, financial institutions. Where there may be a small group of organizations that have a unique position in the market, most banks and credit unions share the same set of core messages. Trustworthy. Communityfocused. People-focused. Great rates.

10â&#x20AC;&#x201A; â&#x20AC;&#x201A; IMDâ&#x20AC;&#x201A; DECEMBER 2020

But positioning is the process of how to best communicate your organization's unique attributes to your target customers based on their needs and to counter competitive pressures. It's carefully crafted key messages and actions that build a distinct and differentiated brand. In short, effective positioning ensures that marketing messages help you clearly stand out, resonate with target consumers, and compel them to take action. If you're not standing out, you're not positioning. It's not an easy task, however, as many organizations lack the insight, drive, or capability to effectively position their company. In the spirit of making safe decisions, many organizations follow what they deem as "successful competitors", copying their key messages and offerings. Alternatively, some organizations get mired in their own internal perceptions and set their sights on emphasizing broad and generic differentiators, such as "customer-focused".

The problem is, this isn't positioning. Let's take the example of "customer-focused". How are you different from your competitors in this regard? Do you simply believe and reinforce that you are just "better" than them? What does this really mean? On the other side of the coin, what competitors are stating they aren't focused on the customer? At the end of the day, this message is simply a belief and leaves any positioning proof-points on the table. If the organization is truly all about customers, what actions and strategies are you taking which illustrate this mindset? Which of those actions are distinctly different? If you greet your customers by name when they come through your door, this might be nice, but sending a personal note and a grocery store gift certificate when your customer has a major life change (i.e. death in the family, moving homes, lost a job, etc.), that carries weight. How you translate your words to action is where positioning becomes truly impactful. It's time for companies to reexamine their brands and reassess how they are creating a unique market position. This not only helps provide direction to your organization's culture and strategy but also increases the effectiveness of your marketing efforts. By having a clear positioning strategy, marketing messaging gains more impact through relevance, resonance, and most importantly, recognition. If we want to cut through the noise and grow our organizations in a way that fosters deeper customer connections, it all begins with having the confidence to take a position.

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ABOUT THE AUTHOR Andrea Olson is a speaker, author, behavioral economics, and customercentricity expert. As the CEO of Pragmadik, she helps organizations of all sizes, from small businesses to Fortune 500, and has served as an outside consultant for EY and McKinsey. Andrea is the author of The Customer Mission: Why it’s time to cut the $*&% and get back to the business of understanding customers and No Disruptions: The future for mid-market manufacturing. She is a 4-time ADDY® award winner and host of the popular Customer Mission podcast. Her thoughts have been featured in news sources such as Chief Executive Magazine, Entrepreneur Magazine, The Financial Brand, Industry Week, and more. Andrea is a sought-after keynote speaker at conferences and corporate events throughout the world. She is a visiting lecturer and is Founder's Club lead coach at the University of Iowa’s Tippie College of Business, a TEDx presenter and TEDx speaker coach. She is also a mentor at the University of Iowa Venture School. More information is also available on www.pragmadik.com and www.thecustomermission.com. Visit her on LinkedIn: www.linkedin.com/in/olsonandrea1/

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Talking Shop

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Tom Kelly — Senior Vice President, Mitsubishi Heavy Industries America, Inc. - Machine Tool Division After 33 years in the machine tool business, you’re set to retire this month. Would you take us on a walk through your career?

agreed, and I’ve been overseeing the Mitsubishi Gear Technology Center in Wixom, Michigan, ever since.

I really started before that, working in the Machine Tool Lab at the University of Michigan. Summertime while in school I ran a lathe in my future father in law’s machine tool shop. Upon graduation in early 1983, I went to work for the Honda Motor Company in Torrance, California. Several months later having difficulty making ends meet, I rejoined my wife of the time, who was in law school in Detroit and ended up going to work for her father’s job shop learning the machine tool business. In 1987, I was recruited by the local Mitsubishi Machine tool dealer and found immediate success. As I learned more about Mitsubishi, I gravitated toward its gear machines. There really wasn’t a lot of competition in that area at the time. That was right when the big Saturn automotive project was getting off the ground in Spring Hill, Tennessee, and we played a big role in that, providing them with 20-30 lathes and 15 gear shaving machines. In 1989 I joined Mitsubishi International Corporation, the importer for MHI in the United States. In the 1990’s I worked on various projects like the Ypsilanti, Michigan, and Muncie, Indiana, GM plants, while I was also selling to job shops in the Detroit area. The problem was MHI had an office in Chicago at the time, and other reps in the U.S., but it wasn’t coordinated all that well, so I approached them in 1999 and said “I’d like to consolidate these efforts and spearhead North American operations myself.” They

You’ve had a front-row seat to a lot of advances in the machine tool industry over the years. What do you think some of the most important milestones have been?

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I think dry cutting with high-speed steel tools is something I never would’ve expected. We worked primarily with Balzers (Oerlikon) on coating technologies in the early days, but they’ve come so far that these types of cutting tools are no longer as exotic and expensive as they once were. To be able to work with an 8620 blank without coolant is really a great thing to see. And, as is always the case, advents in one technology always drives improvements in others, so spindle speeds have needed to be raised in order to meet the potential these cutting tools can provide, so the whole systems ends up being tightened up and made more robust.

How about changes in the marketplace, in terms of how and where machine tools are inventoried and distributed? One advantage we have over most of our competitors is that we stock a lot of machines. Where some OEMs might have a machine or two in stock, we’ll have 20 or 30 hobbers, shapers, or grinders ready to ship at any given time. And when it comes to customization, that

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can be handled in a number of ways, but it really comes down to the customer’s needs. Smaller shops usually need the machine tool immediately, so they want to get it on their plant floor and will handle the integration of any necessary automation or robotics themselves, while larger operations with larger budgets, who can plan months out and might have more specific requirements, can give us more time to handle their customization needs prior to the ship date.

in North Carolina. We’re designing it from that ground up, so while it’s being built we’re going to pack up our dog and travel around the country in an RV towing a Jeep Wrangler behind us. This is something we’ve never done, so I’m looking forward to the idea of having no set agenda. We’ve got a great staff at the Mitsubishi Gear Center, and we’re seeing the market begin to come back to life, so I’m confident that we have every reason to feel good about what the future holds for the machine tool industry.

So what does the future hold for you, Tom? My wife, Cayce, and I are building a new home on the waterfront

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IMD 15

Safety & Maintenance

These modular units can complement, supplement, or replace such functions on a temporary or permanent basis.

The Art of Mobilization:

Ensuring the Continuity of Industrial Production By: Del Williams

apid deployment of mobile production and processing equipment in modular trailers or containers can be customized and outsourced from concept to turnkey asset Industrial manufacturers require production reliability and continuity. However, a wide range of conditions can make this challenging – from unexpected emergencies, power grid failures and blackouts to partial plant shutdowns for maintenance, upgrade, replacement, or expansion. So, when uninterrupted power, power storage, water pumping, filtration, treatment etc. is necessary for production, safety, or regulatory compliance, a growing number of manufacturers are looking to mobile trailer and containerized units. These modular units can complement, supplement, or replace such functions on a temporary or permanent basis. Notably, the units can be customized to meet specific needs and delivered in a fraction of the time and cost that it usually takes to build on-site or off-site. With a collaborative approach and flexible design options, such

16 IMD DECEMBER 2020

modular systems can quickly be taken from concept to turnkey asset. When necessary, supplemental support solutions can even include mobile offices, command and control centers and foodservice kitchens. Organizations with multiple sites can transport the mobile units wherever needed at any time. “Custom built trailers can be configured to act as rapidly deployable mobile units to provide remote power generation and distribution, water treatment, and battery energy storage systems (BESSs). The units can be designed to a variety of specifications and sizes with high output capabilities, sound mitigation, and minimal environmental impact,” says Mark Steele, CEO of St. Charles, MO-based Craftsmen Industries, a rapid designer and fabricator of mobile, containerized units for temporary or permanent use. Since 1982, Craftsmen has fabricated mobile units for organizations such as Verizon, AmerenUE, Dell, and the U.S. Department of Veterans Affairs along with dozens of others

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Overcoming Conventional Limitations Traditionally, adding capacity to an existing industrial facility has been constrained by the limited amount of available space near production or processing lines. Even when space was available outside, constructing structures outdoors to house and protect equipment needed for functions such as power, pumping, and water treatment is expensive, slow, and usually not feasible if the need is temporary. While utilizing industrial With a collaborative approach and flexible design options, such modular systems can quickly be taken from concept to turnkey asset. equipment in mobile trailers is true where locations may have limited access to local skilled has been an option, the solutions are rarely tailored to specific labor or where getting labor to the installation site. This is also applications. Additionally, the lead time to receive a mobile solution beneficial when a schedule requires that many systems be installed can be excessive. This is a concern when the mobile units are built in parallel by allowing subsystems to be built and delivered by firms that outsource much of the work to off-site subcontractors, ahead of schedule. each with their own production lead-time constraints and Fortunately, more nimble, vertically integrated design and potential bottlenecks. fabrication firms that can scale up for larger projects are now Building supplemental systems and delivering them to remote meeting the need for fast, flexible, collaborative construction of locations can have significant schedule and cost benefits. This

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mobile assets. This ensures continuous industrial production capacity, even on short notice. “Manufacturers may not always have much advance notice when they realize that supplemental or replacement power, water, or energy storage is required due to emergencies or unplanned repairs. So, expediting delivery and tailoring it to their process is often critical,” says Steele. To speed mobile unit delivery and customization when it is necessary, Steele recommends that manufacturers work with a firm that offer in-house design, engineering, and fabrication capacity. The units can be customized to meet specific needs and delivered in a fraction of the time and cost that it usually takes to build This can cut traditional delivery time in on-site or off-site. half. In practice, this means that a partially customized mobile unit in a trailer or container can be received with field personnel during restoration efforts. Both command in about 12 weeks versus an industry typical 24 weeks, or a fully centers are 53-foot single drop trailers with custom modifications. customized unit in about 20 weeks versus over a year elsewhere in The trailers are self-sustaining dispatch offices equipped with a the industry, if available. communications room, custom antenna housing, conference room, Also important is working with a firm that is not only an integrator field commander’s office, six work stations, satellite dish and 30but also a fabricator with full engineering capabilities. This helps kilowatt generator. to resolve any issues that can occur at the drawing board as well The mobile assets provider also printed and “skinned” the as any difficulties that occur on the fly, according to Steele, whose trailers with a dramatic photograph of line workers on poles and firm is ISO 9001:2015 certified and fabricates with a wide variety of the message “Help is on the way.” The trailers stay at an AmerenUE materials including carbon steel, stainless steel, aluminum and alloys. operating center in west St. Louis County until the units are “To avoid delays and other issues down the road, I would also dispatched. This occurs during incidents requiring the restoration of advise working with a firm that allows the design and fabrication teams a large number of customers, when a communications center needs to directly interact and communicate on the shop floor on a routine, to be close to the action. preferably daily basis. This can safeguard against misunderstandings According to Steele, almost any requirement can be supplied that could otherwise take the project off track,” says Steele. as a mobilized solution. Mobile office trailers and training vehicles Because circumstances can vary and change, Steele says that can also be used as temporary onsite work locations with specific flexibility and collaboration should also be emphasized. seating, technology, restroom, and kitchen facilities available. If “Sometimes the manufacturer will provide the equipment and we space is at a premium, single and double expandable trailer units can will integrate it into the mobile unit. At times, they will specify and we be designed with hydraulic bump-outs so that up to 980 square-feet will source it. Other times, we might design a portion of the project of space is available. or most of it,” he says. In the marketplace, manufacturers have long been subject to For more complex projects, however, it is important that the units excessive production downtime due to power failures and other are designed to be easily connected. unexpected occurrences. “The modular units are like Lego blocks that can be combined With the availability of rapidly deployable, customizable mobile to optimize function in a minimal spatial footprint. If you have a equipment trailers and containers, manufacturers today have a generator unit, a power storage unit, a pump unit, and a filtration ready means to ensure reliable production despite emergencies unit, you could link them all together wherever needed,” says Steele. like blackouts as well as necessary maintenance for upgrade, When necessary, additional mobile units designed for support replacement, or expansion, which could otherwise lead to extended purposes are required. For centralized control, a mobile command plant shutdowns. center can be utilized. This eases information flow and distribution through data, voice, and video through the center. For more information: Call 1-800-373-3575 toll free; For example, with the use of mobile assets AmerenUE, an electric Visit www.craftsmenind.com; or Write to Craftsmen Industries, Inc. and natural gas utility provider to approximately 1.2 million Missouri at 3101 Elm Point Industrial Drive, St. Charles, MO 63301. customers, developed a creative way to enhance its effectiveness while responding to system power outages when major storms occur. ABOUT THE AUTHOR: AmerenUE relied on Craftsmen to build two mobile command center trailers to improve its coordination and communication Del Williams is a technical writer based in Torrance, California.

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Manufacturing Showcase

Custom Industrial Products, Inc. By: Russ Willcutt

t all began with a sketch on a cocktail napkin. Henry Powers and Darlene Taylor, who owned a small construction equipment company in Melbourne, Florida, were attending a regional tradeshow when a customer described a piece of material handling equipment he’d envisioned that far exceeded the traditional baskets that were available on the market at that time. He wanted a multilevel enclosed lift to carry substantial material loads from as high as five stories up to the warehouse floor. Henry and Darlene got busy, and Custom Industrial Products (CIP) introduced the first Vertical Reciprocating Conveyor (VCR) lift in 1995.

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Since the internet had not yet taken off, marketing the product was fairly rudimentary, consisting of two people, a pickup truck, and the Thomas Register. Henry hit the road, traveling from city to city selling the concept of the VRC to prospective buyers while Darlene scouted out potential customers in the next town on his itinerary. As they began to gain traction, the company moved from a 5,000 square-foot facility to 10,000 square feet. It is now headquartered in a 110,000 square-foot manufacturing plant, according to Tom Tenney, the company’s CEO.

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“Although we have our roots here on the ‘Space Coast,’ we now have customers across North America,” he says. “We have representation in the United States, Canada, and the Caribbean, but all of our products are manufactured and ship out of our facility in Melbourne.” Tenney says VRCs provide a number of advantages over freight elevators. They are far less expensive, for one, since freight elevators can cost five to six times as much, and they are much safer than forklifts. They have fewer moving parts than freight lifts, so less maintenance costs can be expected, and they are designed to run continuously at peak performance, with no disruption to the movement of materials. He also points out that freight elevators are also bound by far more safety regulations than are VRCs. CIP also sells standard material baskets that can

be moved via forklifts or overhead cranes. Both devices aid in limiting personal contact in the workplace during the pandemic. Since the first VRC was introduced, there are now five standard models available, each of which can be modified according to the end user’s needs. Tenney says that about 40 percent of the VRCs they ship require slight modifications, in terms of features or dimensions. While some of these are quite easy to accomplish, others are more challenging, such as working with a customer who is building a new facility and has very specific needs in mind. “When that’s the case, we’ll spend as much time as is required on-site working with the customer to determine exactly what their goals are,” Tenney says, “whether that takes six weeks or six months. We make sure that our VRC

meshes seamlessly with their automation and provides the dimensions and capacity required to handle the size and volume of materials they will be transporting throughout their warehouse.” Tenney explains that the basic setup for a VRC system involves a central unit providing vertical access to any number of floors in the warehouse. The VRC is stationary, from a horizontal standpoint. Automation on each floor of the warehouse carries materials to the VRC where it is loaded manually or via robotics, and the enclosed cage then relocates to another floor or drops down to unload. Looking down the road at the future of material handling in general, Tenney sees opportunity in the changes headed CIP’s way. “Transactions are taking place online more than ever before, so we have to be creative in building out our website so that our customers can choose the options they’re interested in quickly and easily,” he says. “Robotics and automation also present opportunities that we probably haven’t even begun to realize at this point, so that’s an exciting avenue to consider. The company was founded on an idea that a customer shared with us, and we continue to listen to their ideas and concerns because that’s how you stay on the leading edge. For more information visit online at customindprod.com INDUSTRIAL MACHINERY DIGEST.COM

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Workforce Development

New Welding Processes, Technologies and Retraining Help Address Labor Shortage

Learn how to increase productivity of the welding operation through new technology and advanced processes. Keep Operations Competitive The welding industry faces a pressing challenge in the growing lack of skilled welding operators. While this is not a new problem, it is an issue that many contractors, fabrication shops and manufacturing operations struggle with every day as they work to keep their operations competitive. According to the American Welding Society, the industry will face a shortage of about 400,000 welding operators by 2024. This is due both to a lack of incoming skilled welding operators, as well as the aging population of the current welding workforce — in the United States the average welding operator is 57 and poised for retirement.

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The two primary methods for the industry to address the welding operator shortage are increasing the labor pool by training more operators and increasing productivity with the existing welding workforce. In response to this industry challenge, welding equipment manufacturers are developing innovative technologies to make it easier and more cost efficient to recruit and train talent in the industry. Some of these same technology advancements can also be used to help requalify existing employees to build their skills. New advanced welding processes also offer greatly increased productivity through higher deposition rates and a stable,

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easier-to-control arc that can help reduce weld failures, so contractors, manufacturers and fabrication shops are able to complete more code-quality welds faster with their existing labor pool, helping them ease the demand for welding operators. In addition, some contractors are forming training and partnership initiatives with union organizations to help retrain current welding operators in higher productivity welding processes. All of these efforts combined can help contractors, manufacturers, fabrication shops and other welding organizations adapt to the challenges posed by the skilled labor shortage and establish a more competitive, productive welding operation.

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Simpler Designs, Intuitive Products Welding equipment manufacturers are stepping up with easierto-use and more intuitive equipment solutions, which can help address the welding operator shortage. Specifically, technology improvements have resulted in power sources with simplified interfaces, making it easier to complete superior welds — even among welding operators of varying skills sets — and also to set up and operate the machines. Examples of such advancements include features like preset weld parameters that can be established with the push of a button, quick process changeover and point-of-use controls. The preset parameters are based on process wire type and diameter and shielding gas type, and the systems can also limit options based on previous variables selected by the welding operator.

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These technologies can provide exceptional performance, improve productivity and reduce rework — all factors that help maximize labor hours and make the welding process easier for the operator. These equipment advancements help in two ways. First, they allow an employer to open up the labor pool to attract more welding operators who can be trained to produce high-quality welds. Second, the productivity gains make the existing workforce more productive. In an industry struggling to attract enough skilled welding operators, maximizing the current labor pool is important.

Improve Productivity With Advanced Procedures While equipment advances and simpler technologies are important steps to help the industry address the welding operator shortage, it’s also important for contractors, manufacturers and fabrication

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shops to look at business drivers and find additional ways to become more efficient. Labor is a large portion of the cost of a weld in North America — about 80 percent of the cost in field welding, for example. Therefore, finding ways to increase productivity is the biggest cost savings opportunity for these employers. Advanced welding processes, such as Pulsed MIG or modified short-circuit MIG, offer greater simplicity and can be easily taught and learned. This speeds up training, making it easier for welding operators to gain the training and experience necessary to create quality welds. In addition, these advanced processes are more forgiving to variations in stickout and offer exceptional arc stability, which is easier to control and can help avoid weld defects. Wire processes offer higher deposition rates compared to Stick and TIG, increasing productivity. In addition, advanced

wire processes such as Pulsed MIG and modified short-circuit MIG address previous quality issues regarding conventional wire processes, making the advanced processes viable options for completing code-quality welds. Once an operation decides to change welding procedures to take advantage of a more productive process, training new welding operators and retraining the existing workforce are often necessary. The new welding procedures and equipment must be certified, and welding operators must be certified on the new processes as well.

Growing Training Partnerships More training partnerships and collaborations are forming to help address this retraining need as welding operations switch to advanced welding processes and equipment to improve productivity. One example involves the United Association of Journeymen and Apprentices of the Plumbing and Pipe Fitting Industry of the United States and Canada (UA), a union affiliated with the national building trades that represents welders and pipefitters. The UA has partnered with a top national contractor to develop a program to proactively train already skilled welding operators in the new advanced welding procedures based upon the materials and parameters of specific applications and requirements for this particular contractor. It’s an example of a major contractor understanding that it can switch to the latest welding technology and greater-productivity procedures, but without enough qualified welding operators to complete the jobs, it can’t fully realize the productivity gains and cost savings. Some contractors are also working with technical colleges to develop training programs, or they are building their own in-house training facilities. This allows them to hire employees and train them to meet specific welding needs. In addition to the partnerships forming between contractors and union training halls and contractors and technical schools, many welding equipment manufacturers offer training centers and programs to provide expertise and resources for employers, contractors, unions, distributors and other end users. Technology is also playing a role in training and retraining. Among the new technologies that can help address the labor shortage are new training systems that contribute to faster and easier operator training. One system on the market is designed to deliver a real-world, arc-on welding experience by using motion tracking technology. The motion-tracking cameras provide immediate feedback on technique parameters during initial simulation mode and also during live arc training mode. The system uses a real welding power source with a MIG gun. With the push of a button, operators can experience a real welding arc while transferring the learned muscle memory and proper welding technique into a real welding application. This type of new technology offers a faster, more cost-effective method for screening applicants and training new welders, and it is an effective way to retrain current welding operators on new parameters. Welding operations can use this type of technology to maintain or update the skills of their current welding operators, by creating specific training assignments based on existing welding operations.

Keys To Addressing The Shortage In the quest to recruit and train more welding operators — and retrain the current welding workforce — to meet current and future industry demands, new technologies and equipment that are easier to learn and use will be an important part of the solution. In addition, switching to more productive advanced welding procedures is another solution that can benefit many contractors, fabrication shops, and manufacturers and help them maximize the current welding labor pool. Understanding the potential productivity gains offered by advanced welding processes and new technologies can help an organization ensure that contracts are completed on time — and on budget. Growing partnerships and training initiatives are also among the key steps that will help organizations address the challenges posed by the welding operator shortage — while also helping to increase productivity of the welding operation through new technology and advanced processes. For more information, visit www.millerwelds.com INDUSTRIAL MACHINERY DIGEST.COM

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New Technology

Machining Large Components for Wind Turbines Starrag’s Machine Engineering Helps Harness the Wind to Help Provide Cleaner Energy

“As yet the wind is an untamed, unharnessed force, and quite possibly one of the greatest discoveries hereafter to be made will be the taming and harnessing of it.” Abraham Lincoln, 1858

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ight score and two years later, Abraham Lincoln’s prophesy has become reality. Harnessing the wind has become an important source for energy. Wind energy generated 7.2 percent of electricity in the United States in 2019 and supports more than 120,000 jobs. The 280 foot tall wind turbines dot rural landscapes and appear like soldiers guarding the entrance to their domains. The three blades, each measuring 120 feet in length, move slowly, allowing the turbine to rotate smoothly into the wind. Machines with a similarly impressive scale are required to produce these giants. There are some of Starrag’s product ranges including Heckert with its Large Athletic Series, Berthiez RVU vertical grinding machines and Dörries vertical lathes. These machining centers are ideal for particularly large, heavy workpieces and have proven useful for wind turbine manufacturers around the globe. For example, Heckert HEC 1600 machines can process workpieces with edge lengths of 11 feet and up to 13 tons in weight. Dörries lathes combine excellent productivity and maximum precision. These vertical lathes have been developed for tailored solutions of planetary gear carriers in wind power plants with their extreme demands in terms of accuracy. Berthiez RVU 2800/250 machining centers are suitable for grinding, turning, drilling, cutting and performing inline measurements on large components in a single clamping operation. Starrag, with its machining centers have created many sophisticated workpieces, with varying sizes, weights and technological requirements that are required in the production of wind turbines. Starrag’s future in wind energy machining looks bright. According to the US Department of Energy’s Wind Vision Report, the industry supports a strong domestic supply chain with the potential to create 600,000 jobs in manufacturing, installation, maintenance and supporting services by 2050. The same report shows that wind can be a viable source of renewable electricity in all 50 states by 2050. The Heckert ultra-stable cross bed construction and its thermos symmetric design allows high-precision machining with a short turnaround time. It also can

minimize off-peak times with several set-up spaces. The technological challenges in the production of wind turbines include the large, complex gearboxes, which house deep-lying form elements. The Heckert HEC 1600 has an NC quill with stepless adjustment up to 30 inches for long travels and the machining of deep-lying form elements. The NC quill guides the tool into the gearbox houses to work safely without requiring expensive special tools with excessive lengths.

Modular design and flexibility are characteristics of the Heckert HEC 1600. It is possible, for example, to choose between a horizontal main spindle optional with integrated extendable NC quill, or a swiveling horizontal/vertical head for 5-sided machining. This enables the machining center to be matched ideally to customer requirements. The NC quill adds to the versatility of the Heckert HEC 1600. It provides a significant surge in machining large gearbox housings,

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torque support and planetary gear carriers in large components for many sectors, including the power generation industry. Their accuracy is the result of automatic temperature compensation for thermal influences and thermal stability by cooling the quill and its bearing with a separate cooling unit. The Dörries CONTUMAT VCE 1600 and VCE 2800 turning lathes are designed to process diameters of up to 63 inches and 110 inches respectively. VCE indicates the single column design of the compact lathes, which have a vibration-reducing cast iron construction. The symmetrical transmission and frame design ensure even temperature distribution – the basis for the unparalleled accuracy. Speeds of 450 and 224 RPM and hydrostatic guides in the X and Z axes also make a major contribution to the overall productivity.

Features and Benefits Wind turbine manufacturers benefit from numerous Starrag machine product features. For example, manufacturing time can be reduced

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by 50%, set up times are reduced because clamping, unclamping and re-clamping parts are parallel to the machining and non-productive idle times are saved with high dynamics in tool and workpiece handling. Also, the highly reliable machines guaranty highest production safety and workpiece quality This is all possible because Starrag machines incorporate premium machine features including: » Ready-for-assembly complete machining of transmission casings in closed and split designs » High-speed, vibration-free machining of deep-lying drill holes by using an extendable work spindle » Optimum process stability due to comprehensive control and monitoring devices within the system » Fully automatic complete machining on only two clamping positions » High storage capacity for tools, automatic loading and unloading of oversized tools » High, long-term workpiece accuracy and optimum workspace

conditions with improved traverse end positions of the work spindle – 9 in (225 mm) before pallet center » The Heckert HEC 1600 is equipped with two pallets, allowing clamping, re-clamping and unclamping parts are parallel to the machining. Starrag machining centers have supported manufacturers of wind energy turbines around the globe, which produced 64 GW of electrical energy in 2019. The United States, along with China, remain the world’s largest onshore wind energy markets and accounted for 60% of new wind capacity in 2019, according to the Global Wind Energy Council.

Statistics on Wind Energy in the United States » More than 60,000 wind turbines are in operation » 109,919 MW of operating wind capacity at the end of Q2 2020 » Wind energy produces more than 20% of the energy in six states » $208B has been invested in wind energy projects, including $14B in

private investment in 2019 » Wind energy avoided 198 metric tons of CO2 emissions in 2019 and

save 103 billion gallons of water consumption each year

ABOUT STARRAG Starrag Group is a global technology leader in manufacturing high-precision machine tools for milling, turning, boring and grinding workpieces of metallic, composite and ceramic materials. Principle customers are internationally active companies in the Aerospace, Energy, Transportation and Industrial sectors (Industrial Components, Luxury Goods, Med Tech). In addition to its portfolio of machine tools, Starrag Group provides integrated technology and maintenance services that significantly enhance customer quality and productivity. The umbrella brand Starrag unites the product ranges Berthiez, Bumotec, Dörries, Droop+Rein, Ecospeed, Heckert, Scharmann, SIP, Starrag, TTL and WMW. Headquartered in Rorschach/ Switzerland, the Starrag Group operates manufacturing plants in Switzerland, Germany, France, the UK and India and has established a network of sales and services subsidiaries in the most important customer countries. The shares of Starrag Group Holding AG are listed on the SIX Swiss Exchange. For more Information:

STARRAG Elena Schmidt-Schmiedebach Lead Marketing North America (859) 380-2356 info@starrag.com www.starrag.com INDUSTRIAL MACHINERY DIGEST.COM

IMD 29

Process

Cleaning – the Key to Successful Surface Preparation By: Venesia Hurtubise,Technical Chemist at MicroCare, LLC

Vapor degreasing prepares surfaces for painting, coating, or assembly.

urface preparation can be the downfall for many metalworking machine shops if reliable procedures are not put in place to ensure parts cleanliness. Failure to properly prepare parts surfaces can lead to poor results in painting, coating, plating, and welding. Or it will simply affect the final appearance of the parts. The down-line effect of poorly prepped parts is a decline in production, parts quality, and parts reliability. An essential step to achieve a high-quality surface for finishing is cleaning. If a reliable and consistent cleaning procedure is not implemented, the quality of the metal parts may be substandard. The optimal metal cleaning process must successfully dissolve or displace common contaminants without damaging substrates and leave surfaces ready for the next stage of manufacturing. One of the most efficient cleaning methods to achieve perfectly prepped parts is vapor degreasing.

The Mechanics of Vapor Degreasing Vapor degreasing is a closed-loop system that requires two components: a closed-top vapor degreaser and a non-flammable, environmentally sustainable cleaning fluid. Most vapor degreasing systems are comprised of a top-loading batch-style cleaning machine with two compartments, “the boil sump” and “the rinse sump”. In the boil sump, parts are immersed in the heated fluid for cleaning. Once cleaned, the parts mechanically transfer to the rinse

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sump. The parts rinse in pure, uncontaminated fluid or inside the fluid vapors themselves. The parts come out dry and cool enough to easily handle. So, they are immediately ready for the next step in the process which may include assembly, painting, marking, labeling, or packaging. The cleaning fluids used within the system have multiple chemical properties that are advantageous to critical cleaning and surface preparation. The low viscosity and surface tension of modern cleaning fluids allow them to wet every surface getting into and out of tiny spaces to remove contaminant and residue. The fluids also offer high solvency and high density which enables rigorous surface cleaning and displacement of stubborn soils. Additionally, the fluid evaporates quickly out of complex parts geometries or difficult to reach areas like blind holes or small gaps. Unlike other cleaning methods which can leave behind unwanted stains or moisture that can cause corrosion, vapor degreasing ensures the surface is spot-free and dry.

Selecting the Correct Cleaning Fluid The industrial manufacturing sector has a wide variety of cleaning needs. Contaminant varies from machining oils, metal fines, and cutting or polishing fluids, to greases, fingerprints, and waxes. To successfully remove the contaminant, specific cleaning fluid types should be specified to dissolve or displace soils leaving parts thoroughly clean.

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It is important to consider what contaminant needs removal so the correct vapor degreasing cleaning fluid can be carefully matched. Vapor degreasing fluid is categorized into three types and it important to use the correct formulation to clean the parts effectively. Each type of cleaning fluid has its advantages as well as its drawbacks, but they all can be beneficial if used in the right application.

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The simplest cleaning fluids are mono-solvents. They contain one component to clean, rinse and dry parts. Mono-solvents can be aggressive and are very good for removing machining oils and lubricants made with hydrocarbon components. High-boiling mono-solvents also melt waxes and remove other high-boiling contaminants. And since they contain just one component, mono-solvents are typically easier to manufacture, making them an economical cleaning choice. The mono-solvent cleaning fluid may appear on paper to be the easiest and most cost-effective cleaning fluid to use, however, some mono-solvents have certain disadvantages. For example, several of the most commonly used mono-solvents have toxicity issues. N-Propyl Bromide (nPB), trichloroethylene (TCE), and perchloroethylene (PERC) are some of the most popular mono-solvents but they may contribute to poor air quality. In fact, they are currently under scrutiny from governing bodies. Some are being phased out while others have been banned in some regions altogether. In addition, some mono-solvents like nPB require special maintenance to prevent them from turning acid in the vapor degreaser. This means additional investments in monitoring or testing time and materials. Acid acceptance tests must be performed weekly to measure the quantity of acid in the solvent. Depending on the outcome of the tests, stabilizers may have to be added to bring the solvent back into balance. The option is to choose a more modern, non-chlorinated, and non-brominated mono-solvent. They clean very effectively without the extra monitoring, maintenance, or air quality concerns.

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Azeotropic Cleaning Fluids Azeotropes are a combination of components that work together to make the perfect cleaning fluid. Engineers often use azeotropes to formulate cleaning fluid blends, tailoring them to a specific contaminant for removal which boosts the cleaning effectiveness. The physical properties of azeotropes are modified for certain physical properties to clean a range of contaminants including organic, inorganic, and particulate. Or even a combination of contaminant types. Because of this, azeotropic mixtures clean faster and more effectively than some mono-solvents. This reduces cycle times by as much as 75 percent, reducing cleaning costs and increasing overall productivity. Azeotropes are also engineered to enhance worker safety. For example, take a fluid that is an excellent cleaner, but is highly flammable. Then blend it with a second fluid that is a weak cleaner

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IMD 31

Vapor degreasing is a fast, consistent, and repeatable parts cleaning process.

but is nonflammable for safety. The end result? A non-flammable cleaning fluid that cleans extremely well, but is also safe for workers to store and handle. Another advantage of azeotropic cleaning fluids is that once the components combine, they always act like one. They never separate. Even when heated and chilled inside the vapor degreaser, the two fluids always perform as one component. This helps reduce operating costs since the azeotrope can be managed as one fluid. It boils and distills as one component making recycling easy and reduces the amount of hazardous waste and the cost of hazardous waste disposal. Some azeotropic cleaning fluids are also formulated to reduce their boiling point. A lower boiling cleaning fluid requires less energy to clean, another cost-saving factor. Although azeotropes may cost more per pound than mono-solvents, they are still competitively -priced and have the advantage of being safe, stable, and economical to use. They also do not require the monitoring and acid-acceptance testing needed when using some mono-solvents.

Co-solvent Cleaning A third cleaning option is Co-solvent cleaning. Cosolvent cleaning is typically used when more mono-solvent azeotropic cleaning fluid doesn’t have the cleaning power to get the job

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Cleaning fluid washes, rinses dries, and recycles inside the vapor degreaser.

done. A co-solvent cleaning system delivers the convenience and speed of traditional solvent cleaning but intensifies the cleaning with a second solvent to remove difficult soils that often require higher cleaning fluid temperatures. The two solvents, or fluids, have very different and distinct behaviors. The

high-boiling cleaning fluid, also known as the solvating agent, has most of the cleaning power. While the low-boiling rinsing fluid, referred to as the rinsing agent, washes the solvating agent off the parts and dries them in the vapor blanket. The benefit is that the cleaner can be adjusted and modified to fit the specific contaminant. Co-solvent fluids are versatile when used within a vapor degreaser and can easily remove hard to clean contaminants. Combining a non-volatile cleaner with a volatile rinsing solution ensures parts are perfectly clean. Together, the co-solvent fluids deliver excellent cleaning on all types of solder fluxes, oils, greases, waxes, and particulates, paints, buffing compounds, and anti-rust agents. They are highly compatible with most metals, plastics, and ceramics. Co-solvent cleaning does have the disadvantage of requiring a separate cleaning tank. It cannot be used in a one-sump vapor degreaser, or with vapor-only cleaning. This may mean a reduction in throughput from an extra cleaning cycle. It must also be monitored to ensure concentrations of each component are correct. This requires basic operator training to ensure that the correct additions are made to the system when necessary. These drawbacks are outweighed when looking at its cleaning power. It easily removes difficult soils with nearly the same ease and speed of traditional mono-solvent cleaning but boosts the cleaning power to ensure the surface of the part is pristine and ready for finishing.

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Prepare Your Cleaning to Prepare Your Surface Surface preparation is one of the most critical steps in successful processing applications and to achieve a quality finish. Ensuring parts are thoroughly cleaned is essential. Without guaranteed cleanliness, down-line processes may be unsuccessful. The most efficient, reliable, and sustainable solution is through vapor degreasing. Together with highly advanced cleaning fluids that have been specifically selected for the task; this process is a cost-effective way to not only ensure parts are perfectly prepped, but also address worker safety, regulatory requirements, and environmental concerns. Consultation with a critical cleaning partner with specialized expertise in vapor degreasing is essential. By performing comprehensive in-lab tests and evaluating current processes, cleaning can be assessed for its suitability to work on specified parts to guarantee the cleaning of the surface is effective. For more information, visit www.microcare.com

ABOUT THE AUTHOR: Venesia Hurtubise is a Technical Chemist at MicroCare, LLC, which offers precision cleaning solutions. She has been in the industry for more than 6 years and holds an MS in Green Chemistry from Imperial College. Hurtubise researches develop and tests cleaning-related products that are used on a daily basis in precision cleaning and medical applications.

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IMD 33

Industry Insight

The Path Towards Digitalization — Bring Your Running Shoes! By: Brian McMinn, Head of The Machine Tool Business, Siemens Industry, Inc.

e hear the phrases — Big data, Industry 4.0, IIOT, Edge Technology and, perhaps the most imposing, The Cloud. Whether you’re a production department supervisor at an automotive manufacturer, machine tool builder, contract manufacturer or job shop, the question is always the same, though the answers are distinctly different. The question is, of course, how do we begin the journey towards the digital factory, which is surely on the horizon for all of us? The answers do vary, depending upon the type of company. For the machine builder, it’s all about managing big data from the machine, reducing time-to-market, creating smarter machines and utilizing the “digital twin” technology, one that allows not simply simulation of a machining cycle, but today represents an avenue for total development of a machine concept, machining and tooling strategies, plus data communication and instant adjustment of parameters — all in the virtual world. The good news is, this is not a pipe dream, it is a reality today, owing largely to the development of the digital native CNC, which provides machine builders that flexibility. Perhaps the best way to look at it, imagine the traditional sequence of machine concept to building and commissioning as a linear, sequential track. Today, with digital twin technology, the process is more integrated and parallel for the machine builder, as the need for myriad iterations in design are radically reduced. A collateral but very real benefit is the ability to train your customers’ machine tool programmers, operators and maintenance teams while the machine is being developed. For clarity, I’d define the smart machine as one that has the onboard software needed to capture all the process variables, communicate

34 IMD DECEMBER 2020

them and, most importantly, act upon their condition in real time. Lastly, seek a supplier who can bring the portfolio of hardware, software and communications to you and help develop your unique roadmap towards digitalization. It will enable you to track the performance of your entire installed base, within an industry segment or even globally. We have recently instituted a digitalization partner program who can work with machine builders directly. For the CNC machine user, be they a contract manufacturer or job shop, the answer is somewhat different. The machines on the floor do indeed need to be smarter, but the focus is on true KPIs of product cost, tool life, energy consumption, scrap reduction, OEE, achieved delivery targets, etc. Digital twin technology enables a machine shop to be IOT-ready, a tangible benefit for interfacing with your customers. Furthermore, the higher-end software embedded in the control allows real-time adjustments during machining, as the feedback

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improves and the machine literally “learns” its way through the production runs. We believe our integration of machine tool hardware, software and communications, overall, help you create a roadmap towards the digital factory that does not require a radical capital investment and, in fact, can utilize much of what’s on your manufacturing floor today. Even on an individual machine or group of machines in a smaller mold shop, adaptive control and monitoring software can adjust speed/feed rates and spindle condition in real-time and we’ve seen such shops achieve a 20% improvement in machine performance. To talk numbers, we’ve seen shops make an investment less than $10,000 and realize the improvements in less than 90 days. I suggest you seek out an employee or external partner who knows your business and knows the available resources to get started. Siemens now offers such a partner program, though many such integrators abound in the market today. Find your comfort zone and get started. To meet these emerging tech trends, we created, for example, Create MyVirtual Machine and Run MyVirtual Machine software programs, the first to blend all those developmental stages from concept to machine build and commissioning, while the latter can drive the process of streamlining the machining sequence from CAD to CAM to CNC and back, even while an existing machine is on the shop-floor, making parts. These programs can be run entirely in a virtual world, with no need to purchase a dedicated CNC or other hardware, initially.

On the control side of the equation, the advent of the digital native CNC — our new SINUMERIK ONE platform being an example — will open the next chapter in the machine tool world’s journey towards digitalization. Such a control captures all the relevant data, while edge technology apps can feed the data through a program, permitting real-time adjustments in the cycle parameters to optimize cutting path, speed and part quality for the best results on the shop-floor or in mass production. Meanwhile, through the Cloud, in an environment such as our MindSphere platform, all the operational data from a machine or series of machines or even plants across the globe, can be monitored and managed more effectively. So, lace up those running shoes and get going.

ABOUT THE AUTHOR: Brian McMinn is the head of the Machine Tool Business at Siemens Industry, Inc. He is an electrical engineer with 25 years in the motion control and drives business. He has a passion for the emerging technologies in machine automation and control. For more information:

SIEMENS John Meyer cnc.marketing.us@siemens.com

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IMD 35

Product Showcase

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

IMD's Monthly Product Showcase features the latest from some of the manufacturing industry's top suppliers.

ABB Launches Fastest Ever Robot-Based Press Automation Solution Aimed at press automation applications in the automotive industry, the IRB 760PT is a flexible press tending solution offering 25 percent faster cycle times compared to other robot-based press automation solutions. The IRB 760PT features a revised design that reduces the interference in the robot’s fourth axis. This allows the robots to move freely without colliding with equipment such as press clamps, with no compromise for the overall working area and the robot’s freedom of movement. Capable of handling loads up to 450 kilograms, the IRB 760PT reduces the time, cost and disruption associated with repurposing dedicated press tending machines. » For more information, visit www.abb.com

Bernard Expands Power Pin Offering for AccuLock S Consumables System

ANCA’s New Era of Automation: Intelligent Solutions for Maximizing Productivity 24/7 Central to any AIMS system is the AIMS Server that manages data flows between the elements of the AIMS system and established IT platforms, such as your ERP system. Customers can choose from a suite of “auto” solutions for reducing production costs, resolving labor challenges and integrating systems to improve product and process quality. From transferring tools between operations with AutoFetch robot options; fully automated tool measurement and process compensation using AutoComp; and managing data via the AutoSet hub - AIMS delivers streamlined manufacturing, with connected tool production processes integrated to IT systems that takes tool production to the next level. » For more information, visit www.anca.com

36 IMD DECEMBER 2020

Bernard announced that its AccuLock™ S consumables system now includes Lincoln®, Tweco® #4 and Tweco #5 power pins. These are in addition to the power pins for Miller® equipment previously available. All power pins are configurable options for the company’s BTB semi-automatic air-cooled MIG guns using the online configurator. The AccuLock S consumable system addresses errors in liner trimming by locking and concentrically aligning the liner between the contact tip and power pin — no fasteners required. This system provides a flawless wire feeding path to minimize downtime associated with issues like burnbacks and birdnesting. » For more information, visit www.bernardwelds.com

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New Presetter Option, SPI, Speeds Up Data Transfer to the Machine Center

Coxreels® Safety to the Next Level

The SPERONI SPI (Simple Post Interface) is the newest of BIG KAISER's Industry 4.0 upgrades to its offering of tool presetting solutions. SPI dramatically reduces the time and steps needed to transfer precise and accurate tool measurements to a machine tool. As opposed to measuring, printing a label and punching the data into the control, SPI prints a tool label with a QR code at the presetter that’s then read by the SPI module at the machine control. The system can also be configured to send measurements directly into the tool NC’s offset table.

Safety is the first and foremost consideration in business today. Slips, trips and falls constitute the majority of general industry accidents, which cause 15 percent of all accidental deaths. Power up your safety with high visibility hose by Coxreels. When not in use your hose and cable is safely retracted on your Coxreels reel, but when in use the hose can become a hazard. With the addition of high visibility hose to your hose reel, awareness and visibility are increased to create the safest environment possible. With enhanced kink resistance and reduced coil memory, they lay flat for a reduced trip hazard potential.

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IMD 37

Doosan Debuts a Multi-Level Rotary Pallet System for NHP Series The multi-level RPS (Rotary Pallet System) holds up to 21 pallets (3 layers of 7 pallets) vertically, which saves on floor space. The new configuration will be attractive to job shops that need to add capacity to their machine or require an affordable, more compact pallet system to consolidate fixtures that may be feeding their horizontal machining centers. With JIT scheduling, job shops that cater to multiple industries (where tasks may change from month to month) can benefit from the RPS by cutting down on setup time.

Uniform Pressure Allows Dillon Jaw Boring Rings to Securely Grip Large Diameter Chucks Dillon Jaw Forming rings, or Jaw Boring Rings, provide uniform pressure on jaws, allowing soft jaws or full-grip jaws to be precisely machined. A firmer grip of the workpiece allows for a more consistent bore, especially on large diameter chucks. Dillon Jaw Forming Rings provide a jaw surface true to the machine centerline, reduce set-up times, and increase up-times for running machined parts. They compensate for “jaw lift” even in worn chucks, which yields better part concentricity. Available in diameter-specific models or adjustable models to suit a range of diameters, they are ideal for CNC lathes. » For more information, visit www.dillonmfg.com

38 IMD DECEMBER 2020

» For more information, visit www.doosanmachinetools.com

AI-Powered, HD Mode for 3D Scanners Exact Metrology has increased the capability of their Artec 3D handheld scanners with the new HD mode. This Artificial Intelligence-powered scanning technology provides ultra-sharp, clean and detail-rich scans for Artec Leo and Artec Eva. Powered by Artec 3D‘s AI neural engine, users can obtain sharp 3D scans with a resolution of up to 0.2 millimeter. Trained on hundreds of thousands of carefully selected samples, the engine’s neural network detects familiar patterns, surface details and shapes. This allows the 3D scanner to reconstruct a higher number of polygons per frame, resulting in 3D data that’s both denser and higher quality. » For more information, visit www.exactmetrology.com

Wireless Motion Detector Series LCD Counter C12 Series People Counter ENM Company is supplying the new C12 series LCD counter with an integrated Motion Detector. The unit is operated by 4 C batteries and can be mounted easily on a wall or other flat surface. This people counting counter can be used as a part of a simple security system where you can keep track of Events such as door opening and closing., such as sporting events, museums, concerts, and large crowds. » For more information, visit www.enmco.com

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IMD 39

NEW PRODUCT: 3/8 NPT FullStream Liquid Nozzle for Cooling, Washing and Rinsing EXAIR’s new 3/8 NPT FullStream™ Liquid Atomizing Spray Nozzle provides a full cone spray pattern for pressurized liquids. This inexpensive and versatile nozzle offers the ideal solution for cooling, cleaning, washing, rinsing and dust suppression applications for industry. With a vaneless, tangential flow design, the FullStream has wide open internal features to resist clogging while simultaneously producing uniform distribution in a round pattern with medium to large droplets. The compact right-angle design operates at up to 250 PSIG liquid pressure, and functions seamlessly with liquids containing particulate. » For more information, visit www.exair.com

400°F Shelf Oven from Grieve This Grieve oven is a 400 degrees Fahrenheit electrically heated shelf oven, currently used for heat treating parts at the customer’s facility. Workspace dimensions of this oven measure 56” W x 30” D x 60” H. 15 KW are installed for heat input, while a 1000 CFM, 1 HP blower provides side-to-side horizontal airflow to the workload. This Grieve shelf oven features 6-inch insulated walls, integrally welded construction, channel shelf supports and nickel-plated wire shelves. Additional features include 304 stainless steel interior and Trilite Green enamel painted aluminized steel exterior. » For more information, visit www.grievecorp.com

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40 IMD DECEMBER 2020

Enhanced FabCO Triple 7 Wire Offers Expanded Mechanical Properties Building on a proven formulation, Hobart is offering its FabCO® Triple 7 gas-shielded flux-cored wire with expanded mechanical properties. In addition to the American Welding Society (AWS) E71T-1 C/M H8 classification the wire previous held, it now also meets the requirements for an AWS E71T-9 C/M H8 classification. Being able to address the demands of T-9 applications makes Triple 7 ideal for achieving versatility in manufacturing, construction, fabrication, ship, railcar and structural steel applications. A fast-freezing slag and spray-like arc provide excellent weld pool control when welding out of position, allowing even less skilled welders to create flat, consistent welds. » For more information, visit www.hobartbrothers.com

Koike Aronson Ransome Introduces Their New Welding Packages for Pipe Welding and Submerged Arc Welding The pipe welding package incorporates both the new Cricket-I welding manipulator and Koike’s standard Wel-Handy Multi Next and WU-3 weaver mounted on the end of the boom. This package is configured to use the 3-inch by 3-inch manual cross slide and built in weaving functionality to automate pipe welding, increasing quality and maximizing productivity. The SAW package for submerged arc welding includes a 6 x 6-foot Cricket-II Manipulator with powered lift and manual reach, self-standing base and mast rotation for portability.. » For more information, visit www.koike.com

New GARR TOOL Tool Library Available for Mastercam CNC Software, Inc. has announced a new partnership with GARR TOOL to provide their complete line of cutting tools as a native, Mastercam tool library. Mastercam users can download the GARR TOOL cutting tool library, containing both inch and metric tools, from the Mastercam Tech Exchange. The native, Mastercam 3D tool database is fully compatible with Mastercam 2019, 2020, and the latest Mastercam 2021 release. The new library features over 11,000 GARR end mills, drills, reamers, and roughers, including the new VRX-6, VX-7, and 1880KD series of tools introduced to the market in October 2020. » For more information, visit www.mastercam.com

New Thread Grinding Machine Offers Flexibility of Application, High Processing Speeds, and Consistent Precision Mitsui Seiki’s GSH 200A Thread Grinding Machine combines flexibility of application, high processing speeds, and consistent precision to complete an extensive selection of threading jobs. The GSH 200A is engineered to handle a wide variety of workpiece sizes. Automation features on the GSH 200A include an automatic phase adjuster, automatic notch position adjuster and automatic effective diameter adjuster. Together, the features permit an operator to leave the machine rather than remaining there to adjust the steady rest and oblique diameter during the operation. » For more information, visit www.mitsuiseiki.com

C-FRAME PRESSES • Heavy Gauge Steel Design • Press Bed bolted on, not welded, to prevent distortion. • Large press bed to accommodate a variety of tooling other than just punching. • Pump, motor, valve and reservoir are all easily accessible for maintenance. • Large rectangular tubes used at base of machine to give safe, instant portability.

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IMD 41

New Norton Winter IroncladTM Foundry Grinding Wheels

OnRobot Launches Low Cost, Easy to Use 2FG7 Gripper for Demanding Applications

Saint-Gobain Abrasives announced the introduction of its new patent-pending Norton Winter Ironclad™ Diamond Single Layer Superabrasive Wheels that achieve maximum material removal for increased productivity, especially when used in automated grinding cells. Featuring one of the strongest and most durable bond on the market, Ironclad wheels finish up to 50 percent more parts per wheel compared with electroplated wheels. Norton Winter Ironclad Wheels are a superior solution for ductile and grey cast iron applications such as fettling and snag grinding on casting gates, parting lines, sprues, and more.

Designed to enable companies of all sizes to set up gripping applications at low cost, the 2FG7 can be deployed within minutes and is specially designed to handle demanding payloads –even in tight spaces. The new 2FG7 gripper is ideal for low-volume, high-mix production and enables fast ROI for many different applications, including machine tending, material handling and assembly. Seamlessly integrated with the OnRobot product range and compatible with all major collaborative robots and light industrial robot arms, the 2FG7 allows manufacturers of all skillsets to set up gripping applications quickly and easily.

» For more information, visit www.nortonabrasives.com

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Mounted Stone Kit from Palmgren

hydraulic products low speed high-torque motors… The Char-Lynn

motor range consists of three major types based on the valving used to distribute fluid through the Orbit gear set (geroler or gerotor), Spool Valve, Disc Valve and VIS (Valve-in-Star). A variety of displacement sizes are available in each of the three motor types to provide a wide range of speeds and torques.

steering control units… offer these advantages: • Minimal steering linkage reduces cost, provides design flexibility. • Complete isolation of load forces from the control station. • Continuous, unlimited control action with low output torque. • Wide selection of control circuits and meter sizes. • Works with many kinds of power steering pumps or fluid supply. gear pumps… Eaton Series 26 gear pumps with 13-tooth gears minimizes flow ripple to reduce noise and vibration. Bearing lubrication system uses inlet oil rather than high pressure oil, improving volumetric efficiency and power output. The 13 available displacements and many mounting configurations provide for an easy retrofit. Other series available. 7355 N. Lawndale Ave., PO Box 6, Skokie, IL 60076

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42 IMD DECEMBER 2020

Palmgren’s Mounted Stone Kit features high quality mounted stones made from a pure, fused aluminum oxide alloyed with chrome and a vitrified bonding agent. The stones have a distinct pink color due to their components and can be used on a variety of steels and alloys where sharp cutting action is essential. The characteristics of the pink abrasive grain make the stones exceptionally durable while providing cooler cutting. Each kit contains a wide variety of stone sizes for use on both large and small workpieces. Now observing its hundredth anniversary, Palmgren is a C.H. Hanson brand. » For more information, visit www.palmgren.com

Seco Tools Introduces CW100 Ceramic Insert Grades

PFERD Unveils Victograin®, The High-Performance Abrasive With Aggressive, Precision-Formed Grain Its precision-formed abrasive grain triangles are identical in shape and size. Their cutting edges are applied to the workpiece at the optimum angle so that each individual grain needs very little energy to penetrate the workpiece. As a result, VICTOGRAIN delivers a fast and efficient machining process, a long service life, reduced heat buildup, and a consistent surface finish, making it superior to conventional ceramic grains. In addition, since less energy is required to machine with VICTOGRAIN, its characteristic high-performance can be achieved even on commercially available angle grinders.

For manufacturers seeking solutions to unpredictable tool life and slow rough-machining speeds when working with heat-resistant superalloys (HRSA), Seco Tools has expanded its line of highly productive Secomax™ CW100 ceramic insert grade. Featuring new geometries for whisker-reinforced ceramic, this line of ceramic solutions offers superior performance for challenging aerospace, oil and gas and power generation applications involving Inconel 718, Hastelloy, Waspaloy, MAR, Nimonic, Rene, Udimet and other HRSAs. The Secomax™ CW100 grade not only boosts machining speeds in advanced HRSA materials, but it ensures stable and predictable tool life for the lowest possible cost per part thanks to the siliconcarbide whiskers. » For more information, visit www.seco-tools.com

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Fastest, Most Accurate Bar Puller On The Market Watch the video now at: ezpullerusa.com • NO MECHANICAL ADJUSTMENT NECESSARY (X axis end point gets changed in the program when changing bar diameters) • ONE TIME SETUP • NEVER NEEDS ADJUSTMENT •CHANGE BAR SIZE IN SECONDS (BY CHANGING “X” VALUE IN PROGRAM)

SINUMERIK CNC becomes part of the Siemens TIA Portal As part of the Totally Integrated Automation (TIA) Portal, machine builders can shorten their development and commissioning times by up to 50 percent. With its integrated Simatic S7-1500F failsafe PLC, machine tool builders can take full advantage of the benefits the TIA Portal brings. Drag-and-drop is used to network peripherals easily and to establish communication links with other machine components. Machine builders can create software libraries with ready-made hardware configurations and numerous function and software modules in TIA Portal, thus standardizing the development of the CNC machine.

• EXTREME REPEATABILITY RESULTS IN LESS MATERIAL WASTED PER PART • NO GRIPPING FINGERS TO ADJUST, LOSE OR BREAK • EZ-PULLER WORKS ON ROUND, HEX AND SQUARE STOCK. RANGE: .093″ – 1.750″ ROUND STOCK .125″ – 1.375″ HEX STOCK .125″ – 1.000″ SQUARE STOCK

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IMD 43

New SLM Solutions NXG XII 600

Siemens Expands Software Ecosystem for Industrial Additive Manufacturing Siemens is adding support for new methods of AM production, further strengthening Siemens’ end-to-end solution for industrialized additive manufacturing as part of its Xcelerator™ portfolio of software and services. Siemens signed an agreement with Morf3D, an additive engineering and manufacturing service provider, who are helping apply Siemens’ AM software to the design, engineering and production of groundbreaking metalbased product innovations across many industries. Through this partnership, Morf3D will accelerate the delivery of more productenhancing AM applications for companies in a wide range of industries, leveraging design optimization, AM part qualification, and industrial-scale production.

The NXG XII 600 is the latest addition to SLM Solutions' product portfolio and puts productivity on a whole new level, with 12 simultaneously operating lasers with 1 KW each, numerous technological innovations, and automated features. The new machine was designed from scratch for serial production and features a whole new optic system, the most compact on the market. It enables large overlap and is based on a tailor-made laser scanning system to best fit the build area. Additionally, the machine comes with a brand-new UI concept focusing on the operator, which optimizes the workflow and reduces training requirements. » For more information, visit www.slm-solutions.us

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FM-Approved MHP45L Handling Robot for Use in Hazardous Environments

Walter has introduced the D3120, an indexable insert drill built to provide trouble-free drilling in virtually all conditions. It features square positive indexable inserts with four cutting edges, enabling it to reduce cost per cutting edge. Combined with the new Tiger·tec® Gold PVD grade WSP45G, these new drills bring significantly higher tool life and cost savings for the user. Available in diameter sizes ranging from 0.562-1.375 inch and 16-42 millimeter with 2, 3, 4 x Dc, the new drill delivers maximum process reliability with simple and efficient chip removal, two coolant channels and polished flutes.

The high-speed, six-axis MHP45L handling robot is Factory Mutual (FM) approved for Class 1, Division 1 use in hazardous environments. Featuring a wide motion range, this robust robot is ideal for transferring large workpieces while avoiding interference with paint robots and other peripheral equipment. The MHP45L can streamline automated paint line layouts by eliminating the need for dedicated part transfer. Highly reliable, the MHP45L offers a 45 kilogram payload capacity, as well as high moment and inertia ratings, for accommodating large, heavy workpieces such as automotive bodies and components.

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IMD 45

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IMD 49

Ad INdex Accudyne Products USA — www.ezpullerusa.com .........................................................................43 Actek Manufacturing and Engineering Inc. — www.actekmfg.com ............................................ 31 ADB Hoist Rings Mfg. — www.adbhoistrings.com ........................................................................... 23 AIR-VAC Systems — www.air-vacsystems.com ............................................................................... 37

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Allied Machine & Engineering — www.alliedmachine.com ........................................................... 27 AmCon Design & Contract Manufacturing Expo — www.amconshows.com ..........................44

YEARS YEARS

ATTCO, Inc. DBA Syclone ATTCO Service — www.skyhookmfr.com ........................................... 5 Attica Hydraulic Exchange — www.ahx1.com .................................................................................... 9 Betenbender Manufacturing, Inc — www.betenbender.com ....................................................... 13 Carell Corporation — www.carellcorp.com ........................................................................................ 7 Clamprite — www.clamprite.com .......................................................................................................38 Cosen Saws, USA — www.cosensaws.com ........................................................................................ 3 Denver Breaker & Supply — www.denverbreaker.com .................................................................. 47 Design-2-Part Shows — www.d2p.com ............................................................................................45 DHM Associates, Inc. — www.dhmassociates.com ........................................................................49 Dynabrade, Inc. — www.dynabrade.com ..........................................................................................FC Eagle Bending Machines — www.eaglebendingmachines.com ..................................................... 7 ENM Co — www.enmco.com ..............................................................................................................49 Essex Structural Steel Co. — www.essexstructuralsteel.com ........................................................ 47 Formdrill USA Inc. — www.formdrill-usa.com ................................................................................. 35 H&K Equipment, Inc. — www.hkequipment.com ............................................................................48 HMI div of Betenbender Manufacturing — www.betenbender.com ........................................... 41 IMDauctions.com — www.IMDauctions.com ..................................................................... 47, 49, 51

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Kanetec USA Corp — www.kanetec.com ..........................................................................................48 L&L Special Furnace Co., Inc. — www.llfurnace.com .....................................................................49 MacMillin Hydraulic Engineering Corporation — www.macmhydraulic.com ...........................42 Morgan Manufacturing, Inc. — www.MorganMfg.com ..................................................................49 Pro-Line — www.1proline.com ............................................................................................................49 Radwell International, Inc. — www.Radwell.com .......................................................................... IFC RAS Machine Tool Technologies Inc. — www.rasmachinetool.com ...........................................39 Royal Products — www.mistcollectors.com .....................................................................................49 Scotchman Industries, Inc. — www.scotchman.com ..................................................................... 15 Select Equipment Company — www.selectequipment.net ..........................................................46 Sprinter Marking, Inc. — www.sprintermarking.com ......................................................................40 Standard Direct.com — www.Standard-Direct.com .......................................................................48 Stor-Loc — www.storloc.com ......................................................................................................19, BC Tormach — www.tormach.com ...........................................................................................................17 Trim-Lok — www.trimlok.com ............................................................................................................. 33 US Shop Tools — www.usshoptools.com ..........................................................................................11

50 IMD DECEMBER 2020 IMDdirectory-TV-042020.indd 1

3/23/20 4:36 PM

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Industrial Machinery Digest - December 2020

Articles inside

PROCESS

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INDUSTRY NEWS

TALKING SHOP

INDUSTRY INSIGHTS

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BUSINESS 4.0