Industrial Machinery Digest Quarterly - IMD Quarter 4, 2021 by Industrial Machinery Digest

Quarter 4, 2021

IndustrialMachineryDigest.com

MANUFACTURERS DEMAND AUTOMATED SOLUTIONS Also this Quarter

Cobots Improve Productivity and Labor Utilization Automation in Manufacturing and Machine-Assisted Workforce The Path Towards Digitalization and The Future

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Table of Contents

22 16

FEATURES

16 22

WORKFORCE DEVELOPMENT NEW TECHNOLOGY

Manufacturers Demand Automated Solutions

26 PROCESS 30

DEPARTMENTS

Cobots Improve Productivity and Labor Utilization

All Storage Areas at a Glance With a Single Click

INDUSTRY INSIGHTS

The Path Towards Digitalization and The Future By: Brian McMinn, Head of the Machine Tool Business, Siemens Industry, Inc.

6 FROM THE EDITOR 32 PRODUCT SHOWCASE 44 BUYERS GUIDE 54 SURPLUS BUYING AND SELLING 63 CLASSIFIEDS 64 ADVERTISER INDEX

COLUMNS

8 12 54

BUSINESS 4.0 Automation in Manufacturing and Machine-Assisted Workforce

SAFETY & MAINTENANCE CNC Machining: Problem Solving Spindle Repair Shops Boost the Bottom Line

SURPLUS BUYING & SELLING: The Science of Diffusion Bonding or Joining together Dissimilar Metals

ON THE COVER

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From the Editor $1.48 billon – that’s the total, thus far for 2021, of sales of automation technology according to the Association for Advancing Automation (A3). This year has seen the third highest quarter in units ordered, with nearly 10,000 robots ordered just last quarter. While the auto industry has always been ahead of the curve in terms of automation, the report indicated that 6,302 of those orders came from non-automotive industries. Our team here at Industrial Machinery Digest, has not been overly surprised by these statistics. Nearly every industry is trying to keep pace with recovery. While there are still some concerns with the latest reports of COVID variants, most have spent this year preparing and updating their facilities. Automation has practically become a necessity that has often provided a safer, more productive, workspace. Most recognize the fact that robots and other automated technologies are not here to simply replace jobs. The goal should always be to work smarter, not harder. What is holding some manufacturers from making the initial plunge into the world of automation? Lack of knowledge remains a key point. Many still assume that you need an automation expert on staff, ready to install, program, and set-up a sophisticated piece of hardware. That may be true for large scale automotive OEM or tier suppliers, but not so for the small-to-medium job shop. The impact automation can provide can, in some cases, be measured on the first day of deployment. Furthermore, most smaller operations have access to turn-key solutions from each of the major robot manufacturers to meet the needs for part placement, logistics, finishing, and even welding. For repetitive, fatigue-inducing, or even dangerous tasks, automation allows your business to redistribute your top talent to other needs. This has been a key point in bridging the skills gap over the last few years. Yet, as technology moves from hard-coded terminals or proprietary computer systems, the ability to program and monitor from one’s own mobile device has cut the barrier of entry even further, thanks to technology we put into use every day. While robots and automation were once something out of science fiction, their integration into how we work cannot be understated. Clearly, with nearly 29,000 units ordered this year, North America is ready to automate. Stay safe out there,

Nick Boliek

SERVING AMERICAN MANUFACTURERS FOR OVER

35 YEARS

William C. Strickland III, Publisher william.strickland@indmacdig.com 800-366-0676 ext. 103 | Fax: 866-826-5918

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Shane Bell, Creative Director sbell@indmacdig.com

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INDUSTRIAL MACHINERY DIGEST (ISSN 1542-5223) is published 12x per year by Source 360 Media. POSTMASTER: Please send change of address to INDUSTRIAL MACHINERY DIGEST, 3590-B US Hwy 31 South, PMB 233, Pelham, AL 35124. Printed in the U.S.A. SUBSCRIPTION POLICY: Individual subscriptions are available without charge in the U.S. to qualified individuals. Publisher reserves the right to reject nonqualified subscribers. Oneyear subscription to nonqualified individuals in the United States: $9600. Single copies available (prepaid only) $2000 each.

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Business 4.0

Automation in Manufacturing and Machine-Assisted Workforce

utomation technology contributes to manufacturing in both controlled and uncontrolled environments where automation equipment is used to boost safety and productivity. In the coming years, automation will advance at a rapid pace. Automating the work environment is increasing the value of skilled labor that has been adversely affected by outsourcing.

programming pendants. Robots can operate in an environment that is understood and interacted with through the use of advanced sensors. Automated manufacturing environments are able to operate around the clock due to improved designs that require less maintenance.

Types of Automation Used In Manufacturing? Automated Manufacturing: What Is It? The manufacturing industry is undergoing another change today: automated manufacturing. Performing repetitive, precision-required tasks for an extended period of time becomes increasingly difficult for people. Automating the manufacturing process helps to improve safety and efficiency. The advancement of technological advancements has made it possible to write detailed instructions for robots thanks to intuitive

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In manufacturing, there are three types of automation:

FIXED AUTOMATION Automated manufacturing involves assembling purpose-made machinery, as the name implies. When it comes to designing the machine, engineers rely on gears, cams, and other hardware instead of computers and chips. The manufacturer may need to change the machine substantially if they wish to accomplish a different

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task. High-volume facilities with seldom-changing processes and products are more likely to benefit from fixed automation.

PROGRAMMABLE AUTOMATION It is a more flexible method of automation, allowing batches to be created with custom instructions. Manufacturers make use of computers to program their machinery to perform a broader range of tasks, rather than relying on purpose-built machines. A reconfiguration of the systems occurs between batches. Because of its ability to reduce the need for reprogramming, this kind of automation is well suited for manufacturers who need to produce large quantities of similar products.

In addition to reducing workplace injuries, industrial robots work alongside humans. The cobots enable manufacturers to make use of the best aspects of both human and robotic workers; human workers contribute creative problem-solving skills, mental flexibility, and real-world knowledge, while robotic workers contribute repeatability, accuracy, and 24/7 productivity.

FLEXIBLE AUTOMATION

2. Improving Workplace Safety In Challenging Environments In comparison to other industries, construction has the most fatal workplace injuries. It is becoming increasingly possible to offload high-risk tasks to robots. By using robots, construction companies can free their workers from labor-intensive operations like high-pressure presses and heavy drills and focus them on more valuable tasks.

Manufacturing companies can create multiple products with industrial robots by using flexible automation, eliminating the need to shut down production to reprogram the machines. The program is modified or loaded on-demand using a remote terminal. Robots can execute multiple steps before an item moves to the next phase, allowing a robot to take on a number of complex tasks. Also, Cobots expand this flexibility with their small footprints and mobility.

3. Increased Production Capacity Labor laws and certain human limitations limit workers' ability to work. In contrast, a machine can work continuously without stopping, changing shifts, or even interacting with a human. As a matter of fact, it improves the quality of the products produced. System automation makes it possible for computers to operate continuously throughout the day without human input.

Benefits Of Automation In Manufacturing Automating production enables manufacturers to increase precision, consistency, and productivity. You can align with a solution more easily if you know what your goals are. It's important to learn what affects production if your goal is to increase production. Connecting production lines and serving other benefits will be easier and faster with sensors and devices that monitor equipment and produce user-friendly data, graphics, etc. 1. Industrial Robots Improving Workplace Environments Technologists once predicted that the world today would be almost entirely automated, with humans performing little work. Not today, nor tomorrow, but perhaps someday. Our workforce still plays an important role in the design and manufacture of the products we rely on today.

4. Reduction in Employee Costs It's a myth that automated systems are extremely costly. The machines will cost a bit of money to set up, but once operational, the day-to-day working process will be streamlined, independent, and stress-free. Afterward, you won't need workers to take care of the work. It is much better to invest once in the machines than to work with tentative employees for months. 5. Automating the World Will Make it Better Automated systems can not only maximize their efficiency, quality, and productivity but also keep employees focused on important problems rather than menial ones because they're equipped with sensors and high-tech components.

Future of Automation It is expected that robotics and automation will carry on as usual in manufacturing in the future. A recent prediction predicted that 60% of occupations will convert 30% of their tasks to automation in the next few decades. Furthermore, artificial intelligence will likely enable machines to perform previously human-only tasks - creating human-like automation. In addition to manufacturing, this change will affect other industries as well. In addition to healthcare, package delivery and transportation are among the industries predicted to move toward automation. Manufacturing will likely lead the way to technological advancement along with them. Looking for the latest in automation solutions? Be sure to subscribe to IMD’s eNewsletters: www.industrialmachinerydigest.com/subscribe-enewsletters

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Safety & Maintenance

CNC Machining: Problem Solving Spindle Repair Shops Boost the Bottom Line

Working with an expert partner that goes beyond mere part replacement can optimize the machining process, cost-effectively improving quality and production

ith CNC machine tool spindles essential to any drilling, milling, boring, grinding, routing, cutting, or sawing process, many manufacturers and machine shops rely on rebuilders to get production back online as quickly as possible when problems arise, and replacement is required. However, rebuilding a spindle is not always as simple as shipping off a problematic unit to have its parts replaced. Every industry and shop floor has specific even unique factors that involve the materials machined, cut depths, required speeds, volumes, and precision for a range of applications. Failing to take these factors into account can lead to a host of unresolved issues that can degrade quality, consistency, and productivity. At times the problems can be subtle such as intermittent variability or a faint sound indicating an issue that even a routine rebuild will not sufficiently resolve. Sometimes the problem can be serious and immediate. That is when additional expertise is required. To cost-effectively ensure superior outcomes for challenges the best spindle repair shops will provide a true problem-solving approach. This includes understanding all requirements of the application, consulting with the machine shop operators, and even utilizing some expert detective work.

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“The goal is to machine high precision parts as soon as possible at the facilities I oversee. Because our operators run spindles at very high speeds, very fast I need to be a problem solver and want to work with [spindle rebuilder and] repair shops that can problem solve, says Eduardo Flores, maintenance manager at GAMMA Aerospace, a specialized, end-to-end provider of engineered airframe and flight components for leading original equipment manufacturers and Tier I suppliers in the aerospace and defense industries.

Problem Solving Boosts Profitability GAMMA Aerospace’s facilities in Mansfield, Texas; Gardena and Los Angeles, California; and Mexicali, Mexico manufacture a diverse offering of components utilizing advanced, in-house special processes that encompass machining, forming, assembly and wet chemical special processing. As the maintenance manager of two facilities, Flores oversees the use of about 50 CNC machines in Gardena and about 35 in Mexicali. His role is to keep the facilities efficiently running and involves ordering parts, troubleshooting, and problem solving. According to Flores, optimizing spindle reliability including repairs and rebuilds is the “bread and butter of the business” even when using softer metals like aluminum.

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While diligently following preventative maintenance schedules for the CNC machines, Flores seeks expert help when concerns emerge. “Once the spindle starts giving us individual problems that is something I do not specialize in – so I consult with experts because I cannot fix everything despite my best efforts,” says Flores. According to Flores, one specific brand of CNC machine had a unique situation where the spindles on a couple of units lost orientation. “This was something we didn’t hear and didn’t see on the controller. We just saw the result when it was trying to do an automatic tool change. With the wrong orientation the automatic tool changer would jam,” says Flores. “The spindle certainly wasn’t bad; it was spinning correctly. It was just flipping on the orientation and was an OEM defect.” According to Flores, neither reaching out to the spindle manufacturer or the CNC machine OEM was helpful. Instead, Flores turned to MZI Precision of Huntington Beach, Calif., an experienced machine tool spindle rebuilder. He consulted with Ed Zitney, President of MZI Precision who has about three decades of industry experience. “When I consulted with Ed, he came over, observed the machine and saw that it was slipping. He took the spindle and created a retrofit for it,” says Flores.

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Zitney explains that in these cases, the spindle would lose its location in reference to the tool changer, which is typically a proximity switch issue. “We tested the proximity sensor, examined the location settings, the gap, and looked for any damage on the spindle’s pickup diameter or on the sensor,” he says. “We discovered that all the proximity components were in good working order, but that on this particular model of spindle the compression rings were not capable of holding the coupling 100% in place. It would turn slightly, causing the machine controls to see a loss of positioning,” says Zitney. Utilizing all OEM components, MZI Precision engineered four special pins that would locate and lock the coupling in place. This eliminated the movement and solved the issue of the machine faulting out because of the lost position. According to Flores, the retrofit quickly and cost-effectively resolved the spindle problem, facilitating tool changes. “The engineered pins lock the spindle in place. It does not slip and lose its orientation, so tool changes are easy,” says Flores. He points out the significant impact to production and the bottom line. “Purchasing a new spindle would have cost us ten thousand dollars plus about a thousand dollars to expedite it air freight from Taiwan and

may not have solved the problem because it was an OEM design issue,” says Flores. “For the same reason, a rebuild alone probably would not have resolved it. Working with an expert [MZI Precision] we ended up saving thousands of dollars per machine for a critical retrofit that will help us keep six CNC machines reliably operating going forward.”

Solving a Mystery While CNC machining is all about high precision and high production, sometimes when the unexpected occurs with equipment it can take the problem-solving mindset of a detective to track down the culprit and put things right. “We cannot afford to have a CNC machine not producing with unscheduled downtime,” says Jon Welci, Production Manager at a Southern California production site of Lexani Wheel Corp, a global manufacturer of custom luxury wheels. According to Welci he currently oversees about 15 CNC machines in his shop, and most are relatively new. When MZI Precision rebuilt the spindle of an older machine to OEM specification, however, within a few days after installation the grease had mysteriously washed out of the bearings, posing a performance hazard. When MZI Precision investigated onsite its technicians found that the vertical milling spindle was driven by a gearbox filled with oil, and oil from the gearbox had overflowed into the top end of the spindle. “The spindle design did not have a proper seal to restrict the oil from entering the spindle, so the oil displaced the bearing grease. The bearings ran very hot in the oil and would burn up very quickly,” explains Zitney. According to Zitney, the fix was to engineer and manufacture a new top end cover/slinger. This new part covers the top end of the spindle and rotates with the spindle when running, preventing oil from entering the spindle’s top. For even greater reliability and performance, Welci ‘s shop upgraded to ceramic hybrid bearings in the spindle at MZI Precision’s recommendation. With the engineered changes and the upgraded bearings the problem is solved. In fact, the spindle is actually far better outfitted for reliable performance than the OEM supplied unit. “The CNC machine now works great. The increased reliability and performance make a big difference in our business,” concludes Welci.

When manufacturers and machine shops attempt to achieve a little more production uptime, precision and performance from their equipment, relying on a partner with deep spindle expertise can be the difference that truly increases their competitiveness and profitability. For more information: Call (714) 475-4016; email:info@mziprecision.com; visit mziprecision.com; write to:MZI Precision at 5572 Buckingham Drive, Huntington Beach, CA 92649. INDUSTRIAL MACHINERY DIGEST.COM

IMD | 15

Workforce Development

Operator dumps parts into randomized bins and moves to another process, giving ActiNav system about two hours’ worth of work without employee intervention.

Cobots Improve Productivity and Labor Utilization

By picking parts from unstructured bins, the ActiNav system reduced assembly line labor requirements from four operators to three, for an immediate annual savings of $150,000 and a seven percent boost in productivity

n Cheraw, South Carolina, two Schaeffler Group USA factories have been producing high-precision engine components and industrial products for North American markets for more than 50 years. While Schaeffler’s production facilities are already highly automated, Marty Parker, Director of Special Machinery, Americas, is always looking for ways to make production processes more autonomous and less dependent on manual labor. But Parker also notes that, “A lot of the low-hanging fruit’s been wiped out over the years, so now it’s a little more complicated.” Schaeffler’s special machinery group, called Sondermaschinenbau (SMB), supports the company’s global production facilities with special equipment and projects to extend automation and improve labor utilization and productivity.

16 | IMD | Q4 2021

One of the complex holdouts in terms of automation was picking complex-geometry components jumbled together in bins, then placing the components in precise orientation on an automated conveyor for assembly. SMB turned to the Universal Robots (UR) ActiNav machine tending kit to handle this challenging task that couldn’t be cost-effectively automated—until now. The end result is improved labor utilization and productivity on previously manual lines.

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ActiNav’s 3D sensor above the robot scans the bin so the system can calculate appropriate picks for the UR5e cobot, which then accurately places the part on the conveyor based on its orientation.

emissions in internal combustion engines. Four operators used to oversee and feed these lines, ensuring that the complex geometries of the component were accurately oriented for the next process. Because these lines are far from other equipment, workers couldn’t easily be utilized in other areas, and if they left the line for breaks or other reasons, production halted. Like many manufacturers, Schaeffler found it difficult to hire and retain employees for these repetitive manufacturing operations. Mike Reed, VCT Production Leader explains that, “This project came about because we needed to increase our output on the machine and somehow create more of an efficiency on the line. The eight hours a day of having to do that one job can be very cumbersome and very boring to say the least.” By automating the repetitive process, Schaeffler can reduce downtime and lost production and is able to reallocate an operator to other processes.

Quickly Accomplishes What Other Automated Bin Picking Systems Could Not Automating the machine loading on the VCT line initially proved challenging as explained by Bruno Waldmann, SMB Mechanical Design Group Leader. The component is produced by an outside supplier and delivered in bulk. Having those parts delivered in oriented trays for traditional automated machine tending would have added too much cost to the components, plus the additional costs of returning empty trays to offshore vendors to be restocked. Waldmann and his team had tried multiple times over several years to automate this process, with no success. They discovered

18 | IMD | Q4 2021

ActiNav at a trade show and quickly reached out to CIMTEC Automation, a Universal Robots distributor. Within days, ActiNav was demonstrating successful picking and placing of Schaeffler’s components. A key advantage of the ActiNav system is its ability to autonomously pick parts that are randomly oriented in a bin and accurately place them.

Actinav Accurately Orients Outsourced Components for Machine Loading Within Defined Cycle Time On the new ActiNav station, an operator now simply dumps components into multiple bins and then moves to another process. This gives the system about two hours’ worth of work without an employee needed. ActiNav’s 3D sensor scans the bin so the system can calculate appropriate picks for the UR cobot, which then places the part based on its orientation. If the part is face up, the robot places it directly on the conveyor. If the part is face down, the robot places it in a reorientation station, where it is flipped so the robot can repick it and place it accurately on the conveyor. Once the parts are placed, the conveyor transfers the parts to the next cell. If there are no more parts to be picked from the bin, the system triggers the UR5e robot to initiate a bin-change sequence so it can continue to pick from the next bin, with no operator intervention needed. One challenge for this application was the ability to meet the 12-second cycle time requirement for the assembly process. “When we started to research this project, we were looking for some regularity, something that can meet the cycle time,” Waldmann says. “That was the most important thing, but precision is also

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important, because it’s not only to drop the parts; we need to place them in an exact location. The ActiNav system met all these requirements easily. We are under the target, so there is not a bottleneck on the line and everybody is happy.”

Measurable Results In Just Three Months The ActiNav system delivered immediate results by reducing labor requirements from four operators on the VCT line to three, with the freed-up operator being moved to higher-precision tasks on another line. That’s provided an immediate annual savings of $150,000, which leads to a return on investment (ROI) of less than a year. By automating the process, Schaeffler has eliminated downtime and labor underutilization and boosted overall equipment effectiveness (OEE) on the line, with production efficiency improving Robot Flipping part.jpg: If the part picked is not oriented correctly from the bin, the robot automatically places by seven percent. it in a reorientation station, where it is flipped so the robot can repick it and place it accurately on the conveyor. The operator experience has been positive as well. computerization and digitalization are very easy for most of them, Production leader Reed says, “They love it. They enjoy seeing the and it makes it more enjoyable to be at work.” system work efficiently and working well, and actually seeing their Set-up operator Tim Jones agrees. “I don’t have to play babysitter numbers increase. Anything that’s going to simplify an employee’s to that station anymore; I can put two hours’ worth of parts on the job is going to really increase morale, because it takes one more line, and just walk away. I don’t have to constantly look if there’s step off their shoulders.” Employees were also given basic robotics an operator there, doing their job. It’s freed me up to pay more training so that they could do any minor troubleshooting needed. attention to some of the other stations on the machine.” “It’s a fairly simple tool for them to use,” adds Reed. “Electronics and

About ActiNav Universal Robots' award-winning ActiNav is a flexible, easy-to-use, machine-loading solution that synchronously handles vision processing, collision-free motion planning, bin picking and autonomous real-time robot control. The kit consists of: » Autonomous Motion Module » 3D sensor (placed above bin) » ActiNav user interface » Alignment marker » All cables, screws, and brackets » Universal Robots e-Series cobot (UR5e, UR10e or UR16e) ActiNav is part of the Universal Robots UR+ Application Kit portfolio that decreases project risk and complexity. The kits contain software and hardware components for the most popular cobot applications and are certified to work seamlessly with UR cobots. For more information, visit www.universal-robots.com/actinav/

20 | IMD | Q4 2021

Aman Bhave, Schaeffler mechanical design engineer, came into the project with limited robotics experience, but was able to integrate the ActiNav system due to its straightforward, hands-on programming.

UR Academy Speeds Integration, Even With Limited Robotics Experience Aman Bhave, Mechanical Design Engineer in SMB, came into the project with limited programming experience, but found the online UR Academy tutorials to be instrumental in his success. UR Academy’s free, certified training modules range from beginner to professional level robot programming. “I was a bit skeptical that I could get this system running within a few months,” Bhave says. “But as I started looking at the tutorials of this, and started working with the system, I realized that it wasn’t that complicated and people with less experience can easily follow the steps and integrate the process.” Before starting the system, Bhave went through all the tutorials and then installed the free URSim offline simulator on his laptop. That allowed him to have offline programming and simulation software on one screen and the steps of the appropriate tutorial on another. He says, “Being one of our first projects with Universal Robots and our first bin picking application, we expected that the system would be quite difficult to integrate, but once we started working with it, we realized that the steps involved are not too complicated.”

SMB Depends On Collaborative Development And Support For Long-Term Success The UR5e powering the ActiNav system joins dozens of other UR cobots in Schaeffler facilities around the world. SMB specifically looks to cobots from Universal Robots to help them meet customer needs, with ease of integration high on their list of requirements. Parker explains, “We have certain standards that we use for robotics, but our standard robotics companies didn’t have as many tools in their arsenal as UR did, and we felt like UR could cover the whole gamut.”

The versatility of UR cobots provides additional advantages. “We want to try to use modularity as much as possible,” Parker explains. “We don’t want to keep introducing learning curves, so if we can find one best-fit solution, that helps us with many different applications.” He and his team within SMB are looking to integrate the ActiNav bin picking application in other assembly processes, while also looking for additional opportunities that production customers may not think of. In both the development and implementation process, SMB depends on the strong collaboration and support from UR. “We don’t do any mass producing,” says Parker. “Everything we do is very custom, and so we’re the last line of defense. If we have someone that we can partner with to help us when we have a problem, or our customers have a problem, that’s really big for us.” The UR ActiNav team’s ongoing support helped resolve any issues that came up during the development of this system. With extensive experience in bin picking applications, UR was able to suggest improvements such as changing the cable management system to allow the free movements of all the joints during randomized bin-picking and avoid unexpected protective stops. Another improvement was changing the gripper angle to get more pickable points for the system and empty more parts from the bin. “What was most important for us was to find a system that was developed, that was working, and that we would not have to invest so many hours in to get it off the ground,” says Parker. “We can take this and plug it in somewhere else. Because this system has worked so well, it’s made me very optimistic about using it into other stations in other areas.” For more information, visit www.universal-robots.com INDUSTRIAL MACHINERY DIGEST.COM

IMD | 21

New Technology

Manufacturers Demand Automated Solutions

BB is expanding its range of SCARA robots with the launch of the IRB 920T. Designed to meet the re-quirements of the electronics industry for high-speed production in increasingly complex manufactur-ing processes, the IRB 920T provides the highest levels of speed, accuracy and repeatability for assem-bly, picking and handling tasks. “The need for companies to respond quickly to changing consumer demands is making SCARA robots a popular choice for production lines where fast and accurate performance is key to ensuring maximum product quality,” said Antti Matinlauri, Head of Product Management for ABB Robotics. “Together with ABB’s OmniCore controller, the IRB 920T is part of a new generation of robotic solutions from ABB that help manufacturers stay one step ahead of changing market demands.” With a cycle time of 0.29 seconds, the IRB 920T is faster than other SCARA robots in its class and up to 14 percent faster than ABB’s current IRB 910SC SCARA robot, enabling more products to be produced per hour. With a maximum payload of 6kg and available in a choice of variants offering reaches of 450, 550 and 650mm, it can be installed throughout production lines to handle a variety of

22 | IMD | Q4 2021

items, from sin-gle components through to assembled products. Key to the performance of the IRB 920T is its excellent repeatability. Offering class-leading consistency, the IRB 920T can work quickly without the risk of errors, making it possible to achieve the highest levels of manufacturing quality with minimal or zero wastage. This flexibility is further supported by its lightweight and space-saving design. Weighing just 24kg, the IRB 920T is 10 percent lighter than other SCARA robots in its class, reducing cell design costs by eliminating the need for extra materials to support the robot. With all cables routed internally to remove cable interference, it also offers a com-pact footprint, enabling optimization of available production space.

Flexloader M Family Brings the Power of Modularity to Machine Tending ABB has launched a new family of modular machine tending application cells for the metals industry aimed at maximizing flexibility and machine utilization while minimizing lost productivity caused by unforeseen production stoppages. Featuring six different versions, the FlexLoader™ M family offers a variety of ways of

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loading and unloading machines based on the size, shapes and amount of the workpieces being handled, making it ideal for applications such as foundries and die casting operations producing multiple types of products in varying quantities. “As customers demand greater variety and shorter delivery times, metals producers need to have a manufacturing process that can respond quickly and offer the flexibility to achieve high mix, low volume and batch size one production,” says Andrea Cassoni, Managing Director for business line General Industry for ABB Robotics. “FlexLoader M is accelerating this move by providing a single unified machine tool tending platform offering the flexibility needed for handling a wide variety of production demands, whilst also improving productivity by eliminating the time, cost and disruption traditionally associated with production changes.” The launch starts with Tray and Conveyor variants, with further variants due for release over the coming months. The FlexLoader M Conveyor uses a simple but powerful vision system to enable easy loading of workpieces with complex shapes, providing the flexibility to handle a variety of workpieces with a single cell. The FlexLoader M Tray is a drawer solution offering easy machine tending. With a minimal footprint that allows it to be located almost anywhere, it is ideal for handling a variety of workpieces with variable shapes such as cubes, cylinders, plates and pipes. Featuring standardized interchangeable modules, the FlexLoader M offers a flexible and expandable solution for a wide variety of machine tending applications including lathes, mills, CNC and

machining centers. A key benefit is the ability to use the same base machine, exchanging in and out feed modules as requirements change. The FlexLoader M’s modular approach makes upgrading and scaling up easy, with just one to two days needed on average for installation and commissioning. The FlexLoader M meets the demand from manufacturers for a simple automated solution that produces more workpieces in less time. The FlexLoader M robot cells are extremely user friendly and quick to program, even without specific robotics expertise. A smart wizard enables new workpieces to be programmed in less than five minutes with no vision programming expertise required, while changeover between pieces which are already programmed is possible in less than one minute, making “Batch Size One” production a reality. The simplicity of the programming software means that full operator training can be completed in less than half a day, further reducing the time needed to put the cell into operation. The FlexLoader M can reduce labour costs for machine tending processes by up to 90 percent, with one operator able to handle up to 10 cells simultaneously. The automated system delivers machine utilization of over 97 percent, compared to 40-60 percent in manually operated machines. All the variants can be equipped with a vision system that identifies the workpiece’s position and gives commands to the robot, machine tools and other cell equipment such as air cleaning stations, part marking, deburring and measurement systems. The vision system can use either a 2D camera or 3D sensor depending on the application.

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IMD | 23

The FlexLoader M also incorporates data-based optimization features, including remote monitoring, enabling operators to monitor, troubleshoot and optimize their robot systems, while its vision software provides added functions including condition monitoring, fleet management and performance and order management. The FlexLoader M will replace ABB’s current family of FlexLoader cells, which have established a reputation for providing reliable and predictable output. Delivering benefits including higher machine tool utilization and the opportunity for lights out production through unmanned operation, FlexLoader cells have proven their ability to deliver a much faster return on investment whilst giving users a sustainable competitive advantage.

Driving Next Generation Autonomous Mobile Robots ABB is entering into a strategic partnership with Swiss-based start-up Sevensense, founded in 2018 as a spin-off from ETH Zurich, to enhance ABB’s new autonomous mobile robotics (AMR) offering with artificial intelligence (AI) and 3D vision mapping technology. The technology will offer customers unprecedented levels of flexibility as mobile robots will be able to navigate autonomously in complex, dynamic indoor and outdoor environments close to people. The partnership is another important step in ABB’s strategy to drive the

24 | IMD | Q4 2021

next generation of flexible automation and expand ABB’s robotics and automation portfolio, following its acquisition of ASTI Mobile Robotics, a leading global AMR manufacturer, announced in July 2021. The partnership includes a minority investment in Sevensense through ABB’s venture capital unit, ABB Technology Ventures, which is expected to close by the end of November 2021. “Building on our acquisition of ASTI Mobile Robotics earlier this year, our partnership with Sevensense is another milestone in our efforts to fully unlock flexible automation for our customers,” said Sami Atiya, President of ABB Robotics & Discrete Automation. "Integrating Sevensense’s AI and 3D mapping technology with our AMR offering will help accelerate the replacement of today’s linear production lines with fully flexible networks. Our vision of the future workplace is one in which AMRs move materials, parts and finished products between smart workstations in increasingly unstructured, dynamic work environments and our partnership with Sevensense is an important step in realizing that vision.” The Sevensense navigation technology uses advanced computer vision and AI algorithms to create a 3D map that is more accurate than today’s 2D solutions, leading to superior navigation capabilities, and more cost-effective solutions than laser scanner-based navigation. An AMR equipped with 3D Simultaneous Localization and Mapping (SLAM) technology will be able to accurately interpret its environment, identify a person, a pallet or another robot and autonomously make decisions to navigate around these obstacles. This level of intelligence will enable safer humanmachine interactions and ensure material flows around factories and warehouses are safe and efficient for maximum flexibility and productivity. Gregory Hitz, CEO of Sevensense Robotics, said: “This is a

great step for us, coming at the right time. Partnering with ABB lays the foundation for a long-term collaboration, while retaining our complete independence as a business. It allows us to mutually benefit from our expertise and create the best product for all of our customers in the long run. At the same time, the investment by ABB gives us planning security. We are very much looking forward to lifting our technology to a global scale and establishing Sevensense at the top of AI supported vision and navigation companies globally.” ABB will integrate Sevensense’s soft- and hardware technology into ABB’s AMR offering, with pilot customer projects planned in 2022. Sevensense was selected to partner with ABB Robotics after participating in the 2021 ABB Robotics Innovation Challenge, which evaluated the performance of a range of Visual SLAM solutions from multiple global technology businesses.

ABOUT ABB ROBOTICS & DISCRETE AUTOMATION: ABB Robotics & Discrete Automation is a pioneer in robotics, machine automation and digital services, providing innovative solutions for a diverse range of industries, from automotive to electronics to logis-tics. As one of the world’s leading robotics and machine automation suppliers, we have shipped more than 500,000 robot solutions. We help our customers of all sizes to increase productivity, flexibility and simplicity and to improve output quality. We support their transition towards the connected and collaborative factory of the future. ABB Robotics & Discrete Automation employs more than 11,000 peo-ple at over 100 locations in more than 53 countries. For more information, visit go.abb/robotics

ABOUT ABB: ABOUT SEVENSENSE ROBOTICS ABB (ABBN: SIX Swiss Ex) is a leading global technology company that energizes the transformation of society and industry to achieve

Sevensense Robotics was founded in 2018 as a spin-off from ETH Zurich

a more productive, sustainable future. By connecting software to its

and received early support from Wyss Zurich. Headquartered in Zurich

electrification, robotics, automation and motion portfolio, ABB pushes

and ETHZ Foundation, Switzerland, Sevensense employs 25 people

the boundaries of technology to drive performance to new levels. With a

and offers industry-grade 3D SLAM based localization and navigation

history of excellence stretching back more than 130 years, ABB’s success

solutions for all kinds of autonomous service machines, from forklifts to

is driven by about 105,000 talented employees in over 100 countries.

professional cleaning machines.

For more information, visit www.abb.com Modex 8in x 4.75in Ad Amanda.pdf

For more information, visit www.sevensense.ai

13/02/2020

17:33

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IMD | 25

Process

All Storage Areas at a Glance With a Single Click

anage and operate automatic and manual storage areas with a single system – at SchwarzwaldEisen, located in Lahr, Baden, this is reality. Two KASTO solutions make this possible: The warehouse management system, KASTOlogic, and the intelligent app, KASTOlogic mobile. These two solutions allow the steel distributor to simplify and accelerate its processes, minimise the error rate and track all batches seamlessly. "We love steel": With this motto, Schwarzwald-Eisenhandel GmbH & Co.KG – abbreviated as SchwarzwaldEisen – has evolved into the leading steel distributor in Baden, Germany. The roots of the fourth-generation family-operated company date back to 1870. Since 1966, the headquarters is located in Lahr; SchwarzwaldEisen has other facilities in Freiburg in Breisgau, Bad Säckingen and Karlsruhe. With subsidiaries in Baden-Württemberg, RhinelandPalatinate and Switzerland, the specialist is active at a cross-regional level and continues to expand with new locations. The group turns over approx. 120,000 tonnes of material per year.

26 | IMD | Q4 2021

"We focus firmly on organic growth and a decentralised organisation," explains Dr Steffen Marco Auer, who manages the activities of SchwarzwaldEisen together with his brother Ingo Auer and Alexander Hatt as the Managing Directors. "Instead of operating one major facility, we have several regionally active sites that are close to the customer, enabling fast and flexible deliveries." Efficient communication between the individual regional locations and well-organised logistics are essential requirements for the operation of such a network. "That is why we try to structure all subsidiaries according to a similar principle to utilise proven processes, to use technologies across all sites, and to standardise interfaces while keeping them at a minimum," continues Auer.

Preferred Partner for Storage Technology This approach is also evident in the storage technology. SchwarzwaldEisen puts its trust in KASTO Maschinenbau GmbH & Co. KG as the preferred partner in this area. For about eight years

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at the headquarters in Lahr, an automatic bar stock storage system from the UNICOMPACT 3.0 series provides quick and efficient storage and removal of sections, tubes and solid materials, which are up to six metres in length. SchwarzwaldEisen offers its customers a range of goods consisting of around 10,000 products, mainly construction steel, stainless steel, and aluminium. "Approx. 70 to 80 percent of the orders for sectional steel are semi-processed" reported Managing Director, Auer. It is prepared according to the customer specifications using in-house machinery in Freiburg and then dispatched. For bar stock with a length of up to 6 metres, the KASTO system supplies the product needed using an operating gantry crane (OGC) with short access times based on the principle "materials to operator" at one of two removal stations. However, the company stores metal sheets in a separate, manually operated storage area. Steffen Auer outlines the challenges by stating, "Our customers expect us to provide fast, error-free and trackable deliveries". "To ensure this, we depend on a simple, clear and reliable control system for our entire material flow." SchwarzwaldEisen relies on the goods management system (GMS), eNVenta used across all of its sites. The storage system in Lahr is linked to it via an interface created specifically for this purpose – the same

as two other automatic KASTO storage systems in the sites at Karlsruhe and Westerwald. "This ensures a standardised order management and a high level of inventory transparency," explains Auer. The GMS transfers the respective order data electronically to the warehouse management system, KASTOlogic, which then triggers the removal of the required products at the respective site. All processes can be tracked seamlessly, operational and assignment errors can be virtually eliminated.

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IMD | 27

Manual Storage was Prone to Errors In the past, the manually and paper-managed metal sheet warehouses looked quite different recalls Auer: "Due to the broad product range, mix-ups occurred, for example, employees removed the wrong sheets or incorrect quantities – and in the end, the customer did not always receive what was ordered." It was not always easy to locate the required goods in the long rows of shelves. Therefore, those responsible at SchwarzwaldEisen searched for a possibility to integrate these storage areas into the intelligent electronic control system. "To achieve this goal, we compared two competitors, and quickly selected KASTO," stated Auer. This decision was not based solely on the proximity to the specialists for sawing and storage technology with headquarters located just a few kilometres away from Achern. "Of course, it is an advantage to collaborate with partners in the region, who can be onsite quickly if needed," the Managing Director emphasised. "However, KASTO's extensive technical competence and willingness to provide a solution tailored to our particular situation was equally important to us." Together with the steel distributor, the KASTO experts thoroughly assessed the conditions onsite and in the entire company and developed a solution to display all storage areas in a standardised and consistent control system. One of the tools used was KASTOlogic mobile, a platform-independent and mobile version of KASTOlogic. The software makes it possible to use the essential functions of the warehouse management system on mobile devices such as tablets and smartphones – independent from permanently installed operator panels which are available in the automatic storage system, UNICOMPACT. "For instance, with this system, we can flexibly manage the bar stock storage system regardless of the location," Steffen Auer explains. "But more importantly: We are now able to manage our manually operated metal sheet storage with KASTOlogic."

Order and Product Data Always Within Reach Thanks to KASTOlogic mobile, the warehouse employees have access to the order and product data at any time. When removing the sheets, the system directs the user to the respective storage location and specifies the required quantity. The shelves are equipped with QR and barcodes. For instance, when the users scan them with the mobile device, they can confirm the removal or trigger a follow-up order if the inventory is getting low. All information is available both in the warehouse management and the goods management system – customised interfaces make this possible. Auer summarises by saying, "The result is a standardised, controllable, and seamless, transparent material flow." "We have fewer errors when picking the orders, we can work faster and more efficiently, and individual batches can be followed up and tracked seamlessly." With the new warehouse management concept, KASTO proved itself to be both a machine supplier and a solutions provider. "KASTO provided us a customised, software-based system that works completely independently from the existing storage systems and can be scaled for other sites as needed – a remarkable achievement,"

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Auer stated. The concept is impressive in every aspect – so impressive that SchwarzwaldEisen wants to implement it at its other sites as well. "As stated, we try wherever possible, to simplify and standardise processes and avoid unnecessary interfaces," Auer says. "It helps us to become even more efficient and transparent across all sites." If an ordered product is not in stock at a specific facility, it is found in the system quickly and can be delivered to another site when necessary. "Ultimately, we are not the only ones who benefit from this organisation; above all, our customers profit from it – that is the main thing for us," exclaims the Managing Director.

Impressive Service Another benefit of the KASTO system for those responsible at SchwarzwaldEisen is the high degree of availability. "Both the storage system and the control system can be serviced remotely. If needed, KASTO can access the software and clear malfunctions quickly and easily at any time." Thanks to the proximity, the service experts can be onsite at short notice – "an additional bonus that not every manufacturer can provide," Auer finds. In addition to the impressive

technology and the attractive priceperformance ratio, the excellent partnership with KASTO was a pivotal factor to continue along the path embarked on together. "We are extremely satisfied with the collaboration and certain that both companies will reap long-lasting benefits."

ABOUT KASTO: The KASTO Group, based in Achern, Germany (KASTO Maschinenbau GmbH & Co. KG) specialises in sawing and storage technology for bar stock and sheet metal. The company is a global leader in the manufacture and sale of metal-cutting saws and semi-automatic and automatic storage systems for bar stock and sheet metal. It is also a leading manufacturer of automatic handling systems for metal bars, sheet metal and pre-cut parts, as well as the corresponding software. One of Europe’s oldest family-owned

a branch in Schalkau, Thuringia, KASTO has subsidiaries in England,

companies, KASTO celebrated its 175th anniversary in 2019. In the

France, Switzerland, Singapore, China and the USA as well as Sales

course of its successful history it has registered 170 patents, delivered

and Service Partners in many other countries.

more than 140,000 sawing machines to all parts of the world and installed more than 2,200 automatic storage facilities. In addition to

For more information, visit www.kasto.com

INDUSTRIAL MACHINERY DIGEST.COM

IMD | 29

Industry Insight

The Path Towards Digitalization and The Future By: Brian McMinn, Head of the Machine Tool Business, Siemens Industry, Inc.

ig data, Industry 4.0, IIOT, Edge Technology and the Cloud are all terms we know. Whether you’re a machine tool builder, a job shop or contract manufacturer, you’re thinking about digitalization and the best way to get started. For the machine builder, it’s about managing big data from the machine, reducing time-to-market and using the newest technology to create smart machines. These are cognitive computing systems, meaning they can make decisions and solve problems without the help of a human. This is where artificial intelligence (AI) enters the equation, as the machine learns from what it does. In addition, machines must be ready to engage the Internet of Things (IOT) to be successful in the current market. Machine builders still sell on the features and benefits of their machines, but this isn’t the only way to distinguish themselves from the competition. The digital twin concept in machine development allows simulation of a machine tool not only in its design, but also in its physical performance, before the machine is even started physically. With the digital twin, every condition on the machine is simulated in real-time, with feedback to the design loop. That way, engineers don’t need to waste time on the shopfloor or in a test center as they’ve done previously, with the “trial and error” method. The science has developed, so the build process must likewise. CNC machine users need their machines to be smart, as well — communicating with each other and the control center in their shop or in a large production facility. Thinking you can’t implement digitalization because you’re a small machine shop? Think again. Key performance indicators (KPIs) can be established and achieved sooner in terms of production, machine run time, maintenance and even energy use. For CNC users, the digital twin enables a machine shop to be IOT-ready. The higher-end software permits real-time adjustment in-process, everything from cycle time to tool tip position or tool magazine loading for the next jobs, to facilitate both faster startup and precision workflow.

30 | IMD | Q4 2021

This can be achieved with a competent digital team that is both in-tune with the current technology and how to implement it in a particular environment. If needed, take time to find a system integrator in your area (we have a nationwide network of solution partners) that can provide you with relevant technical and industry knowledge. This is vital to your success. Our newest digital-native CNC, SINUMERIK ONE, for example, will open the next chapter in the machine tool world’s journey towards digitalization. It features the latest power and software options to allow expansion, as the job volume increases, or the complexity of the work increases for you. Virtually, it offers the machine builder and end-user total flexibility to move from the CAD to the CAM to the CNC machining steps, then onto the virtual shopfloor and into a virtual production, all before the first cut is made on the machine. As ransomware attacks have become common in the industrial environment, the issue of cybersecurity has taken on new importance. Preventing any attack means taking into consideration several issues. One is the integrity of the network. The other is the effect of the wireless network in the plant and externally. The third, and most important, is how effective the defense is. Like a football game, one wrong move from a player can adversely impact the game plan. Furthermore, there must be several layers of specific security, so that setup, operation and programming, maintenance and plant operations/control personnel all have different defined levels of access to machines and data. This is often a time-consuming, but very worthwhile endeavor. If we look towards the future, what we see is digitalization at essentially every level of your factory. This would include robotic handling and the transfer of materials to the next machine. The “factory of the future” wouldn’t be without people, however. Rather, personnel will take on higher level tasks that don’t involve machining. Cobots and CNC will work with a human or directly with the machine intelligently. Digitalization is here to stay, so get started today!

IMD – The Industry’s Most Extensive Industrial Publication

ABOUT THE AUTHOR:

ABOUT SIEMENS CORPORATION

Brian McMinn is the head of the Machine

Siemens Corporation is a U.S. subsidiary of Siemens AG, a global powerhouse

Tool Business at Siemens Industry,

focusing on the areas of power generation and distribution, intelligent

Inc. He is an electrical engineer with

infrastructure for buildings and distributed energy systems, and automation

25 years in the motion control and

and digitalization in the process and manufacturing industries. Through the

drives business. He has a passion for

separately managed company Siemens Mobility, a leading supplier of smart

the emerging technologies in machine

mobility solutions for rail and road transport, Siemens is shaping the world

automation and control.

market for passenger and freight services. Due to its majority stakes in the publicly listed companies Siemens Healthineers AG and Siemens Gamesa

ABOUT SIEMENS DIGITAL INDUSTRIES (DI)

Renewable Energy, Siemens is also a world-leading supplier of medical technology and digital healthcare services as well as environmentally friendly solutions for onshore and offshore wind power generation. For more

Siemens Digital Industries (DI) is an innovation leader in automation

than 160 years, the company has innovated and invented technologies to

and digitalization. Closely collaborating with partners and customers,

support American industry spanning manufacturing, energy, healthcare and

DI drives the digital transformation in the process and discrete

infrastructure. In fiscal 2018, Siemens USA reported revenue of $23.7 billion,

industries. With its Digital Enterprise portfolio, DI provides companies

including $5.0 billion in exports, and employs approximately 50,000 people

of all sizes with an end-to-end set of products, solutions and

throughout all 50 states and Puerto Rico.

services to integrate and digitalize the entire value chain. Optimized for the specific needs of each industry, DI’s unique portfolio

For more information, please contact:

supports customers to achieve greater productivity and flexibility. DI is constantly adding innovations to its portfolio to integrate

SIEMENS INDUSTRY, INC.

cutting-edge future technologies. Siemens Digital Industries has its global headquarters in Nuremberg, Germany, and has around 75,000

John Meyer – Marketing Communications Manager

employees internationally.

cnc.marketing.us@siemens.com

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IMD | 31

Product Showcase

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

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

Virtually Dust Free Sanding Debuts Under New 3M Xtract™ Brand, Delivering Superior Performance and Enhanced Safety 3M (NYSE: MMM) is reinventing the sandpaper game with the introduction of the 3M Xtract™ Cubitron™ II 710W Net Abrasive Disc which provides twice the life and cut rate, while removing up to 97% of dust particles as it sands metal, wood and composite surfaces. The new product recently hit the market in the US and Canada and is already the talk of the internet as users eager to give it a test-run, have shared demonstrations on platforms like YouTube with fantasti…

ANCA’s Newest Smart Factory Tool, LaserUltra, is 70% Faster Measuring Tools

Beaumont Machine Provides SpaceX Small Hole EDM with Robotic Articulation

ANCA’s LaserUltra allows the measurement of tool geometries to tolerances of 0.002mm without removing the tool from the grinder, saving time in the manufacturing process, and ensuring maximum accuracy in measurement is maintained over large batch grinding. Pat Boland, ANCA Co-Founder said: “The intersection of 5 axis milling machines, advanced CAD/CAM software and advanced profile geometry cutting tools is revolutionizing the Die and Mold and Aerospace machining industries. ANCA’s Laser Ultra tool measurement system…

The new Beaumont small hole machine at SpaceX has a reach of 8’ in diameter and 8’ in height. Beaumont has built equipment as small as a phone booth and as large as this newest SpaceX collaboration. Ed Beaumont further comments, “All our machines are built for production purposes, right here in Southwest Ohio. Our customers demand the uptime we provide as well as preventative and predictive maintenance programs with NADCAPapproved calibrations. Beaumont equipment, built for the long haul on the strength of our 22-year experience and machines…

32 | IMD | Q4 2021

IMD – The Industry’s Most Extensive Industrial Publication

Caldwell Provides Beam for Balancing Rolls

German Industry Award for the Aisle Master AME-OP

The Caldwell Group has provided a 1,500-lb. capacity roll lifting beam and leveling system for a company that manufactures various types of hygienic wipes. A major advantage is that one operator can now complete the application instead of two. The beam, which is 86 in. between the j-style hooks and 95.75 in. from end-to-end, is designed for unbalanced loads. In the end user’s application, it is common for a roll to be slightly off-center and the operator would previously have to handle the load or below-the-hook equipment to straighten it. These substrate rolls must be lifted into place during an important phase…

One of the new products to be launched this year by Combilift, the Aisle Master-OP (AME-OP) was a winner in this year’s “INDUSTRIAL Production – handling award 2021”, organised by leading German publication, Industrial Production. A jury of industry experts and votes from the readership determined the winners from over 30 entries, and the AME-OP won second place in the Handling and Assembly Category of this year’s Awards. The new AME-OP is a stand-on electric powered model that combines the advantages of a narrow aisle articulated forklift and an order picker for versatile operation…

WATCH VIDEO BELOW

COXREELS® Exceeds Industry Recommended Salt Spray Testing Hours Due to its numerous properties and, specifically, its corrosion resistance, powder coating is used for many applications in the industrial sector. The salt spray test is the oldest corrosion resistance test and the most widely preferred to evaluate anti-corrosion coatings. COXREELS is proud to announce that they recently exceeded 20% more hours than the recommended industry standard for salt spray testing. The independent lab test performed measured the corrosion and UV resistance of COXREELS’ powder coated materials…

The Sky Hook is your personal safety lifting solution, preventing lifting injuries while saving you both time and money!

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IMD | 33

Dillon Extruded Aluminum Pie Jaws Now Available to 28-Inches in Diameter Dillon Manufacturing introduces pie jaws made from 6061 extruded aluminum now available up to 28-inches in diameter. Machined from aluminum bar stock, these new large diameter full grip pie jaws are stronger and more reliable than cast aluminum, with none of the inherent porosity. Jaw heights of up to 10-inches are available. They can also be made in diameters larger than the chuck, thus increasing the chucks capacity. Maximum contact area from the full grip jaws provides a solid gripping surface which yields more friction for drive with…

Epson Overcomes Automation Barriers with No-Code, Easy-to-Use Epson RC+ Express Robot Teaching Environment Developed for Epson T-Series All-in-One and LS-B Series SCARA robots, Epson RC+ Express features a simple, visual-based teaching environment that integrates an easy-to-learn, block-style format with the power and flexibility of a scripted-text programming language. Ready-to-use templates are included, allowing users to quickly create common pick-and-place, palletizing and depalletizing applications. Epson RC+ Express includes a simple-tonavigate visual user interface, making…

Lightweight EM 210 and EMP 210 Welders Deliver Big Power, With Superior Performance And Control

Leica Absolute Tracker AT960 Offers Speed, Accuracy and Portability

ESAB Welding and Cutting Products introduces its EM 210 MIG/ Flux Cored welder and EMP 210 MIG/Stick/TIG welder. These inverter-based power sources are small in size but deliver professional-grade power and performance for most auto/truck repair and restoration, light fabrication and construction and HVAC work. These units feature state-of-the-art digital controls typically found on industrial machines and use power management technology that delivers positive arc starts and a smooth, steady welding arc…

This is a robust, all-in-one laser tracker that fits in a single flight case. Offering high-speed dynamic measurement as standard, it is a complete solution for six degrees of freedom (6DoF) probing, scanning and automated inspection as well as reflector measurement. The AT960 laser tracker can be transported easily, unpacked quickly and powered up in minutes to deliver high-performance measurement almost anywhere. Featuring wireless communication and a battery operation option, the integratedtechnology design …

34 | IMD | Q4 2021

NEW PRODUCT: 1/4 NPT Hollow Cone Liquid Nozzle for Cooling and Washing EXAIR’s new 1/4 NPT HollowStream™ liquid atomizing spray nozzle provides a hollow cone spray pattern for pressurized liquids. They are applied to solve cooling, cleaning, foam breaking, rinsing and dust suppression applications for industry. The tangential flow design is vaneless, with wide open internal features to resist clogging while producing a uniform distribution in a ring pattern with medium to large droplets. Their right-angle design is compact and works well with liquids containing particulate. Liquid operating pressure is up to 250 PSI…

Fastems Launches Version 8 of its Manufacturing Management Software (MMS) Offering Data-Driven Insights into Manufacturing Processes MMS Version 8, the newest release of Fastems’ Manufacturing Management Software (MMS), boosts CNC automation intelligence to the next level by introducing a new MMS Insights view, giving practical ideas and suggestions on how to improve CNC production. In addition, Fastems has developed the user experience and added functionalities that support an economical use of modular fixtures, allowing higher production mix with smaller work holding investment. Version 8 will be available for…

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FANUC Introduces New Compact LR-10iA/10 Robot – Ideal for Machine Tending and Warehousing/ Logistics Applications Weighing just 46 kg, the LR-10iA/10 robot mounts to the floor, upside down, or on an angle. It’s also very easy to mount the robot to an AGV or other mobile platform to accommodate a variety of repetitive tasks or automate machines that are standing idle. The LR-10iA/10 has a 10 kg payload and a large work envelope with a long reach of 1101 mm. Its compact size makes it an ideal solution for companies with limited floor space, and the slim arm fits into machine…

The Sky Hook is your personal safety lifting solution, preventing lifting injuries while saving you both time and money!

800-4-SKYHOOK 800-475-9466 • 208-365-5770

www.skyhookmfr.com INDUSTRIAL MACHINERY DIGEST.COM

skyhook-q-video-ErgSafety-03-2021.indd 1

IMD | 35 3/19/21 9:45 AM

GF Machining Solutions CUT P 550 Pro Builds on More Than a Century of Advanced EDM Technology The new CUT P 550 Pro electrical discharge machine (EDM) from GF Machining Solutions capitalizes on more than a century of EDM technology expertise to deliver superior performance. Like all the wire EDMs in the company’s CUT P Pro Series, including the CUT P 350 Pro and 800 Pro, the CUT P 550 Pro features the new highly intuitive Uniqua human/machine interface (HMI), Intelligent Power Generator (IPG) technology and advanced QUADREX® machine design. All CUT P Pro machines are also well suited for every application, provide increased…

Fume Hood Blowers From HEMCO Complete line of belt and direct drive exhaust blowers which are chemical resistant and available in standard and explosion proof models. HEMCO blowers are designed to operate effectively and efficiently to remove hazardous fumes from a fume hood. Blowers are, epoxy coated steel, belt or direct drive blowers with adjustable discharge and weather covers from 250 cfm to 2000 cfm. PVC belt or direct drive blowers ranging in size from 230 cfm to 1600 cfm. A wide selection of ventilation accessories including ducting, filters, and components are available…

quality matters. every time.

New Honeywell Headgear Combines Innovative Face and Respiratory Protection for Enhanced Worker Safety PRO GRADE

HOSE, CORD, & CABLE

REELS

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TOLL FREE | 800.269.7335

www.coxreels.com

36 | IMD | Q4 2021

With its optimized air-flow distribution, air can be kept away from the worker’s face to avoid dry eyes or directed toward the face for cooling, making it easier to perform on the job tasks comfortably. The ratchet at the back of the headpiece is easy to grab and adjust to ensure a precise fit for various head sizes, even when wearing gloves. The anti-fog and anti-scratch visor provides clear visibility with downward and peripheral vision. PAPRs are reliable, sustainable and deliver respiratory, face, eye and sometimes head protection depending on the headgear style…

Hypertherm Introduces Three New Plasma Systems with Built-In Intelligence and a Revolutionary Single-Piece Cartridge Consumable Powermax SYNC and its SmartSYNC™ torch replaces the traditional five-piece consumable stack-up with a single colorcoded cartridge. Technology embedded in each cartridge automatically sets the correct amperage, air pressure, and operating mode and lets operators know when a new cartridge is needed. Additionally, controls on the SmartSYNC torch allow operators to adjust the amperage and change the cartridge without returning to the power supply…

Kennametal Introduces FIX8™ for Heavy-Duty Turning with Eight Cutting Edges per Insert FIX8 is designed to cover a wide range of applications, including turning and facing, smooth surfaces, interrupted, and heavily interrupted cuts. From medium depth-of-cut to roughing in steels, cast iron, and challenging materials like stainless steel, FIX8 handles it all. Even extreme feed rates of up to 1.4mm (0.055") and depths of cut up to 12mm (0.472") are possible with FIX8, says Matthew Fuerst, Product Manager, Kennametal. The tangential design of the FIX8 insert features a rigid clamping system that pulls the insert securely into the pocket seat…

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KHK USA Inc. Announces Premium Circular Pitch Metric Racks & Pinions KHK CP Racks & Pinions are engineered to simplify the application design process, such that a specific number of revolutions of the gear will result in an exact distance of translation on the gear rack. Circular pitch is defined as module / pi. For example, a circular pitch of CP5 would equate to a pitch of 5mm. and for a 20 tooth pinion, one revolution would result in 100mm of travel. From the many available materials and configurations, the KHK USA online catalog makes it easy to find the best solution for each particular application. Using the…

The Sky Hook is your personal safety lifting solution, preventing lifting injuries while saving you both time and money!

800-4-SKYHOOK 800-475-9466 • 208-365-5770

www.skyhookmfr.com INDUSTRIAL MACHINERY DIGEST.COM

IMD | 37

Kurt Introduces New DX8 Crossover® Vise The Newest And Largest Vise In The DX Crossover® Vise Family

L&L Ships Box Furnace on a Tight Schedule for Ceramic Applications

Kurt Manufacturing today announced the new DX8 CrossOver® vise—bringing their benchmark DX-series vise design to an 8-inch platform. Featuring a premium one-piece body design with a cast stationary jaw—now standard on all Kurt single-station vises—The new Kurt DX8 CrossOver® combines the best features of the Kurt D810 and Kurt 3800V vises into a single vise. New stationary-jaw Kurt DX8, DX6 and DX4 vises were designed using Finite Element Analysis—providing 30% less horizontal push-back deflection than previous DX…

The furnace has a series of inlets on the side and an outlet on the top. These can be capped off when not in use to preserve heat, and can provide a “candling” effect where various ceramic byproducts can be removed from the furnace. Some of these byproducts can be corrosive and need to be removed from the system. The XLE 3636 is equipped with solid-state relays for fast, quite cycle times to offer good control. These are housed in a NEMA 1 control panel with single-point power connection. All required fusing and interconnections are included…

Markforged’s FX20 and New Continuous Fiber Reinforced ULTEM™ 9085 Filament to Expand Use of 3D Printing in Demanding Industries like Aerospace and Automotive

Mazak Launches New Swiss-Style Machine Series at DISCOVER 2021

Built to scale distributed global production, the FX20 is precisiondesigned and sensor-driven to deliver breakthrough accuracy, quality, and reliability to fabricate parts directly at the point-of-need with the simple click of a button. As the biggest, fastest, and smartest 3D printer Markforged has ever produced, the FX20 pairs size and throughput to make larger parts at incredible speeds. This new technology, alongside high-temperature…

38 | IMD | Q4 2021

These new Swiss-type machines use a collet plus single-motor ball spline drive for heightened accuracy and reduced material waste. A 10,000 rpm spindle and a variable vibrating system ensure the utmost in stable, repeatable performance. “Now shops can count on Mazak quality to expand their productivity into new areas and applications,” said Dan Janka, president of Mazak Corporation. “We are excited to showcase this new technology at DISCOVER 2021 and give our customers new reasons to choose Mazak. We are also extremely proud…

New Norton Rapid Polish Discs Quickly, Easily Produce Superior Finishes

OnRobot Makes Software Debut with WebLytics Solution for Collaborative Applications

Saint-Gobain Abrasives, one of the world’s largest abrasives manufacturers, has introduced new Norton Rapid Polish felt polishing discs featuring premium quality, pressed, hardened, thick felt material for quickly and easily creating exceptionally smooth surfaces with single digit Ra and mirror finish shine. At 2,000 – 3,000 RPM, Rapid Polish discs stay cool and do not produce vibration, ensuring optimal finishes. Soft felt material makes the discs ideal for final finishing. “We are very pleased to offer our customers new Rapid Polish Discs, for…

Capable of monitoring the performance of multiple collaborative applications simultaneously and in real-time, WebLytics gathers equipment data from both robots and tools and transforms it into easy-to-understand, visualized device and applicationlevel intelligence. “The launch of WebLytics is an important landmark for OnRobot, our customers, and our global integrator network,” said Enrico Krog Iversen, CEO of OnRobot. “WebLytics is the first software solution to provide real-time, application-focused data for collaborative…

5-inch Power Feed Gear Head Drill Press from Palmgren

REGO-FIX Announces the Launch of the 3D-EdgeMaster Precision Centering Device Product Line

The 25-inch Power Feed Gear Head Drill Press from Palmgren combines power with precision to handle virtually any drilling application. What makes this drill press so exceptional is the gear drive transmission that delivers full power at any speed, driving the cutting tools at nearly 100% of the available motor horsepower. Palmgren is the exclusive North American joint venture partner for Arboga and its line of drills. The drill press features helical ground gears to ensure positive, quiet operation and make speed changes. The premier drill has…

40 | IMD | Q4 2021

REGO-FIX recently announced the development of an innovative new 3D-EdgeMaster precision centering device product line. Continuing the REGO-FIX tradition of providing solutions to manufacturing customers’ most challenging toolholding needs, 3D-EdgeMaster measuring technology was developed to provide shops with process reliability and improved production quality. The new 3D-EdgeMaster is shock and splash proof in accordance with IP 67…

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Test Our Trims and Seals for Quickly View Our Most Popular Fit and Function Lines of Trims and Seals

DESIGN ASSISTANCE Precise Machining For Smaller Diameters Sandvik Coromant, a leader in metal cutting, has launched CoroCut® QI, a range of internal and face grooving inserts designed for smaller diameters. Optimized to enable a lighter cutting action and reduced cutting forces, CoroCut® QI ensures high process security, reliable grooving operations and precise chip evacuation, resulting in high surface quality grooves. The addition of CoroCut® QI completes the CoroCut® Q platform, which already consists of CoroCut® QD for parting off and CoroCut® QF for secure face grooving. CoroCut® QI provides a comprehensive selection of optimized tools for numerous…

New SINAMICS PCS Power Conversion System for Battery Storage Systems With SINAMICS PCS, Siemens presents a new power conversion system for battery storage applications. The SINAMICS PCS grid converter makes locally generated batter power usable for industrial and public power grids. SINAMICS PCS controls the charging and discharging process of the battery and helps to handle load peaks and grid disturbances via the battery storage, to store the electricity in an energy- and cost-efficient manner, and to bring the energy stored in batteries efficiently and reliably into the grid…

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WWW.TRIMLOK.COM INFO@TRIMLOK.COM INDUSTRIAL MACHINERY DIGEST.COM

IMD | 41

Signode to Highlight Storefast Technology at Modex 2022

New Coolant-Through-The-Tool Application for Quill Feed Units

Signode, a leading manufacturer of a broad range of end-of-line packaging equipment, tools, consumables as well as end-to-end automation and warehouse automation solutions, announced it will be showcasing its StorFast technology at MODEX. The event, which will take place in Atlanta at the Georgia World Congress Center, March 28-31, 2022, will also feature additional Signode solutions that support the warehousing, distribution and logistics operations of its customers. Signode’s StorFast Automated Storage and Retrieval System (ASRS) is an innovative…

What is the main purpose for coolant application? Of course, among many reasons, primarily it’s for the lubrication and cooling of the cutting edge and, in addition, to help facilitate chip evacuation. REGO-FIX® has launched a cost-effective and efficient attachment for the application of coolantlubrication liquids through the tool, based on an ER collet nut, which is ideal for use on SUHNER feed drilling units. Optimizing the cooling and lubrication effect to help increase chip removal, tool life and performance requires the coolant-lubricant…

New, Anti-Fishtail Device Automatically Secures Lightweight Products in Place for Smooth, Consistent Pallet Wrapping

THINBIT® Square Angled Toolholders

Devised for wrapping thin gauge sheet metal, lightweight cardboard boxes, plastic parts, and other palletized loads, the anti-fishtail device offers an extra layer of certainty in the wrapping process when stretch wrapping loads weighing less than 100 lbs. With the new device, the TAB Wrapper Tornado Perfect Storm enables a single forklift operator to manage the entire pallet wrapping process without interruption when packaging lightweight pallet loads as well as much heavier pallet loads. The orbital…

42 | IMD | Q4 2021

THINBIT®, manufactured by Kaiser Tool Company Inc., expands offering of SQUARE ANGLED TOOLHOLDERS. These toolholders are designed for CNC and conventional machines. The new SQUARE ANGLED TOOLHOLDERS position the insert at 30°, 45° or 60° angles for reliefs, undercuts and angled OD and face grooves. Square shank sizes are available in 3/8”, 1/2”, 5/8”, 3/4” and 1”. The SQUARE ANGLED TOOLHOLDERS are for use with THINBIT® inserts in grades for ferrous and non-ferrous materials. Inserts are available in sizes .004” to .150” in .001” increments coated with TiN, TiAlN, TiCN…

New Face Milling Cutter From Walter Delivers Stable And Cost-Effective High-Performance

Reliable, Small Footprint PL80 Robot Adds High-Speed Versatility to PL-Series Line

Walter has introduced the Xtra·tec® XT M5009 face milling cutter for face milling, roughing, and rough finishing with wiper inserts on steel, stainless steels, materials with difficult cutting properties, and non-ferrous metals. With its small, tough, double-sided SN X0904 or SN X1205 indexable inserts and high number of teeth the M5009, is able to maximize feeds, tool life, and productivity, and boost process reliability while also reducing cutting tool material costs. Its high level of stability makes it ideal for minimal material removal and variable…

Highly efficient and flexible, the five-axis PL80 robot brings robust capability in a compact design to Yaskawa’s PL-series robot family. Ideal for a variety of palletizing applications, order picking and other logistical tasks for end-of-line or distribution automation, the PL80 excels at case palletizing, bag palletizing, de-palletizing, layer picking and layer forming. Featuring an 80-kg payload capacity, the highly reliable PL80 robot offers a 2,061 mm horizontal reach, 3,291 mm vertical reach and 0.03 mm repeatability…

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IMD | 43

Featured Suppliers

2021 ANNUAL

SUPPLIER'S DIRECTORY FEATURED SUPPLIERS

Accudyne Products – EZ Puller

Actek Manufacturing & Engineering

Accudyne Products sells the EZ-Puller which does not need adjustment. Your time is too valuable to waste adjusting a bar puller. Join the thousands of machinists worldwide who are enjoying the benefits of a reliable puller that does not need adjustment. Change bar size in seconds and end the frustration. EZ-Puller, BAR PULLING MADE EASY!

Since 1989, Actek® Manufacturing & Engineering has established a reputation for providing top-quality products as well as excellent service. Actek hoist rings are ISO 9001:2015 certified, 200 percent proof-load tested, and come with a certificate.

(303) 991-1500 dan@ezpullerusa.com | www.ezpullerusa.com

(800) 752-7229 sales@ActekMfg.com | www.actekmfg.com

AeroGo, Inc.

AGMA – American Gear Manufacturers Association

AeroGo manufactures innovative load moving equipment, utilizing wheels and hovercraft technology, that move heavy, awkward, or delicate loads in factories. AeroGo works with companies large and small to find a load moving solution that is safe, efficient and cost-effective.

AGMA is the global network for technical standards, education, and business information for manufacturers, suppliers, and users of mechanical power transmission components. The association includes about 495 of the world's top gearing companies across more than 30 nations.

(800) 426-4757 info@aerogo.com | www.aerogo.com

(703) 684-0211 membership@agma.org | www.agma.org

Allied Machine & Engineering

American Technical Publishers

Allied Machine & Engineering is a leading manufacturer of holemaking and finishing cutting tool systems. Located in Dover, Ohio, Allied devotes its advanced engineering and manufacturing capabilities to creating the widest selection of value-added tooling available to metal-cutting industries around the world.

American Technical Publishers (ATP) produces effective training materials for technicians and skilled-trades workers in construction, electrical, mechanical, and maintenance industries. Our high-quality instructional materials are widely used in apprenticeship and industrial training programs.

(800) 321-5537 info@alliedmachine.com | www.alliedmachine.com

(800) 323-3471 service@atplearning.com | www.atplearning.com

44 | IMD | Q4 2021

IMD – The Industry’s Most Extensive Industrial Publication

AMS | Press Brake Safety

Baker Engineering LLC

Advanced Manufacturing Solutions | Press Brake Safety is a leading industry advocate for press brake operator safety. PBS is the exclusive North American installer of Germany-based Fiessler AKAS® laser safety systems, the most sophisticated press brake safety systems in the world.

Precision machining company, Baker Engineering LLC.’s core business centers around the design and development of high tech, high-performance technologies for a variety of applications, from custom engines, to engine components, to the production of parts and mechanical assemblies for other industries.

(800) 901-1193 sales@pressbrakesafety.com | www.pressbrakesafety.com

(616) 837-8975 jones@bakerengineeringmfg.com | bakerengineeringmfg.com

BEHRINGER SAWS, INC.

Betenbender Manufacturing, Inc.

BEHRINGER SAWS manufactures high-performance superior sawing technology bandsawing machines, circular cold saws, and structural fabricating equipment. Our primary goal is to create additional value for our customers by striving to achieve the highest combination of speed, accuracy, and cost-effectiveness.

The Betenbender Family of American Hydraulic Shears and Hydraulic Press Brakes are made by Betenbender Manufacturing,Inc. in Coggon, Iowa, U.S.A. Now in their fifth decade in business, this Midwestern Company continues to produce, what they believe, is America's best built shears and press brakes.

(610) 286-9777 info@usa.behringer.net | www.behringersaws.com

(319) 435-2378 sales@betenbender.com | www.betenbender.com

Burr King Mfg., Co., Inc.

Carell Corporation

Since 1951 Burr King grinders, polishers, and mass finishing systems have utilized innovative designs of uncompromising quality. They are industrial grade and intended for use on metals, woods, composites, plastics, rubber, stone, fiberglass and other materials.

Founded over 27 years ago to provide higher quality fabricating machines, faster deliveries, and superior service. Carell Corporation & Eagle Bending Machines, Inc. proudly maintain their goals and have placed over 8,000 machines in North America. Proof that their commitment, quality, and service are valued by today’s industry.

(660) 438-8998 info@burrking.com | www.burrking.com

(251) 937-0947 sales@carellcorp.com | www.carellcorp.com

Clamprite, LLC

Combilift

The Clamprite Gage was designed for accurate spindle tension testing right on the machine. The actual force exerted by the spindle drawbar mechanism is read directly on the dial, so there is no need for any calculations or conversions. Drawbar force checking is made easy using the Clamprite drawbar force gage.

Combilift is a specialist four-directional forklift and straddle carrier manufacturer producing a wide range of customized handling solutions, all of which are designed for the safe, space-saving, and very productive handling of long and awkward loads. Capacities from 3,200-pounds to 18,000-pounds.

(775) 246-5100 jerome@clamprite.com | www.clamprite.com

(877) 266-2456 info@combilift.com | www.combilift.com/us

Cosen Saws, North America

COXREELS

Cosen Saws is a global leader in COSEN SAWS Since 1976 manufacturing industrial band saws and technologies. Offering cutting solutions for a wide variety of industries and applications, we offer over 70 different models with nearly 200 units in stock and ready to ship from our Charlotte, NC HQ.

COXREELS® has remained focused on manufacturing high-quality professional-grade hose, cord, and cable reels since 1923. Offering a full product line serving the industry in every channel and application, COXREELS® designs, builds, and supports their products in America.

(704) 943-1030 info@cosensaws.com | www.cosensaws.com

(480) 820-6396 info@coxreels.com | www.COXREELS.com

Custom Machine & Tool Co., Inc.

DCM Tech, Corp.

Custom Machine & Tooling is an American-made manufacturer of power transmission and motor control components. Since 1964, CMT has supplied the world with high-quality products at competitive prices from its Northeast manufacturing location. The multigenerational company continues to expand its global reach.

DCM Tech is a family-owned manufacturer of rotary surface grinders and automotive rebuilding equipment. Our machines are backed by factory-direct service and support from our production facility in Winona, MN. Check out their full lines of equipment and request a quote.

(781) 924-5154 cstevens@cmtco.com | www.cmtco.com

(800) 533-5339 info@dcm-tech.com | www.dcm-tech.com INDUSTRIAL MACHINERY DIGEST.COM

IMD | 45

Featured Suppliers Dynabrade, Inc.

Eagle Bending Machines

Dynabrade has earned a reputation in the innovative design and manufacturing of unique portable pneumatic abrasive power tools, related accessories, and dust collection. Dynabrade tools have been proudly designed, manufactured, and built in the USA for 50 years.

Eagle Bending Machines’ precision engineered quality is designed to meet the demands for tough, dependable Section Benders for bending pipe, tube, profiles, sections, and ornamental pieces and working day after day with minimum downtime.

(800) 828-7333 customer.service@dynabrade.com | www.dynabrade.com

(251) 937-0947 sales@eaglebendingmachines.com | www.eaglebendingmachines.com

Essex Structural Steel Co., Inc.

Federal Knife, Inc.

Essex Structural Steel has been manufacturing pre-engineered building since 1972. Their buildings are designed for easy erection, energy efficient, designed to exceed local and state codes and are built in the USA by American Workers.

Federal Knife Inc. is a global supplier of high-quality machine knives and blades of all types. Federal Knife also provides the correct replacement blade for your equipment. In addition to our large inventory and custom manufacture blades to your specifications. Federal Knife has over 25 years of experience in cutting edge technology.

(800) 323-7739 sales@essexstructuralsteel.com | www.essexstructuralsteel.com

(812) 364-1448 sales@federalknife.com | www.federalknife.com

Formdrill USA, Inc.

Fortville Feeders, Inc.

Formdrill helps you produce your own inserts out of the same parts material. Users save money by eliminating the need to buy nuts or threaded inserts. You do not need to weld or install fasteners.

Fortville Feeders is a manufacturer of Feeding Systems that are engineered to easily integrate into your automation system. Maintenance and changeover friendly. Turnkey capable. Of the highest quality and ability.

(773) 290-1040 info@formdrill-usa.com | www.formdrill-usa.com

(317) 485-5195 info@fortvillefeeders.com | www.fortvillefeeders.com

H&K Equipment, Inc.

HE&M Saw

H&K Equipment, Inc. was founded in 1983 to provide specialized material handling solutions and exceptional service to their customers. H&K Equipment is a comprehensive leader in lift trucks, container handlers, personnel carriers, yard trucks, and industrial sweeping and scrubbing equipment.

HE&M Saw manufactures more than 70 different models of production band saws for the metalworking industry. Their product line, includes vertical, horizontal, plate and double column saws with capacities ranging from 12 feet x 12 feet to 80 feet x 80 feet machines.

(800) 272-9953 info@hkequipment.com | www.hkequipment.com

(888) 729-7787 sales@hemsaw.com | www.hemsaw.com

HMI a Division of Betenbender

HYDMECH Canada Corp.

HMI offers the most versatile C-Frame press or punch of all machines available today. Their frames are designed to have fewer tons-per-square-inch of pressure on their side plates, thus reducing spring back of the frame and reducing tool wear.

HYDMECH is a world leader in metal band saw and cold sawing solutions. Their innovative solutions are geared to meet the practical needs of the aerospace, automotive, steel service centers, metal fabrications shops, racing, and other sectors.

(319) 435-2378 sales@betenbender.com | www.betenbender.com

(877) 276-7297 info@hydmech.com | HYDMECH.com

Hypneumat, Inc.

Jergens, Inc.

Hypneumat, Inc. manufactures an array of automatic drilling units, tapping units and multiple spindle heads under the Hypneumat, Commander and Snow brands. Hypneumat also specializes in contract machining services offering multi-axis turning and vertical machining capabilities.

Since their founding in 1942 Jergens, Inc. has grown to comprise three distinct business units: Workholding Solutions, Lifting Solutions and Specialty Fasteners. Their tooling components, fasteners, and hoist rings are at work in just about every industry on every continent.

(414) 423-7400 info@hypneumat.com | www.hypneumat.com

(877) 486-1454 info@jergensinc.com | www.jergensinc.com

46 | IMD | Q4 2021

IMD – The Industry’s Most Extensive Industrial Publication

Kanetec USA Corporation

KHK-USA

Kanetec has been at the forefront of magnetic tools and equipment since 1959. The company has expanded their magnetic bases, tools, and chuck lines with the latest technology and electronic controls.

Having been a company solely devoted to the manufacture of gears for 80 years, KHK is world renowned for their brand of gears. KHK USA is a factory direct, full-service distributor of KHK gears to meet your gearing needs.

(800) 959-0449 sales@kanetec.com | www.kanetec.com

(516) 248-3850 info@khkgears.com | www.khkgears.us

L&L Special Furnace Co., Inc.

Lenzkes Clamping Tools, Inc

L&L Special Furnace Co., Inc. has a longstanding reputation for designing special industrial furnaces, ovens, kilns, quench tanks and heat treating systems. Their broad product line allows L&L to provide special treatment in creating the best system for thermal needs.

Lenzkes clamps assist with QMC-Quick Mold Change, QDC-Quick Die Change, SMED-SingleMinute Exchange of Die and other machining/safety issues. Their free trial program allows use in real-time working situations (such as Stamping, Milling, and Injection Molding) without obligation to purchase.

(610) 459-9216 sales@llfurnace.com | www.llfurnace.com

(540) 381-1533 info@lenzkesusa.com | www.lenzkesusa.com

LS Industries, Inc.

Motion + Power Technology Expo (formerly Gear Expo)

From design and manufacturing, to parts and service LS Industries is committed to providing the highest levels of performance in addressing your metal cleaning needs. LS Industries designs and manufactures a full line of metal cleaning equipment for the industrial and automotive markets.

At Motion + Power Technology Expo 2021 in St. Louis, you'll see the full range of power transmission solutions, including hybrid solutions, utilizing mechanical power transmission, pneumatics, hydraulics, electric motors, and drives. Anyone looking to facilitate new ideas and connections is invited to attend this in-person event.

(316) 265-7997 info@lsindustries.com | www.lsindustries.com

(703) 684-0211 mptexpo@agma.org | motionpowerexpo.com

Northwest Machine Tool Expo | Endeavor Business Media

OnRobot

Northwest Machine Tool Expo is a unique regional event for the machining and manufacturing industries. This event features free educational sessions and an exhibit floor showcasing the latest products and services in the industry. See what is new in the world of machining and manufacturing, and network with peers and key industry players.

OnRobot's cutting-edge robotic tools for lightweight industrial automation empowers end-users to work alongside cobots on applications such as machine tending, quality control, materials handling, packaging, assembly, or surface finishing. Their One System Solution yields unified programming, easy deployment, and zero complexity.

(913) 565-2199 info@machinetoolexpos.com | www.MTENW.MachineToolExpos.com

(469) 586-8384 americas@onrobot.com | www.onrobot.com

Pro-Line Work Benches

Radwell International, Inc.

Pro-Line has been a leader in workbench manufacturers since 1978. Pro-Line offers a wide selection of workbenches that feature a modular designs and interchangeable accessories. Pro-Line continues to be on the leading edge of modular ergonomics.

Radwell International stocks and sells new and surplus industrial automation, MRO, pneumatic, motion, electronic, hydraulic, HVAC and electrical control equipment for plant floor and facilities maintenance machinery. Radwell has full component level repair capabilities for industrial electronic and electrical equipment.

(800) 739-9067 bench@1proline.com | www.1proline.com

(800) 332-4336 sales@radwell.com | www.radwell.com

RAS Machine Tool Technologies, Inc.

RHH, Inc.

RAS Machine Tool Technologies is your one-stop CNC shop; serving Machine Tool Builders/Dealers/End Users and Service Companies. Contact RAS to help you find those hard-to-find Japanese, Taiwanese & Korean Machine Tool parts and accessories.

Specialists in fine pitch Carbide Gear Hobs, Gear Shaper Cutters, Spur + Helical Master Gears. Our precision line of TRU-VOLUTE gear products are known for reducing setup times, improving gear quality, and producing more parts per regrind. Quality Products Since 1915

(413) 323-9041 sales@rasmachinetool.com | www.rasmachinetool.com

(201) 226-9000 gears@tru-volute.com | www.tru-volute.com INDUSTRIAL MACHINERY DIGEST.COM

IMD | 47

Featured Suppliers Salinger Electric Co.

Scotchman Industries

Salinger Electric Co., Inc. has been selling quality electrical equipment both new and reconditioned since 1946. We can supply all new, all reconditioned, or a combination of both at very competitive prices. Call or email us with your requirements.

Scotchman is the most trusted hydraulic ironworker manufacturer in the USA, and also builds a complete line of Circular Cold Saws: manual to fully automatic, plus distributor of quality Digital Measuring Systems, Band Saws, H-Presses, and Tube and Pipe Notchers/Grinders.

(248) 585-8330 info@salingerelectric.com | www.salingerelectric.com

(605) 859-2542 info@scotchman.com | www.scotchman.com

Sprinter Marking

Standard Direct.com

Sprinter Marking manufactures a range of machines models that automatically ink code-mark message on a wide range of porous and non-porous surfaces. While very small in physical size, they are designed for rugged industrial operation.

Industrial Grade, All-Welded STEEL Carts, Cabinets, Tables & Work Benches. Shipping points in Illinois, New York, Virginia, Nevada. Standard-Direct.com offers you the best quality and service in the industry with its “more metal” and “quick ship” programs. We offer the industry’s largest selection with OVER 450 models!

(740) 453-1000 sales@sprintermarking.com | www.sprintermarking.com

(800) 622-2692 standardpaul@aol.com | www.standard-direct.com

Stor-Loc

Suhner Industrial Products, LLC

The original heavy duty Modular Storage Drawer Cabinet that was the norm in the industry until the early 1990s is available only from Stor-Loc®. Their durable Modular Drawer Cabinet comes complete with a unique 55 Year Satisfaction Guarantee.

Since 1914, Suhner has offered solutions for specific applications and process improvements in the areas of refining industrial surfaces with their abrasive products, tool holders for machining units that multiply capacity, customized flexible drive shafts, and stamping technology. Remanufacturing Services for Machining Spindles.

(815) 936-0700 sales@storloc.com | www.storloc.com

(706) 235-8046 machining.us@suhner.com | www.suhner-machining.com

Sure Tack Systems, LLC SERVING AMERICAN MANUFACTURERS FOR OVER

Sure Tack Systems, a division of Crist Company, Inc. established in 1980 and offers a diverse product line for your hot melt adhesive equipment and application needs. Whether your need is for high-speed extrusion, wide web spray, slot coating or manual product assembly; STS has a hot melt system to fit your individual needs and budget.

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(800) 580-2803 info@suretacksystems.com | www.suretacksystems.com

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(208) 365-5770 sales@skyhookmfr.com | www.skyhookmfr.com

MOST EXTENSIVE INDUSTRIAL PUBLICATION

Tap Associates, Inc. The innovative Self-Locking “Jüngere” design has offered the smallest OD Tap Extension in the industry. For that reason, it is the preferred solution for close quarter and long tapping applications.

SUBSCRIBE & Stay Informed

(800) 566-4827 info@tapextension.com | www.tapextension.com

www.IndustrialMachineryDigest.com IMD-FP-022021.indd 1

48 | IMD | Q4 2021

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IMD – The Industry’s Most Extensive Industrial Publication

The Caldwell Group, Inc

Trim-Lok, Inc.

Caldwell is the leading manufacturer of below the hook lifting solutions. We provide the most effective material handling solutions available. Our team of employee-owners take the time to understand your application. This understanding allows us to apply our experience and provide the most effective material handling solution available.

Trim-Lok, Inc. manufactures high-quality plastic and rubber extruded trim and seal profiles. From plastic edge trims to sponge rubber seals, our profiles add protection from rough edges while sealing out moisture and debris with a clean, finished look to your application. In-stock profiles and custom engineering is available.

(800) 628-4263 contact@caldwellinc.com | www.caldwellinc.com

(888) 874-6565 info@trimlok.com | www.trimlok.com

Tormach, Inc.

TS3, LLC

At Tormach, our mission is to empower people who make things. We are dedicated to providing exceptionally engineered compact CNC machines, tooling, and related products with best-in-industry technical support and customer service.

TS3 – The Saw Sales and Service Company – provides all aspects to support for your saws - Names you know and trust – Amada, Marvel, Tigerstop, MK Morse, and many more. New machine sales, on-site repairs, applications and replacement parts. TS3 - factory trained or factory authorized in many current and former saw manufacturers.

(608) 849-8381 info@tormach.com | www.tormach.com

(612) 503-8670 ts3machine@gmail.com | www.ts3machine.com

Trilogy Machinery, Inc.

US Metal Crafters, LLC

Trilogy Machinery, Inc. is committed to bringing the highest standards of professionalism, integrity and service in order to achieve a reputation as a leader in the metal fabricating machinery industry. Trilogy proudly offers products from Italy, Sweden, Turkey, and Taiwan.

American-owned and operated, US Metal Crafters knows the right supplier transforms your supply chain. Our broad service offering coupled with our commitment to quality & on-time delivery will transform & simplify yours. Laser cutting, stamping, fabrication, assembly, powder coating, tool & die services, and more all under one roof!

(410) 272-3600 sales@trilogymachinery.com | www.trilogymachinery.com

(336) 861-2100 info@us-metalcrafters.com | us-metalcrafters.com

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IMD | 49

Featured Suppliers

2021 ANNUAL

SURPLUS GUIDE

FEATURED SUPPLIERS

Aaron Industrial Services

AMCbid.com

At Aaron Industrial Solutions, we understand that liquidating/transferring assets isn’t a one-size-fits-all scenario. Aaron Industrial Solutions is your trusted source for Equipment Auctions, Liquidation Sales and Asset Management Services.

At Auction Management Corporation, we understand the importance of liquidating your asset in a timely and professional manner. When we take your property to auction, we invest our time and resources into generating willing and able buyers that are qualified to bid on your asset.

(630) 350-2200

(780) 980-9565

jbersh@aaronauctions.com | www.aaronauctions.com

info@amcbid.com | www.amcbid.com

Arizona Auctioneers LLC

BidIndustrial.com, LLC

For over 70 years THE ARIZONA AUCTIONEERS have provided a time-tested, skilled appraisal and auction service – The vital link between Buyer and Seller! For business owners who wish to dispose of complete or partial inventories or equipment!

BidIndustrial.com provides online auctions at a local, national, and global reach for industrial machinery, heavy commercial equipment & commercial real estate.

(602) 258-6981

(888) 777-9888

steve@arizonaauctioneers.com | www.arizonaauctioneers.com

info@bidindustrial.com | www.bidindustrial.com

BTM Industrial

Capital Recovery Group, LLC

Our overall goal at BTM Industrial is to develop and nature relationships that allow our customers to receive maximum value for your company and asset disposition needs. Whether your company defines value as quick turnaround, convenience or cash, we understand that true value is meeting and exceeding your production needs!

CRG is a global private equity firm that creates liquidity for its clients through expertise, innovative solutions, and access to worldwide markets. Specializing in complex scenarios comprised of industrial assets and real estate, we revitalize idle or marginally productive assets and liquidate surplus.

(616) 745-5953

(860) 623-9060

sales@btmindustrial.com | www.btmindustrial.com

info@crgllc.com | www.crgllc.com

50 | IMD | Q4 2021

Featured Suppliers Centra Corp.

Cincinnati Industrial Auctioneers, Inc.

Centra Corporation has been selling machinery Since 1988, The President Michael DiBlasi has been selling machinery for over 25 years and is a Certified Machinery & Equipment Appraiser (AMEA).

CIA is a nationwide provider of asset disposition, auction and appraisal services. Our expert services are rendered to a variety of organizations. A fifty year history with thousands of satisfied clients and customers, has afforded our company a reputation that is second to none in the industrial auction business.

(410) 945-0040

(513) 241-9701

sales@centracorp.com | www.centracorp.com

info@cia-auction.com | www.cia-auction.com

Compass Auctions & Real Estate

DeCosmo Industrial Auctions

Compass specializes in industrial and job completion surplus auctions. Every month Compass auctions machinery, heavy equipment, contractor grade tools and more! Our multi-platform system coupled with the ability to auction your items in place makes for a fast, convenient way to sell your items and put profit back into your business.

Our primary focus is to help you understand today's market and which auction format fits your needs to maximize your financial return. Whether it is an Online or Onsite/Webcast style auction, we have a knowledge of values along with current market conditions second to none in the industrial auction world.

(800) 729-6466

(413) 530-0019

info@soldoncompass.com | www.soldoncompass.com

info@diauctions.com | www.diauctions.com

Denver Breaker & Supply

Harbor Machinery, Inc.

Denver Breaker and Supply was established in 1984 and has always had a "Customer First" approach of doing business. They provide new and reconditioned electrical equipment and guarantee the finest quality and best prices you can find in the business.

Harbor Machinery Inc. buys and sells all types of manufacturing machinery and equipment. In addition, we offer full auction services, brokerage services, consignment and appraisal services. Our expert knowledge of the manufacturing industries and their use of machine tools enables us to achieve high net returns for our customers!

(800) 544-7375

(231) 526-9525

sales@denverbreaker.com | www.denverbreaker.com

sales@harbormachinery.com | www.harbormachinery.com

Harris Auctions

Henderson Auctions

Harris Auctions is a specialist in surplus asset management. We utilize online only auctions, live webcast, and live on-site auctions, and have an aggressive marketing system to reach a wide audience of bidders. Harris Auctions also participates in other auctions by providing high quality, consignment items to those auctions.

Henderson Auctions is one of the oldest equipment auction firms in existence and is recognized as a leader in the industry. We specialize in heavy construction machinery auctions, truck and trailer auctions, mobile home auctions, travel trailer auctions, industrial equipment auctions, and real estate auctions.

(713) 462-5800

(225) 686-2252

jeanjr@harris-auctions.com | www.harris-auctions.com

auctionoffice@hendersonauctions.com | www.hendersonauctions.com

HMI Asset Sales

Industrial Auction Services, LLC

Industrial Auction Services, LLC acts as an agent or principal in the conversion of industrial machinery, tooling and related assets into cash, through public auction, privately negotiated sale, or a combination of both.

(231) 526-9525

(848) 229-2500

sales@harbormachinery.com | www.harbormachinery.com

sales@ind-auctions.com | www.ind-auctions.com

Infinity Asset Solutions

James G. Murphy Co.

Infinity Asset Solutions is your Full-Service Asset Solutions provider for AUCTIONS, LIQUIDATIONS AND APPRAISALS. We serve businesses of all sizes in a variety of industries. Our team of experienced professionals are ready to help you obtain the best value for your assets.

Since 1970, JGM has conducted thousands of NO MINIMUM NO RESERVE auctions throughout the USA. Our past experience auctioning items and businesses from various different industries is what sets us apart from our competitors. JGM brings its past experience and wide range of industry specific knowledge and advertising to every auction!

(905) 669-8893

(425) 486-1246

info@infinityassets.com | www.infinityassets.com

Ray@murphyauction.com | www.murphyauction.com INDUSTRIAL MACHINERY DIGEST.COM

IMD | 51

Featured Suppliers Joiner Sales Corp

KD Capital Auctions LLC

Longevity earned from a track record of many successes! Joiner Sales Corp has over 44 years of experience in providing market leading industrial auctions and appraisal services coast to coast in Canada. We are a family team of experienced industrial auctioneers and machinery appraisers. We work to make every client a reference client.

KD Auctions has over 100 years of combined experience in market place knowledge, equipment valuations, international experience, preparing machinery for viewing, marketing and selling, making KD Auctions the right choice for your next auction! With our experienced staff we can help alleviate some of the stress involved in the process!

(604) 852-8711

(480) 922-1674

info@joinersales.com | www.joinersales.com

service@kdauctions.com | www.kdauctions.com

Kingfish Capital Advisors, LLC

Lee Stevens Machinery, Inc.

Kingfish Capital Advisors, LLC is a national appraisal and valuation firm for machinery and equipment. Our ASA and AMEA appraisers provide expert advice for asset disposition, acquisition, tax challenges, estate planning, banking and management requirements. We are Accurate. Ready. Reliable.

For close to 70 years, Lee Stevens Machinery, Inc. has been providing solutions to manufacturers worldwide for their machine tool needs. Their services range from buying and selling used machine tools to appraising, brokering, marketing, leasing and financing production equipment.

(401) 792-4300

(248) 926-8400

valuation@kingfishcapital.com | www.kingfishcapital.com

info@stevensmachinery.com | www.stevensmachinery.com

Levy Recovery Group

Machinesused.com

With over 30 years experience in the machinery business, our management team has been instrumental in some of the industry's most coveted sales, responsible for over $50 million in direct sales. We hope that you'll give us an opportunity to show you that "Complete Asset Solutions" is not just a tag line – it's what we deliver.

Machinesused.com has been providing affordable and reliable used machines for sale across the US for over 18 years. We provide a variety of models and brands of used machines which include, Haas, Mazak, Fadal, VMC, Grinders, Inspection Equipment and Rotary Tables. We will also buy, trade-in, online auction or consign your used machines.

(248) 914-4226

(763) 745-1166

sales@levyrecovery.com | www.levyrecovery.com

sales@machinesused.com | www.machinesused.com

Moecker Auctions, Inc.

Perfection Industrial Sales

Moecker Auctions, Inc. is licensed, bonded, & fully insured and maintains a staff of experienced personnel to administer and facilitate its operations. With combined experience of over 40 years in auctions and appraisals, Moecker Auctions offers a unique approach to auctions, appraisals and liquidations.

Perfection Industrial Sales excels in performing live and online industrial machinery auctions. Whether you are looking to sell one machine or an entire facility. We want to partner with you to ensure your next auction or liquidation project is both seamless and profitable.

(954) 252-2887

(847) 545-6374

info@moeckerauctions.com | www.moeckerauctions.com

sales@perfectionindustrial.com | www.perfectionindustrial.com

Pressbid Auction, LLC

Prestige Equipment

PressBid Auction, LLC conducts complete plant liquidations and online auction sales in North America. We serve the metal stamping, fabricating, roll forming, tool and die, prototype, machining and plastics industries.

Founded in 1990, Prestige Equipment is a worldwide leader in the procurement and sales of metalworking machinery, fabricating equipment and complete manufacturing facilities. Related services include both online and on-site auctions and liquidations, asset management programs, appraisals, financing, plant turnaround and business sales.

(248) 268-1603

(631) 249-5566

sales@universalpress.com | www.pressbid.com

sales@prestigeequipment.com | www.prestigeequipment.com

Prime Machinery, Inc.

RAAR Group USA Inc

Prime Machinery is one of the nation’s most trusted quality used machinery dealers specializing in buying and selling vertical and horizontal boring mills, CNC machining centers, CNC turning centers, lathes, EDM's and fabricating equipment.

Since 1988, RAAR Group USA has been conducting auctions in North America in all types of industrial categories such as machine tools, presses, power generation equipment, railroad, aerospace and automotive. We guarantee that we are the most transparent and honest!

(516) 922-7977

(310) 487-3800

sales@primemach.com | www.primemach.com

rick.raargroup@gmail.com | www.raargroupusa.com

52 | IMD | Q4 2021

IMD – The Industry’s Most Extensive Industrial Publication

Rabin Worldwide, Inc.

Resell CNC Auctions

Rabin is a family-held industrial auction and real estate investment company, with a focus on the acquisition and sale of industrial equipment and facilities around the world. As leading industrial and commercial liquidators, Rabin has sold equipment assets in every trade sector and on almost every continent.

Our online, timed auctions are a terrific way to buy and sell used CNC machinery, tooling equipment, plant support equipment, and ancillary items. Whether you are looking to buy or sell a single item or an entire facility, we can help you. We even help facilitate the logistics of prepping, loading, and shipping the items sold

(415) 522-5700

(844) 478-8181

info@rabin.com | www.rabin.com

sales@resellcnc.com | www.resellcnc.com

Salvadore Auctions, Inc.

SIGMA Auction

Salvadore Auctions, Inc. provides full service online, live and simultaneous webcast auctions for machinery & equipment nationwide. Metalworking equipment, water well drilling equipment, machine shop and commercial and industrial assets. Whether buying or selling assets contact us first.

For over 20 years, the SIGMA Group of companies have established themselves as one of the leading industrial reselling and auction companies in the world. SIGMA Auctions is dedicated to providing professional, organized, and profitable auction services to the industrial and commercial equipment market.

(401) 792-4300

(812) 308-6400

auctions@siaai.com | www.siaai.com

jrivera@sigma-auction.com | www.sigma-auction.com

Stone Auctioneers & Appraisers

UPM, LLC

From manufacturing and transportation equipment to inventories and real estate, Stone Auctioneers & Appraisers’ specialized training and affiliations allow them to offer asset marketing, appraisal and consulting services in plastics, metalworking, construction, transportation, and more.

UPM, LLC is a stocking used machinery dealer specializing in buying and selling metal stamping and fabricating equipment. We will buy a single machine or an entire facility. Our three generations of family have been in the used machinery business since 1963. UPM also has a Certified Equipment Appraiser on staff

(205) 373-1130

(248) 268-1603

auctioneer@stoneauctioneers.com | www.stoneauctioneers.com

sales@universalpress.com | www.universalpress.com

Westbrook Asset Management Westbrook Asset Management is a full-service industrial auction and liquidation company. We offer a wide range of programs for sellers to quickly turn their surplus machinery and equipment into cash. Our marketing team will customize a program that is designed to bring maximum exposure to every asset we sell on your behalf.

(800) 899-8182 info@westbrook-eng.com | www.westbrook-eng.com

Winternitz Industrial Auctioneers & Appraisers National asset disposition services firm considered one of the nation's leading and most successful industrial liquidation firms, and industry pioneer. Auctions conducted throughout the United States, Canada, and Mexico.

(847) 272-0440 charlie@winternitz.com | www.Winternitz.com

Workingman Capital Corp. Workingman Capital Corp. provides personalized solutions to industrial business problems. Be it asset monetization, valuation or strategic sale, professional advice is essential when your business needs assistance. With offices in Toronto and Chicago, we look forward to meeting you.

(416) 847-7336 info@workingmancapital.com | www.workingmancapital.com

char-lynn 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

Phone: 847-676-2910 Fax: 847-676-0365 www.macmhydraulic.com INDUSTRIAL MACHINERY DIGEST.COM

IMD | 53

Surplus Buying and Selling

The concept is to bond layers of sheet metal that contain machined channel/microchannel structures.

The Science of Diffusion Bonding or Joining together Dissimilar Metals Working with an expert manufacturing partner can help to utilize the best properties of both similar and dissimilar metals

etal diffusion bonding is an essential joining method for achieving a high-purity interface when two similar metals require superior structural integrity. The process involves applying high temperature, and pressure to metals mated together in a hot press causes the atoms on solid metallic surfaces to intersperse and bond.

54 | IMD | Q4 2021

There are probably no other commercially viable materials joining process that can produce such consistent results today. The applied pressure induced by a hot-press tool, combined with software and loop-back sensors for precise control to within micrometer accuracy, can produce constant pressure over several square feet of area for a component assembly. As a result, this

IMD – The Industry’s Most Extensive Industrial Publication

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technology has attracted the interest of design engineers in the semiconductor, aerospace, and energy industries. With such a high degree of process control, the diffusion bonding process is increasingly used to join dissimilar metals. Commercial processes of interest are titanium to iron-nickel alloys, titanium alloys to stainless steel, and even some aluminum to metal applications. The process also enables coupling between different alloys in the same material group, such as mild steel, tool steel, and Metal-Matrix Composites. To successfully use diffusion bonding, an understanding of the complexities of the interface and its effect on the chemical and thermo-mechanical properties of the bond is required. However, with the industry’s traditional focus on welding and brazing, there has been minimal formal education on diffusion bonding, according to Thomas Palamides, Senior Product & Sales Manager - Industrial Furnaces, PVA TePla AG, a global manufacturer of industrial furnaces and PulsPlasma nitriding systems. “Combining the beneficial properties of different metals is the main reason to explore diffusion bonding. However, when manufacturers reach out [to us about it], they often understand little about how the parts should be designed, prepared, or handled. They may have questions about process data and need guidance on issues such as heating, cooling, and pressing rates,” says Palamides. Consulting with an expert manufacturing partner is often the quickest way to consider the possible benefits of diffusion bonding. The approach can also help to tailor diffusion bonding to the manufacturer’s process cost-effectively.

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The Benefits of Diffusion Bonding The importance of designing a dissimilar metal joint often lies in a desire to expose the correct metal surface to specific environmental conditions where a single alloy may not perform as well. Another reason is to introduce material systems that are lighter in weight or provide a level of corrosion resistance that can only be achieved by “packaging” dissimilar metals. Diffusion bonding also has tremendous potential applications for conformal cooling. The concept is to bond layers of sheet metal that contain machined channel/microchannel structures. When combined, the channels can provide for cooling or heat dissipation. The layers can be bonded up to a stack height of 600mm in the MOV diffusion bonding press, retaining the strength as the parent materials. Another application related to conformal cooling is for plastic injection molds made in 2-layer designs of low alloyed tool steel with stainless steel such as STAVAX.

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Understanding Diffusion Bonding Combining the beneficial properties of different metals is the main reason to explore diffusion bonding Academia has researched dissimilar joining for decades, and much of the focus has been on high-performance materials like titanium alloys. According to Palamides, expanding beyond commercially pure (CP) titanium, one often finds the existence of an intermetallic layer at the mating interface after processing. “The

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IMD | 55

Advances in high vacuum hot presses now allow superior pressure control and rapid cooling systems to improve the bond, increase yields and significantly decrease cycle time.

influence of the solute elements, such Cu, Ni, and Ag are the major drivers for the intermetallic layer formation in titanium,” he says. The diffusion bonding process can occur as either a solid-state or a liquid-phase bonding process. Similar pure material bonding has historically been as a solid-state operation. This method simplifies the process from an assembly standpoint, as faying surfaces can be easily matched before placing a charge into the furnace. Alignment pins and tack welding may be used for this process as well. Because no liquid phase is present in diffusion bonding, slight deformation occurs at the surface. This results from applied pressure used to flatten surface asperities and break up residual surface oxides before bonding. In the liquid-phase diffusion bonding process, an interlayer typically melts at the faying surfaces. In this instance, lower pressure than solid-state diffusion bonding is used, and even less deformation occurs at the surface. Depending on the thermal cycle and composition of the interlayer materials combination and the interlayer selected, an interdiffusion occurs between the interlayer and base materials on either side of the joint through the metallurgical processes known as a eutectic or peritectic phase change. The thickness of the final intermetallic reaction layer is a result of first from the liquid-phase diffusion and second, from the solidstate diffusion. Bond strength is a function of the intermetallic compounds formed, the thickness of the intermetallic zone, and anomalies, such as voids, at the interface.

Exploring Diffusion Bonding There are several ways for a manufacturer to investigate how diffusion bonding of dissimilar metals could benefit their process. Much scientific literature is readily available for specific material combinations and processing times and temperatures depending on the application. For example, Kavian O. Cooke and Anas M. Atieh

56 | IMD | Q4 2021

conducted an exhaustive review published in 2020 titled Current Trends in Dissimilar Diffusion Bonding of Titanium Alloys to Stainless Steels, Aluminum, and Magnesium Journal of Manufacturing and Materials Processing. While ample research exists on the subject, design engineers can still find it challenging to convert the information into real-world manufacturing of a specific part. When this is the case, it can be helpful to partner with experts with an extensive database of successful processing parameters from previous applications and access to industrial-scale equipment. “In most cases, we start talking with the manufacturer about introducing new designs, and consult on possible materials, designs, and also conduct pre-bonding runs as needed,” says Palamides. PVA TePla provides support, including specific material combinations, processing times, and temperatures. He notes that proper design will allow diffusion bonding of assemblies, whether an intimate interface or multiple interfaces that are planar parallel simultaneously. However, surfaces that are not perpendicular to the compressive force of the hydraulic ram will not bond properly. Palamides says that the manufacturer begins by working with their mechanical, thermal, and modeling teams. Once a design is complete, the next step is to fabricate trial samples that are truthful to the characteristics of the final interface. “Locate a vendor who can perform contract service trial runs. Propose a test matrix to ensure your schedule is aligned with project goals,” says Palamides.

Advances in Diffusion Bonding Equipment Advances in high vacuum hot presses now allow superior pressure control and rapid cooling systems to improve the bond, increase yields and significantly decrease cycle time.

Despite its benefits, the use of diffusion bonding has been limited by more practical considerations until recently. Specifically, the size limitation of the furnace chamber and limits to the amount and uniformity of the pressure applied across the entire surface area of the part. Run times are also long, often lasting an entire day. Advances in high vacuum hot presses now allow superior pressure control and rapid cooling systems to improve the bond, increase yields and significantly decrease cycle time. In the case of the pressure applied, for example, integrated single cylinder hydraulic presses can apply a consistent, measurable amount of force. However, this provides very little control over large parts with more complex geometries. To improve force distribution, thick graphite pressing plates (10”-15” in height) mate the metal layers together at a more consistent pressure. Unfortunately, this takes up furnace space while adding to the time to heat the surfaces of the metals. Today, manufacturers such as PVA TePla offer multi-cylinder systems with large pressing plates that can accommodate various parts. The largest, the company’s MOV 853 HP, can process substrates as large as 900mm (35.43”) x 1250mm (49.21”), which is quite large for diffusion bonding. The pressing force is 4,000 kN. By controlling each cylinder independently, the integrated press provides remarkably consistent pressure across the entire surface. The MOV also comes with built-in pressure transducers along the bottom of the pressing plate. The individual hydraulic cylinders can be adjusted in the software to achieve uniformity even over large areas based on the sensor feedback. PVA TePla has optimized a physical ink test method that identifies areas on the substrate where uneven pressure is applied. “Today’s equipment provides detailed measurements of the material properties during bonding,” says Palamides. “This valuable feedback can show how the materials are compressing, if it is being crushed, and if a transient liquid layer is forming – and other KPIs of the procedure.”

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Verifying the Integrity of the Bonding Interface To ensure the quality of the interface, Palamides recommends analyzing samples through non-destructive inspection techniques, such as Scanning Acoustic Microscopy (SAM). Or more costly analysis performed using Scanning Electron Microscopy/Energy Dispersive X-ray Spectroscopy (SEM-EDS). Subsequently, trial samples may be destructively analyzed and fabricated into standard mechanical test specimens to collect repeatable data. While there is growing interest in diffusion bonding, all applications require thorough research to optimize the joining process. Only a few global firms can work with manufacturers through the process with the ability to advise on commercial system adoption. From the beginning, partnering with an expert in diffusion bonding will give manufacturers a competitive edge from part design through production ramp-up. For more information, contact PVA TePla America at 951-371-2500 or 800-527-5667 or visit www.pvateplaamerica.com.

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Industrial Machinery Digest Quarterly - IMD Quarter 4, 2021

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