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AUTOMATION & ELECTRICITY Machine & Automation Magazine - EMO 2017 HANNOVER - Special Issue - 2017 / 3


Machine & Automation & Electricity Magazine

EDITOR ilker kaplan

WORLD MEDIASpecial edition for EMO 2017: Machine Automation &Electricity Bulletin

In order to support the development and conversion of

Turkey, we are keeping the development of seven specific publications which are lightening their sectors. In addition to our periodical special publications such as Machine & Automation, Industry 4.0, Cutting Tools, Roller&Linear, Cad/Cam/Cae/Plm, Industrial Piping, we are making new publications from time to time. The bulletin you are currently reading is a special edition for EMO 2017: Machine Automation &Electricity Bulletin. EMO 2017 Special Edition in English Published on the first days of April and distributed extensively in the EMO HANNOVER 2017 Fair. Our EMO Special Edition has given place to many pioneer companies on its pages. It has been published in English in order to be distributed more easily and extensively in whole Europe. We can proudly say that we made a productive work in favor of all our companies we work together. There is a great sympathy for World Media Summits There was a broad participation in our Industry 4.0 Summit we organized with the sponsorship of SIEMENS last year in Istanbul. Now we can easily say that in this year’s Industry 4.0 Summit there will be a broader participation. You can also be a part of this organization. Also we are organizing the first Metalworking and Cutting Tools Summit this year. You can follow our bulletins The World Media Magazines with their pioneer bulletins in sectorial publications not only enable you to reach your target audience but also makes the sectorial information transfer possible with the scientific- technical articles and news. You may have a contact with us for news, advertisements and subscriptions. Please continue following and reading us…

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Publisher Dünya Medya Basın Yayın Reklam Tanıtım Hizmetleri Publisher and Managing Editor İlker Kaplan +90 505 400 94 34 Administrative Affairs Manager Hatice Karabay +90 505 400 94 33 Advertising Executive Ziya Alkan +90 546 675 59 49 Accounting Managers Sevda Öncü Düzgün Turgut +90 542 292 83 85 Public Relations Manager Ayşe Savranoğlu Editorial Departmet Simgenur Savranoğlu Gamze Onat Graphic Design Ezgi Kamburoğlu Subscriptions Supervisor Defne Deniz Kaplan Beste Kamburoğlu Photo Editors Murat Çapkın Sinan Temur Human Resources Manager Sibel Şanlı Communication Advisor Alper Tuna IT Supervisor Kerem Mercan Regional Representatives Çetin Sülün (Ankara) Mesut Karabay (İzmir) Umut Yıldız (Bursa) Representatives of Europa-Germany Pınar Açıkgöz Social Media Fatma Kurşun Distribution Ali Savranoğlu Zafer Kamburoğlu General Coordinator Süleyman Kaplan Hüsniye Kaplan Contributors Meryem Savranoğlu Fatma Kaplan Selda Kamburoğlu Distributor Aras Kurye - PTT - Yurtiçi Kargo Place of Management Akşemsettin Mah. Güneş Sokak No: 48 D :10 Eyüp / İstanbul Tel:+90 850 532 94 68 Fax : +90 212 427 00 15 Print World Media Groupe Machine Automation Magazine guaranteed to agree with the media profession principles. The literary and visual materials cannot be used in written visual, audio and electronic media without permission. The advertisers have the legal responsibilities of their advertisements

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TOOL, PATTERN 64 AND MOULD MAKERS HAVE A HOME Machine - Automation & Electricity / EMO 2017 5


High-ranking experts from India inform about the growing market at EMO Hannover 2017 on 20 September. India sends the second biggest visitor group from outside Europe to EMO Hannover.


A re Modinomics fuelling an industrial renaissance in India?

This question will be addressed during the India Day hosted by the VDW (German Machine Tool Builders’ Association) at the EMO Hannover 2017 on 20 September. Investors and rating agencies on the Indian stock exchange, at least, are anticipating good business opportunities in the medium term. Jeremy Leonard, Director of Global Industry Services at the British research institute Oxford Economics India Day notes that “More scope for proat the EMO active economic stimuli when it Hannover comes to the refinancing costs of 2017 will be the commercial banks, plus the showcasing planned tax reform for goods potentials for pro- and services, could unleash duction some accelerated dynamics.” technology and capital A view that’s confirmed by V. investment Anbu, Director General & CEO of the Indian Machine Tool Manufacturers’ Association. “Game-changing initiatives such as ‘Make in India’, opening up of strategic sectors to foreign direct investments, and the implementation of ‘One nation, one tax’ for goods and services have spurred manufacturing growth”, is his firm conviction. India’s economy is growing India’s economy is indeed expanding, as is its industrial production output. In the machine tool industry, the nation 6

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ranks 8th among the world’s largest markets, with a volume of most recently 1.7 bn euros in 2016. This corresponds to growth of eleven per cent in euros. For 2017/2018, too, a continuingly moderate increase in consumption is predicted. India imports around 70 per cent of the machine tools it needs. In 2016, these were worth approximately 1.2 bn euros. The EMO’s India Day aims in particular to elucidate the perspectives for the mechanical engineering, automaking and aviation user sectors. Dr. Andreas Wolf from Bosch Ltd., for example, sees potential in the automotive industry. “Triggered by the new legislation in regard to vehicle safety and emissions, we’re going to be seeing rapid implementation of modern-day technologies,” he says. Milind Madhav Shahane, Member of the Board of Directors at Tata Advanced Materials Ltd., sees major opportunities in the growing importance of privately owned companies: “Since the turn of the century, India’s aviation industry has been experiencing dynamic growth at privately managed companies, supported by large conglomerates and their engineering expertise.” This is one of the main reasons why United Grinding has opened a subsidiary in Bangalore and set up a technology centre. “This

enables us to perform meaningful tests on customers’ components and to offer realistic training for machine operators,” says C.R. Sudheendra, President India Operations of United Grinding. India’s government keen to attract investors The EMO’s India Day will also be supported by the Indian government. We shall be honoured to host Shri N. Sivanand, Joint Secretary of the Department of Heavy Industry in the Ministry of Heavy Industry & Public Enterprises. He will be spotlighting the government’s initiative for boosting the manufacturing sector. We shall also be welcoming six delegations of high-ranking Indian entrepreneurs, which will be organised and accompanied by various Indian customer associations and the staff of the VDMA’s liaison office in Kolkata. “We are particularly gratified to note that it will be almost exclusively Indian speakers or pundits who are thoroughly familiar with the country from their own career experience there who will be presenting their expertise on the India Day,” says Gerhard Hein, who is the co-organiser of the India Day at the VDW, who are hosting the EMO. “So we’re expecting an exciting event, offering exceptional added value to everyone involved.”


Ilyndustry 4.0 is progressiveemerging as the crucial

factor in the race for leading-edge technology and market shares in the future. And time is running out for the German machinery and plant manufacturers. On one side of the world is the USA, with its exceptional software competence and not least its digital entrepreneurship when it comes to new business models. On the other side of the globe is China, which with its “Made in China 2025” and “Internet Plus” programmes is channelling substantial resources into digital transformation. So despite the good starting position that German companies have created for themselves, they would be well advised not to rest on their laurels. The German Mechanical Engineering Industry Association’s (VDMA) Metro-logical and Testing Technology and High-Precision Tools will accordingly be spotlighting ideas and products from the Industry 4.0 environment. At the VDMA’s stand (Hall 4 / D44), member companies and partners from the re-search community will from 19 to 21 September be contributing 30 brief pres-entations, focusing primarily on high-precision tools, metrological and testing technology, research, and tool data interchange. “At the VDMA forum, we shall be aiming to show what solutions our sectors are offering in order to translate the concept of Industry 4.0 into shopfloor reality,” explains Markus Heseding, Executive Direc-

Fair VDMA invites to the event “Innovative Solutions for Industry 4.0” at the EMO Hannover 2017

tor of the two associations. “We already have a good track record with a forum of this kind, and are looking forward to a high attendance.” Specifically, the “Innovative Solutions for Industry 4.0” event will be informing its participants on issues like intelligent clamping systems and how production processes can be simulated by networking tools and software, tool life-cycles monitored, and costs reduced. The presentations there will elucidate how the self-monitoring machine tool support the quality assurance processes involved, or what an automated measuring cell can achieve in a production process featuring Industry 4.0. Contributions from the companies concerned offer insights into highly sophisticated metrological technology and highprecision tools for challenging tasks. The presentations will cover the advantages of Markus Heseding, Executive Director of The standardised tool data for German Mechanical Engineering Industry Associsimulations, tool manageation’s (VDMA) Metrological and Testing Technoloment and presetting, as well gy and High-Precision Tools (picture source VDMA) as the research work being performed at the universities. The following companies and universities will be presented at the VDMA’s event: Cimsource, Diatest, Emuge, Etalon, Fagor Automation, Fraisa, Gühring, HaimerMicroset, Hainbuch, Iscar, Kelch, Mahr, Mimatic, Oberndorfer Präzisions-Werk, OSG, Römheld, Sandvik, Tekon Prüftechnik, pro-micron, Vargus, Fraunhofer Institute for Production Technology in Aachen, GFE-Schmalkalden, Bremen University, TU Dortmund, Bayreuth University.

The German Mechanical Engineering Industry Association’s (VDMA) Metro-logical and Testing Technology and High-Precision Tools invite during EMO Hannover from 19 to 21 September to the event “Innovative Solutions for Industry 4.0” in hall 4, booth D44.

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Fair The whole world is talking about 3D printing, additive manufacturing and generative multi-layer construction technologies. Nevertheless, this is a long way from meaning that the classical machine tool is going to be pensioned off. The EMO Hannover 2017 will be showcasing an international banquet of production technology – with alternative processes as the highly auspicious icing on the cake. ********** FIT Group FIT AG specialised in solutions in the field of additive manufacturing. From the production of prototypes and small series with short delivery times all the way through to software and hardware solutions, the FIT Group covers everything to do with additive manufacturing. Founded in 1995, FIT AG operates in the fields of rapid prototyping and additive design and manufacturing (“ADM”) through its subsidiaries FIT Prototyping GmbH and FIT Production GmbH. The turnover in 2016 totalled 24 m euros, up by 40 per cent compared to the preceding year. FIT is currently employing a total of 250 people at the company’s headquarters in Lupburg and at other facilities, e.g. in Hamburg, Brasov (Romania) and Boston (USA). For more information, please visit: technology ******** Siemens PLM Software Siemens PLM Software, Cologne, is a business unit of the Siemens Digital Factory Division, is a leading global provider of product lifecycle management (PLM) and manufacturing operations management (MOM) software, systems and services with over 15 million licensed seats and more than 140,000 customers worldwide. Headquartered in Plano, Texas, Siemens PLM Software works collaboratively with its customers to provide industrial software solutions that help companies everywhere achieve a sustainable competitive advantage by making real the innovations that matter. For more information, please visit:



To quote Carl Fruth, Managing Board Chairman of FIT AG, Lupburg: “At the EMO, the very latest CNC-based production technologies will be on show, additive manufacturing among them. Innovative potential product solutions in this field will be demonstrated.”

C arl Fruth has meanwhile long since achieved his goal

of “transferring competences in the field of multi-layer technologies into product manufacturing”: moreover, within the framework of a Technology Day featuring an in-house exhibition held in April 2017, FIT AG (Fruth Innovative Technologies) in the Upper Palatinate village of Lupburg, in addi-tion to inaugurating a new office building also opened the “first additive factory”. The “FIT factory is even on an international comparison unique in terms of manufacturing capacity and automation technology, and is intended to serve as a template for further additive manufacturing facilities of the FIT Group,” to quote the firm’s founding father and Managing Board Chairman Carl Fruth. He is a pioneer of additive manufacturing – and a visionary for whom ten years ago it was already a certainty that multi-layer con-struction technology would in future be the norm in everyday production operations and the sales of milling machines or injection moulding machines would inexorably decline. But that is still a long way from meaning that the days of

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the “mother of all machines (i.e. the traditional machine tool) are numbered. This is impressively confirmed by the innovations that will be showcased by the exhibitors at the EMO Hannover 2017. One of the impediments to the widespread adoption of additive technology in individualised mass production was described several years go by Carl Fruth himself as the “lack of production-suited manufacturing lines”. This has changed in the meantime. Carl Fruth puts it like this: “There are a large number of delicate seedlings: many of our customers would like to use additive technologies to manufacture replacements for existing com-ponents. But this is possible only in a very few cases. Usually, a new component has to be developed and very often the adjoining components of the system as well. Firstly, many companies are deterred by the outlay involved, and secondly, of course, you need specialised development competence for this new production technology.” The country needs new designer engineers When traditional design guidelines no longer apply, a new generation of design engi-neers is needed, keen to embrace function-driven thinking. According to Carl Fruth, additive manufacturing means “that in the design phase not only the geometry, but also the material properties and the component costs are essentially specified in full. This complexity necessitates specialised training and experience. Moreover, up to now there is no software tool in existence that provides all the requisite functions. So firms have to work with different, complex software tools. Very

often, information is lost in transi-tioning from one tool to another. When you need up to eight iterations for developing a component, the substantial outlay involved is obvious.” ˝The competences required, moreover, are possessed not by a single design engineer, but only by a team. In traditional companies, furthermore, the competences concerned are divided up among different departments - a situation exacerbated by squabbles about prerogatives and uncertainty. Innovative companies, however, also see this as an opportunity: “We support our customers in this process, and train them component by component to achieve maximised performance in AM design. That’s why we also call these products ADM – Additive Design and Manufacturing”.

As is the case with other production technologies, additively manufactured components also require quality testing.

When the talk turns to “additive manufacturing in an automated process chain” (some-thing he used to refer to as the “Achilles’ heel!), Carl Fruth becomes veritably effusive: “This is my own particular hobbyhorse. We don’t have a digital specification of our products. This is why Industry 4.0 hasn’t taken off, and also why automation isn’t working properly either. When everything has to be automated and optimised by hand, then the traditional forms of mass production are – old hat!”

Whether there’s a robot standing at the production line or a human employee turning the product, there are no fun-damentally new approaches involved: “For as long as a drawing and thick ring binders of text are required for specifying a product, Industry 4.0 is never going to get off the ground. In this context, it’s immaterial whether there’s a PDF file for the specification involved – we’re talking here about machine-readable specifications and their fully automated implementation.” Some former weak points, by contrast, he adds, like the reproducibility of the processes, quality assurance in mass production, or dependable simulation methods, have been almost eliminated: “Everyone involved has understood the problem, and is working purposefully to solve it.” More technologies are sharing the market The inevitable question of whether the conventional machine tool will soon be out of a job receives a differentiated answer from the AM expert: “Components are manufac-tured in a process chain. That’s true today and will still be true tomorrow. Additively manufactured components, as is the case with other production technologies, too, require quality-testing: it’s immaterial in this context whether this means each individual component or every 50th one of identical components. So I don’t think existing tech-nologies are going to be replaced.” CNC-driven processes, he adds, are all very flexible in use, and all have a market of their own. The question is rather: “What share can each technology have of the cake as a whole?” The slice for the various additive production technologies is currently so small that it can only increase. Carl Fruth, however, also believes “that the cake as a whole for CNC processes is becoming larger, at the expense of tool-linked production technologies and other highly personnel-intensive processes. We’re looking here at a combination of different CNC technologies.” At the upcoming EMO Hannover 2017, Carl Fruth expects “to find the very latest CNC-based production technologies, plus innovative potential products in this category. A large number of equipment man-

ufacturers for additive processes and material produc-ers will be exhibiting at the EMO Hannover. For us as users of this equipment, this adds a special interest to the fair.” Harmonised software solutions for additive manufacturing A “new solution for additive manufacturing” has recently been premiered by Siemens PLM Software, the Business Unit for Product Lifecycle Management (PLM), Cologne, an. It consists of an integrated software package for design, simulation, digital manu-facturing, plus data and process management. This enables a “generative design to be created automatically, on the basis of new functions for optimised topologies”. This frequently results in organic shapes that a design engineer would be highly unlikely to think of himself, and that would be very complicated or even impossible to manufacture using conventional production methods. Possible user target groups include the auto-motive industry, the aviation sector or medical technology. The “revolutionary solution” and its possible applications are explained by Peter Schel-ler, Marketing Director at Siemens PLM Software: “What’s special about it is that this is a consistently harmonised platform. On the basis of our Convergent Modelling technol-ogy, we incorporate within our NX software for integrated CAD all the relevant product development steps for 3D printing, from scanning to the actual printing. In the field of 3D printing, there are already a whole lot of individual solutions in various niches, either from printer manufacturers or other vendors. The important step we’re now taking is the integration of all process steps into a platform with a central user interface, on which both the geometry and the print path generation are stored in a secure data format.” To quote Peter Scheller, Marketing Director at Siemens PLM Software, Cologne: “The EMO Hannover 2017 is an excellent platform for learning more about ongoing challenges and customers’ wishes.”

Fair this strategy, Siemens PLM Software has unveiled plans for a new online collaboration platform providing an option for worldwide coop-eration in the manufacturing sector. The declared aim is to render “on-demand product designs” and 3D printing production operations more easily accessible to a global manufacturing industry. In mass production environments,” says Peter Scheller, “3D printing has not yet arrived completely: it originated in prototyping, and so far has been predominantly used for this purpose. But we’re approaching a threshold here: the process is emerging from this niche; many companies are currently thinking about using it for mass production or have already introduced it for this purpose.” When you think about an additive production process on an industrial scale, “from our point of view a process-reliable data format is extremely important, as a basis for enabling components to be dependably manufactured again and again in the same quality. So far there hadn’t been a platform of this kind, which is why we’re now providing one for our customers.” For industrial production operations, in particular, it is very important to have an exhaustive description of your components on file in digital form. This is es-sential for accessing this digital twin in the event of queries or cases of damage and investigating the relevant causes. Peter Scheller sums up his expectations for the EMO Hannover 2017 as follows: “Sie-mens will continue to invest in innovations, and to work together with technology part-ners in order to develop new solutions designed to progress the efficacy of additive manufacturing and drive 3D printing forward still further. That’s why we’re looking for-ward to fruitful meetings at the EMO Hannover 2017 and plenty of mutual feedback with customers and associates. The fair is a superlative platform for learning more about current challenges and customers’ wishes.”

Highly sophisticated integrated technologies for simulations and analyses enable a design’s behaviour to be calculated in advance. This new technology, with its high change-triggering potential, will encourage innovative design approaches.

In addition, within the framework of 8

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Article Author Walter Frick, specialist journalist from Weikersheim

“Smart System Optimisation” ensures technically detailed and at the same time automated evaluation of standstill causes and error causality relationships in a production line.

PROCESS AUTOMATION: ON THE WAY TO THE CLOUDS can now draw conclusions using the algorithms developed at the Fraunhofer IPA and edit the information concerned in the desired form.

Cloud solutions are on ev-

eryone’s lips: digitalised data in app-based strongholds in the clouds are being tasked with automating processes and rendering them more efficient. The EMO Hannover 2017 will be showcasing viable approaches and providing fitfor-purpose navigational aids on the data highway to the smart factory of the future.

A “smart system optimisation” capability that detects errors in concatenated production EMO Hannover 2017 processes and automatically will showcase navigational aids for indicates their causes and the smart factory of their propagation” will be exthe future hibited at the EMO Hannover 2017 by the Stuttgart-based Fraunhofer Institute for Manufacturing Engineering and Automation (IPA). How does this work in practice? Felix Georg Müller, the institute’s designated specialist on autonomous manufacturing system optimisation, explains: “Smart system optimisation involves a technically detailed and at the same time automated evaluation of standstill causes and error causality relationships in a production line. As soon as the production operation is up and running, data are synchronously communicated from all steps of the process to an analytical tool.” This tool 10 Machine - Automation & Electricity / EMO 2017

Data-driven production optimisation The database comprises status and process information from all technical sub-steps of the entire process chain. The analytical tool can use these to continuously identify in near-real-time where errors or standstills are occurring, or will occur as a result of several nonconforming factors interacting in different steps of the process. In contrast to classical OEE, the user receives a cause assignment immediately. (Editor’s note: OEE – Overall Equipment Effectiveness – is a measure for the added value created by a line, and a ratio that helps to determine, monitor and improve the productivity, the profitability and the overall effectiveness of production lines in the context of the manufacturing process.) For example, the user sees which process is blocking the other one, and can identify where the causal trigger is located. It’s also possible to prioritise trouble-shooting, since the real bottleneck of the production line is being computed at any time. This is based on all currently detected error patterns, brief stops and reject rates, thus reflecting a real-time view of the line concerned. The data sources are either additionally installed sensors, like smart cameras, or (if no process information is avail-

able) the machine data logger developed at the IPA. This is already capable of supplying to the analytical tool mass data from the Siemens S7-1500, Beckhoff CX1020 and Mitsubishi Q series of industrial control systems. Since this means that all relevant variables are available at millisecond intervals, the operating behaviour can be learned. “Thus we can give commonly used machine control systems a Big-Data capability, and integrate existing machine data into the analytical model,” comments IPA expert Felix Georg Müller. “Our tool has already enabled us to achieve cycle time reductions of between six and ten per cent and monitor continuous compliance with the optimum on highly standardised machines at automotive component suppliers.” This data-driven production optimisation is based upon continual, extremely detailed analysis of the line’s behaviour, and of all individual processes involved in a production line. This cannot be done manually; automation is essential, due to the extremely high data processing volume concerned. For instance, the causes of errors are no longer sought solely in the line’s dynamic behaviour, but also, for example, by detecting anomalies in the process data of all individual processes. This means errors can be determined and eliminated even more precisely. With conventional approaches, a process optimiser would be occupied for hours or even days simply by reviewing and analysing a data record, and nonetheless could always only

examine one time section – namely the one represented by the data record concerned. At the EMO Hannover 2017, says Felix Georg Müller in conclusion, “visitors will be able to experience live how data-driven production optimisation actually works. The guests we welcome to our stand will be able to see for themselves at our mini-factory how dynamic bottlenecks, dependences in production lines, and anomalies are detected and evaluated. This means complete real-time transparency for complex production lines is possible at an time.” Process chains in automakers’ plants Process automation was also a keynote of the “Process Chain in Automakers’ Plants” (PiA) conference held in Bielefeld on 3 and 4 July 2017, where one of the projects presented was HL-Pro-Ket. What precisely is new about the “integrated approach”? Patrick Kuhlemann, a research assistant at the Institute of Production Engineering and Machine Tools (IFW) at Leibniz University in Hanover, explains: “First of all I should mention the innovative turning/rolling process: for this purpose, a hybrid turning/rolling tool has been developed which unites conventional turning and deep-rolling in a single tool. Another important result is the milling tools, which combine the process operations of smoothing, roughening, and chamfering, thus making for enhanced efficiency. The above processes replace the conventional forming processes, and render superfluous the hard fine machining hitherto required.” Turning/rolling enables hardening distortion to be precompensated, which well-nigh halves the process chain involved. Moreover, flexibility is massively increased since in the event of a variant change only the NC code has to be altered, and no forming machines need to be retooled. The “holistic process chain control,” says the IFW scientist, “is a crossmachine concept: this means that the turning/milling centre and the

inductive hardening machine are interlinked, and coordinate with each other using process-integrated geometry measurements.” If a component after the hardening process is approaching a tolerance limit, then for the next component precompensation will be directly adjusted during soft machining. This means that the manufacturing quality is autonomously assured on a cross-machinery basis. Driven by the rising number of individualised products, says Patrick Kuhlemann, “we are expecting a definite trend at the EMO Hannover 2017 towards optimising manufacturing processes by means of integrated, innovative process control. This is designed to bring the optimisation costs per component variant into line with the costs of efficient mass production.” The IFW will be presenting a “feeling” machine tool. Thanks to skilful integration of process control and rigorous utilisation of the multiplicity of sensor signals available, the machine is able to detect and anticipate deviations in geometry or shape, and thus to compensate for them automatically: “In the shape of our demonstrator, we are thus presenting an innovative procedure that efficiently meets and masters the challenge of rising variant diversity.” Interaction of processes is crucial for productivity For Gerald Mies, President Milling & Factory Automation at FFG-Werke GmbH, Eislingen, “line productivity has always been crucial to a properly functioning manufacturing process”. It is here, he says, that in future many decisions will be taken on the ideal interaction between machining, automation and assembly processes. For this purpose, vendors are needed who comprehend the planning and design work involved throughout the entire line, and can supply it from a single source. This, he continues, offers options for flexible modification of components and sequences while the development process is still ongoing, which in its

Article turn assures perfectly harmonised machining and automation cycles, and thus maximised productivity. In future, data interchange between automation, machining equipment and peripherals will be playing an increasingly significant role. “We optimise this,” says Gerald Mies, “by having specialists in-house for CNC machining and automation, and can thus synergise the interfaces and match them precisely to the specific requirements involved. Besides optimisation of line effectiveness and the operating costs, a significant role is also played by new automation concepts, which have to be conceived in a symbiosis of machinery and automation. For the EMO Hannover 2017 “we shall be showcasing new ideas and visions.” For example, there will be an “unparalleled, wide-ranging exhibition of modern-day production technology with path-breaking digital solutions”. What precisely can visitors expect? Gerald Mies explains: “We offer practically everyone involved with mechanical manufacturing and automation ideas for their own manufacturing operations.“ The bandwidth ranges from standard machines to highly productive series manufacturing in turnkey systems and on rotary transfer machines. Other exhibits will feature large-component machining with integrated additive technologies and non-cutting processes. “On our stand, we’ll be aiming to show visitors that we can provide them with an added value that they haven’t yet been able to expect from any other vendor.” Massively progressing digitalisation How does the Emag Group in Salach intend to massively progress the digitalisation of its production technology for establishing intelligent factories? Oliver Hagenlocher, Head of Marketing, explains: “Digitalisation is already a reality for us. Today’s world is now digital, so we need solutions immediately.” Firstly, he says, the task is to identify how existing applications can be optimised and rendered accessible to the digital Machine - Automation & Electricity / EMO 2017 11

Article world. Secondly, it needs to be clarified what requirements this will entail for the production operation of tomorrow. Besides developing software solutions, Emag also intends to render the relevant hardware (in the shape of machine tools and automation solutions) fit for purpose in the smart factory. This thrust is exemplified by the modularised machines and the matching modularised Trackmotion automation concept. This combination enables production lines to be constructed on a modular principle. Machining processes are broken down into easy-to-handle sub-processes, and set up on the appropriate modularised machines – which is already being practised in sprocket manufacture, for example. The Trackmotion automation system here enables the modularised machines to be very simply and efficiently concatenated. With harmonised usability of the software, Emag aims to “simplify control, monitoring and analysis of the production operation”. In practice, says Oliver Hagenlocher, it works like this: “The usability or user experience (UX) constitutes developments within the context of digitalisation, and describes the experiences that an end-user has gained with a par-


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ticular software package. In the category of mobile apps, particularly, a positive UX is crucial to the success of a software package.” Nowadays, users expect not only a substantively fit-for-purpose software package, but also an intuitive operator control concept, one that facilitates a fast start-up without any elaborate training being required. “We’re looking forward,” says Oliver, “to presenting our new solutions to existing and prospective customers at the EMO Hannover 2017, and in a direct dialogue collecting further ideas and opinions, enabling us to tailor our products even more responsively to the requirements obtaining in the industrial sector.”

Solutions in the cloud and at the machine Another instrument for process optimisation is the Tool Lifecycle Management Strategy (TLM) from TDM Systems GmbH in Tübingen. Managing Director Peter Schneck explains how important this strategy is for the factory of the future: “Two years ago, when we introduced this strategy, we raised classical tool data management to a whole new level.

Thus it’s the unique selling point of our software that the system not only manages and makes available any information once inputted, but above all that during production of a workpiece it collects the relevant data at the machine. This data feedback creates a continuous improvement process quasi in the loop.” From the EMO Hannover 2017, Peter Schneck is primarily expecting a focus on the issues of digitalisation and networking: “This has always been our core competence, long before the times of Industry 4.0. With this new era, the options available for tool lifecycle management are multiplied.” Networking – and thus TLM – no longer stops at the doors of the factory hall. Modern-day TLM, he says, means transparency and cooperation that transcend the boundaries of individual plants, locations and nations, with short response times and mobile utilisation. To quote Peter Schneck: “We are, of course, embracing the dominant trend of being able to manage data and make them available through and in the cloud. Thus the future of TLM lies in the cloud as well.” As soon as the production operation is up and running, data are synchronously communicated from all steps of the process to an analytical tool. The data are based on status and process information from all technical sub-steps of the entire process chain.

ce + t

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AVENTİCS NAMED “FACTORY OF THE YEAR” İN HUNGARY Krisztián Herczeg (r.), Director Finance Hungary, accepts the award from Gyula Pomázi from the Ministry for National Economy.

Factory in Eger, Hungary, one of the best in the country The Aventics location in Eger, Hungary, may now call itself the “Factory of the Year 2016”. The Hungarian production location for the pneumatics specialist was honored in three categories, making Aventics Hungary he award ceremony on Kft. one of the May 5, 2017, in Budapest top-rated compawas thrilling: Aventics won nies in Hungary. three categories in this country-wide competition. The pneumatics specialists were honored for “Best Management Process”, “Best Production Support”, and “Most Energy-Efficient Factory”. Thanks to this excellent ranking, they also received the Factory of the Year award. Jury member Gyula Pomázi, who is also Deputy Under


Secretary at the Ministry for National Economy, handed over the award to Krisztián Herczeg, Director Finance Hungary at Aventics. “We are proud to receive the prize during this special year,” said István Gödri, Managing Director at Aventics Hungary Kft, after the ceremony. The Hungarian Aventics factory already has more reasons to celebrate in 2017: The pneumatics specialists have been producing in Eger for 50 years

and the Pneumobile, an international design competition and race for students, has taken place for the tenth time. This cross-industry competition is held annually by the Hungarian trade journal “GyártásTrend” and supported by the Hungarian Ministry for National Economy. Prizes are awarded in eight categories. The jury of experts assesses the companies on site and then decides which will move on to the final.

Award-winning: The Aventics location in Eger, Hungary.


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The ECD-LV compact ejector comes with a digital display.

Aventics expands product range to include intelligent compact ejectors with display

Aventics is expanding its project range for vacuum technology. In August 2017, the pneumatics specialists will launch the ECD series with four compact ejectors. The new products, some of which are IO-Linkcapable, will reduce air consumption significantly.

With the ECD-IV and three further compact ejector variants, Aventics is expanding its product range for vacuum technology.

P neumatics specialist Aventics is expanding its

range with intelligent compact ejectors. The new ECD (Ejector Compact Display) series consists of four product versions: ECD-BV, ECD-SV, ECD-IV and ECDLV. Equipped with a special nozzle, these compact ejectors ensure more efficient vacuum generation. When operated at the optimum pressure of 4 bar, air consumption is reduced by 15% compared to a product without this technology. The new ECD ejector series is suitable for handling metal and other non-permeable workpieces, as well as pastries and other slightly porous products. 16

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Four versions for various workpieces In the cost-effective basic variant ECD-BV, the compact ejector is equipped with two switching valves on the top of the product. In contrast to the basic variant, the ECD-SV (Smart Version) has an LED display that operators can use to directly read the vacuum values. This version also comes with a system monitoring function, an electric air economizer, and automatic drainage, and is suitable for use with a wide range of workpieces. The ECD-IV compact ejector is equipped with a digital display that shows all of the values as numbers. Operators can manually enter the

switching point and hysteresis via the user-friendly display. The ECD-IV also comes with an IO-Link connection for bi-directional communication with all common fieldbus systems and offers remote parameterization and diagnosis. Errors in the system can be detected early thanks to detailed condition monitoring, enabling forward-looking maintenance to assess and optimize system performance. With its ECD-LV (Large Version) compact ejector, Aventics offers a fourth variant which is comparable to the intelligent version ECD-IV, but enables higher performance.



“ asier, faster, and more precise” are the words Abdelhakim Boulakhrif uses to concisely describe the advantages of CAT. The sensor expert at Aventics continues, “Thanks to visual support with the LED traffic light system, even a child could correctly adjust the cushioning.” The tool clearly shows the installer which way the cushioning needs to be adjusted. A smartphone app also visualizes the set cushioning characteristics and piston speed. This allows users to fully benefit from

the excellent characteristics of Aventics cylinders in the system, as fine adjustment becomes a thing of the past. The diagnostic tool is simply fixed to the cylinder. CAT detects if and how the cushioning setting must be changed by evaluating the position and speed of the piston using magnetic sensors. The device only measures 5.5 by 8.3 centimeters and can be removed once everything has been set correctly. An integrated battery that can be re-

Cushioning Adjustment Tool from Aventics ensures correct cushioning charged via a micro USB with a traffic light system connection supplies the In the past, you power. The associated app is often needed excompatible with Android perience, a special and iOS smartphones. CAT touch, and a lot of can be used to commission patience to correctly adjust the and check Aventics cylinder cushioning for series PRA, CSL-RD, MNI, pneumatic cylICL, IST, TRB, and CCL. The inders. The new Cushioning Adjustment CAT (Cushioning Tool adds to Aventics’ wide Adjustment Tool) diagnostic tool range of engineering and assists assembly tools. Aventics’ the installer with push to digitalize pneumat- an LED display and ics aims to reduce costs, visualization in a increase system reliabil- smartphone app. Optimal adjustity, simplify machine dement of signs, and boost life cycles. cushioning is important for trouble-free operation, quiet running, and high cycle frequencies in systems.

The right direction: Thanks to the tool, installers know which way they need to adjust the cushioning. The light indicates when it’s right – a traffic light logic prevents incorrect adjustment

The Cushioning Adjustment Tool from Aventics helps to adjust the cushioning for pneumatic cylinders.

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The APK group (AgroPromKomplektatsiya) is one of the leading agricultural enterprises in the swine, beef and milk market.

Tr o heP r o mAPKK o m pgroup (Aglektatsi-

ya) is one of the leading agricultural enterprises in the swine, beef and milk market. The commissioning of its newest meat processing plant called KMPZ (English: Kursk meat-processing plant) in spring 2016 increased the capacity of APK to process 5,000 cattle daily, one of the highest meat processing capacities worldwide. The “state of the art” facility is operated in closed cycles that reduce residue production to a minimum, improving resource efficiency and keeping pace with modern sustainability s t a n d a r d s . To grant a permanent energy

supply and quality, ETW developed a customized CHP solution able to deliver the demanded electricity, heat and steam, independently from the grid. Yet this was not the first time ETW supported the APK group in a clean independent energy concept. Already in 2012 ETW could implement a similar system thus reducing the energy expenditures by 40%. The new one is a composition of three CHPs with 2 MWel capacity, producing a total of 6 MWel power and 3,021 MWth power, fueled by natural gas and expanded by three steam boilers. Those are hybrid steam boilers that run on both, exhaust heat and natural gas, producing up to 14.7 tons

of additional process steam. To overcome the very unstable grid supply, ETW designed the energy system to be operated parallel to the grid and in island mode. In case of a grid failure, the CHPs automatically switch to island mode without shutting down the APK meat production. Once the grid is back in stable conditions, the CHPs can be re-synchronized automatically due to a customized automation system developed by ETW. The whole plant was especially designed to attend the energy, heat and steam demands from the APK group. This customized configuration is unique in Russia and abroad. Next

The new one is a composition of three CHPs with 2 MWel capacity, producing a total of 6 MWel power and 3,021 MWth power, fueled by natural gas and expanded by three steam boilers. 18

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Plant Manufacturer honoured for Projects in Colombia and Australia

WELTEC BIOPOWER WINS TWO ADBA INDUSTRY AVARDS T& heBioresources Anaerobic Digestion Association

(ADBA) also organised the gala night at which the winners of the various categories were announced and received their ******** awards. This was already the WELTEC BIO- sixth time that the renowned POWER received industry award for outthe renowned AD standing projects, products & Biogas Indus- and services from the biotry Award in two gas industry was conferred. categories from WELTEC BIOPOWER was and pleased the British an- honoured to receive two of the aerobic digestion ADBA Industry Awards. association ADBA at the UK AD & „Both projects had their Biogas and World own special challenges and Biogas Expo 2017 were already very demandin Birmingham, ing in planning. Therefore, we UK. An indepen- are delighted that both plants dent expert jury not only work successfully, but nominated the have now also been awarded German biogas with these prestigious awards. plant manufactur- The awards encourage our er in the category entire team to continue to develop smart and !exible solu„Best international ag- tions for our customers“, says ricultural project“ Kevin Monson, Sales Manager. in recognition of The construction of the AD its 800-kW plant plant for Colombia‘s largest in Colombia. The egg producer took place unaward “Best inter- der consideration of the high quality and hygiene requirenational commercial plant” ments of the South Ameriwas given to WELTEC BIOPOWER for its 1-megawatt-plant in Melbourne, Australia.


can agricultural industry. This was one of the main reasons why investor Juan Felipe Montoya Muñoz had opted for stainless steel tanks from WELTEC BIOPOWER. Montoya Muñoz owns several poultry farms in Colombia, at which about 3.5 million eggs are produced every day. As the process yields large amounts of dry chicken manure and process water, the 800-kW biogas plant can be operated without using any other substrates. Right from the planning phase, WELTEC BIOPOWER took the investor‘s expansion goals into account and planned and built this agricultural energy plant according to industrial standards. The experience gained with industrial standards is also useful in other projects. No wonder that WELTEC BIOPOWER reached the “nal round of the ADBA Industry Awards in the category „Best international commercial plant“. WELTEC won the award with a 1-MW biogas plant in Melbourne, Australia. The basis for energy generation is 100 tons of organic waste a day. More than half of this amount will come

from cafeterias and restaurants. The rest will comprise fats and oils, brewery and dairy leftovers, fruit and vegetable waste and sludge that will be pumped from the adjacent wastewater treatment plant. The operator Yarra Valley Water is one of Australia‘s largest water supply and wastewater disposal enterprises and is now able to satisfy its energy needs at the Aurora site from biogas. Besides Yarra Valley Water can fed surplus electricity into the public grid. The objective of the ADBA contest is to draw attention to such intelligent plant concepts. „Their dedication to enhancing our industry‘s reputation and performance is testament to the innovative and entrepreneurial spirit that has built the AD industry“, says Charlotte Morton, Chief Executive of ADBA. In the opinion of David Newman, the award winners and the companies that have been shortlisted „serve as a shining example of how biogas can help to meet the UN Sustainable Development Goals“

The award “Best international commercial plant” was given to WELTEC BIOPOWER for its 1-megawattplant in Melbourne, Australia.

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WELTEC BIOPOWER was honoured and pleased to receive two of the ADBA Industry Awards. Left to the right: Mike Webber, Ann Börries, Carsten Hesselfeld, Kevin Monson (all WELTEC BIOPOWER) & Charlotte Smith (Moderator of the Gala).


PRECISION FOR CHALLENGING ENVIRONMENTS DOSIC® FLOW SENSOR A compact stainless- tact between the sensor and Tmodel he rugged and compact steel sensor for flex- the flowing media, and the combined with a hy-

gienic design ensures highly reliable measurement results. This makes the sensor ideal for a wide range of application possibilities, including those where space restrictions or aggressive media play a role. Two configurable digital inputs and outputs and up to The new non- two analog outputs, as well as contact DOSIC® an IO-Link interface to a superultrasonic flow sensor is used to ordinate control unit, ensure detect the flow that you get just the right start volume of conduc- position. The IO-Link reduces tive and non-con- cabling and also enables comductive liquids. plete control and monitorWith its measurement channel and ing of the sensor in Industry stainless-steel 4.0 machine environments. housing, the ultrasonic flowmeter is suitable for measuring tasks in hygienic and highly demanding environments.

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ible flow measurement The absence of moving parts in the sensor eliminates potential contamination risks in the demanding hygienic environments of the food industry. In addition, the sensor has a straight, seal-free, and self-emptying measuring tube made of high-quality stainless steel (316L with Ra ≤ 0.8). The high-quality stainless-steel housing also provides the necessary ruggedness and resistance. It therefore goes without saying that the sensor has EHEDG certification and demonstrates FDA conformity. Since there is no con-

flow volume is determined in a non-contact manner, aggressive cleaning agents in CIP and SIP operations are not a problem either. The sensor can easily withstand temperatures up to 143 degrees Celsius in SIP processes for up to one hour. In addition, the sensor automatically adjusts its parameters if the medium is changed. This “Plug & Measure” solution eliminates the need for initial medium calibration and reduces installation and operating costs.


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• Lifeblood of the industry: unique, flexible, versatile and indispensable • Team player and master of adaption: a hidden talent among materials • Dandelion: sustainable source of raw materials for future rubber extraction


A team player and a master of adaption, rubber is a hidden talent among materials. Without products made of rubber, virtually no complete industrial system would be able to function today. This material keeps the world moving and is the key to pioneering developments and technical innovations.

On World Rubber Day on

September 12, technology company Continental will be presenting this hidden star of the modern world. More than any other company, this materials specialist has been injecting dynamism into a variety of industries around the world for over 145 years with its rubber-based solutions. “Without products made of rubber, virtually no complete industrial system would be able to function today. This material keeps the world moving and is the key to pioneering developments and technical innovations. Our expertise in materials is therefore a decisive factor in our lasting success, and we have mastered global production and procedural trends,” says chemist Dr.

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Wolfram Herrmann, responsible for material development in the ContiTech division. Often, rubber is a material that works away seamlessly in the background where nobody looks closely. It is a unique and resistant master of adaption, which is unbelievably versatile, indispensable and fascinating. Life without rubber is unimaginable A world without rubber would be like a football match without a ball, or a book without letters. After all, a bedframe without a latex mattress would be very uncomfortable and a washing machine without a drive belt would not spin. And what would happen to your car? It is not only the tires that would

disappear. Without hose lines, the engine would not work because the drive, brakes, steering and the exhaust system would all fail. What’s more, without dampening mounting elements, the noise caused by the vibrations of the engine would not be insulated, and the driver would not be saved from unpleasant jolts. The doors would rattle in their frames and the window panes would not be air or watertight. It would not even make sense to switch to other means of transport – whether bikes, buses, the subway or trains – nothing would be moving anymore. The world would come to a standstill. Eventful history The Mayans themselves were



astonished when they heated up the milky sap tapped from the trees and created latex. The sap turned into a solid yet elastic mass from which the ancient peoples made balls, vessels and hoses for everyday use. The Mayans gave the tree the name “caa-o-chu,” meaning “weeping tree.” For a long time, however, people did not know what to do with

the material. It was not until the dawn of industrialization that rubber was successfully converted into a modern material. The biggest challenge was to improve the material so that it could be used more easily. When very hot it began to stick and when cold it became brittle. The effects of light and the weather quickly made the rubber products of this time

unusable. It was the process of vulcanization that gave rubber its elasticity. The industry used it for seals in steam engines, to insulate telegraph cables and for bicycle tires. Soon, it was used as an insulator in the emerging electrical industry and to manufacture vehicle tires. In this way, the raw material developed into one of the key materials of the Industrial

The Mayans themselves heated up the milky sap tapped from the trees and created latex. The Mayans gave the tree the name “caa-o-chu,” meaning “weeping tree.” Rubber was successfully converted into a modern material with the dawn of industrialization. It was the process of vulcanization that gave rubber its elasticity.

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tapping general steels, aluminium and aluminium wrought alloys, stainless and acid-resistant, high-tensile steels or cast iron – Guhring’s PowerTap range promises powerful taps for all common threads. Golden Power “Made in Germany” Guhring’s Powertap range can be visually identified by its gold ring. The message is: With universal PowerTaps you are always spot-on. State-of-the-art manufacturing technologies guarantee maximum quality “Made in Germany” at an unbeatable price performance ratio. Guhring has developed its own production machines for the manufacture of uni-

versal taps, where the highly accurate geometries of the PowerTaps are ground.

Wide range of application thanks to optimised geometry The special geometry of Guhring’s PowerTaps turns them into true allrounders and enables outstanding machining results for a wide application range. Thanks to the optimised geometry a long and consistent tool life is achieved. Straight-fluted taps for through holes as well as spiral-fluted tools for blind holes achieve optimal machining results thanks to highly accurate cutting edge geometries.

HSS-E- as well as HSS-E-PM quality steels are used as tool materials. Universal Powertaps are surfacetreated with TiN-coating to maximise their performance and to achieve higher cutting rates as well as providing long tool life. As well as the conventional B and C forms for machine taps, Guhring’s PowerTap range also includes specialists with the short chamfer lead of form E. With blind hole machining this form enables the production of threads where the thread depths are close to the base of the hole.



The universal taps of the PowerTap range are available for the most important thread types and thread sizes.

Optimal tool materials and forms Machine - Automation & Electricity / EMO 2017 27

Company ,

Continental develops pioneering technologies and services for sustainable and connected mobility of people and their goods. Founded in 1871, the technology company offers safe, efficient, intelligent and affordable solutions for vehicles, machines, traffic and transport. In 2016, Continental generated sales of €40.5 billion and currently employs more than 230,000 people in 56 countries.

The sustainable rubber source of the future: Continental is exploring new horizons in the field of rubber extraction with the Fraunhofer Institute for Molecular Biology and Applied Ecology IME, the Julius Kühn Institute, and plant cultivators ESKUSA. Rubber from dandelion root is an environmentally and economically attractive alternative to the tropical rubber tree.

Revolution. Today, around 40% of rubber is extracted from the rubber tree, Hevea brasiliensis. Elasticity – the secret of its success Its elasticity is what makes rubber so unique. After being subjected to loads or tension, it returns to its original form. This is also one of the unique, basic functions of our life and of nature. This property proves rubber to be a real expert in the art of adaption. Hardly any other natural invention has had quite the sustained impact on human life of this durable, tough material. “Viewed from the perspective of the designer, the outstanding and unique property of this material is its elasticity. When various substances, such as fillers and additives, are added to rubber, it becomes a structural material. A virtually unlimited variability of compounds results in tailormade solutions for every application,” explains Herrmann. Rubber can be resistant to

28 Machine - Automation & Electricity / EMO 2017

high and low temperatures at the same time. It can be hard yet not brittle, gastight, electrically insulating or electrically conductive and resistant to aggressive substances such as oxygen, ozone, UV radiation, extreme temperatures and pressure. These properties are significantly influenced by the processing methods used – nowadays also in the area of nano-technology. Continental has rubber compounds for the extremely wide range of applications at its disposal. The standard range alone comprises well over 700 different formulas for various applications. At the same time, and above all, the compounds satisfy the required product properties. Successful team player Rubber is an excellent team player, so most of its mechanical properties are dependent on the materials with which it is combined. Joined with other materials, it becomes a high-tech product and is a

high-performance component in complex technical systems. Hardly any other material has the ability to be combined with so many different substances to create something new. This enables Continental’s research and development departments to come up with pioneering material combinations with improved or hitherto unprecedented properties. “We provide the knowledge needed to combine various materials, such as rubber or plastic, with metals, fabrics or other structural components or electronic components. We have developed substantial expertise in this field of hybrid materials and compound products and are increasingly converting our skills into new applications,” continues Herrmann. Without rubber, individual mobility would also be hardly conceivable. It is largely responsible for safety and comfort in today’s cars. Drive belts, hose lines and mounts, for instance, are integral components of engines and chassis. Whereas

Company around 1900, a vehicle had between only 15 and 20 rubber parts in total, nowadays there are around 600 functional parts, components and systems made from this material. What’s more, over 70 percent of the rubber extracted worldwide is used for the production of tires for cars, trucks and airplanes – almost two billion units per year. Other products include around 40,000 items used in daily life, which contain rubber. Dandelions: The Sustainable Rubber Source of the Future


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Continental is also exploring new horizons in the field of rubber extraction with the Fraunhofer Institute for Molecular Biology and Applied Ecology IME, the Julius Kühn Institute and plant cultivators ESKUSA. “The objective of this joint project is to develop a procedure for the industrial use of dandelions as a supplier of rubber. In agricultural terms, it is an undemanding plant and can also be cultivated in the northern hemisphere. This means that rubber production is conceivable near our tire factories, for instance, and the significantly shorter transport

routes would considerably simplify logistics” explains Dr. Carla Recker, who heads the Continental project concerned with the development of this promising material. The quality of the rubber from dandelion root is the equivalent of that from the rubber tree. At Continental, the use of natural rubber from dandelion roots has already proven itself in prototypes for tires and engine mounts. Products are expected to be ready for production in the next five to ten years.



Dr. Wilfried Schäfer, Executive Director of the VDW (German Machine Tool Builders’ Association), Frankfurt am Main


“ he EMO Hannover 2017 will be the highlight of the year for the metalworking sector,” says a gratified Dr. Wilfried Schäfer, Executive Director of the EMO’s organiser VDW (German Machine Tool Builders’ Association), in Frankfurt am Main. From 18 to 23 September, it will once again be the international meeting point for trade visitors interested in production technology. Under the motto of “Connecting systems for intelligent production”, the focus here will be on networking and digitisation. The VDW will shortly be publishing the provisional EMO exhibitors’ directory under So far, around 2,000 exhibitors from 42 different countries have registered. That means that this year the event is well on

the way to topping the record figures achieved by the EMO Hannover in 2013. The major exhibitors in 2017 include DMG Mori, Mazak, Fanuc, FFG, Grob, Doosan, Okuma, Makino and Siemens. “The complete EMO exhibitors’ directory reads like a Who’s Who of international production technology manufacturers,” says Wilfried Schäfer. Numerous supporting events will round off the EMO Hannover’s attractions The EMO Hannover is not only the most important meeting point for all protagonists in the metalworking sector, manufacturers and users alike. It is also traditionally a forum for innovations and trendsetters. “We shall be organising numerous events designed to address and indeed progress important technical and commercial issues in the world of

EMO Hannover 2017 once again a premier-status event for the metalworking,” reports Wil- metalworking industry fried Schäfer. They comple-

ment the manufacturers’ range of exhibits, and communicate to visitors a comprehensive picture of trends and issues themed around metalworking.

They are exemplified by the “Industry 4.0 Area” with its presentation forum addressing multifarious aspects of the motto embraced by the EMO Hannover 2017: “Connecting systems for intelligent production”, the “India Day”, the conference on the topic of “Additive Manufacturing”, the seminar on machine safety, or the special show on “Aerospace Technology”. The picture is rounded off by other activities themed around youth recruitment, a match-making initiative, or a special stand featuring international start-ups.

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Heinrich Mรถdden, machinery safety expert at the EMO organizer VDW

The safety of machine tools

is a major issue. Complex machinery, high speeds, and high power levels can be a danger32

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ous mixture for the operator. Nevertheless, machine tools are very safe products. Many stakeholders have been col-

laborating for a long time to reach the current safety level: machine tool manufacturers, operators, health and safety

Fair experts, EU policy-makers and international standardisation groups. At the Safety Day for Machine Tools at EMO Hannover 2017, top experts will present their insights on the requirements and challenges entailed by the current state of the art, mapping out how practical solutions ensure high levels of safety and elucidating what remains to be done in the future. It is a remarkable story: “For many decades, our companies have proven that they can handle the risks that come with the operation of machine tools”, explains Heinrich Mödden, a machinery safety expert at the EMO organizer VDW (German Machine Tool Builders’ Association). Certainly there is a lot of work still needed, but, as Mr. Mödden continues, “it pays off, as the number of accidents is continuously declining.” This shows that a high level

of safety has already been achieved with traditional design practices. Machine tools: Safety Inside! A large contribution to this gratifying trend has to be attributed to European Machinery Directive 2006/42/EC (MD), which was issued in 1993 and aimed at levelling the safety standards for machinery across the European Union. “The EU Machinery Directive has been a success story, making working envi-ronments significantly safer and reducing hazards”, says Felicia Stoica, policy officer for the Machinery Directive at the European Commission’s Directorate-General for Growth. “The involvement of all stakeholders in the machinery sector, especially manufacturers and their equipment suppliers, has ensured that the actions taken are practicable and beneficial.”

The MD takes manufacturers of machine tools into its focus, too, and they have to conduct risk assessments for their design. Since the first version of the MD was established, there have been considerable alterations in the standardization environment covered by this directive and in particular to risk assessment. As a result, the safety requirements are still being animatedly discussed, e.g. the reliability of mechatronics in safety functions. Following strict subsidiarity, such rules for safety measures are formulated by expert panels in standardisation processes. For machine tools, this work is being performed on a global ISO level. Hence, many of the international mar-ket actors are negotiating about the state of the art. “Machine safety evokes strong involvement of companies or authori

At the EMO Safety Day on 19 September in Hanover experts from different professions demonstrate how safe machine tools are.

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Fair ties. It can be a tough job to find a consensus”, states Christian Neumeister, secretary of the ISO working group for safety of milling machines. “But in the end, we usually find compromises to satisfy the demands of health and safety authorities and keep the effort in-volved for the industrial sector to an acceptable level.” Functional safety: the next big thing Functional safety means that safety has to be proven by quantification of failure probabilities. For machine tools, this is quite difficult, as hazards can be high, even though they occur very rarely. In a scientific study that the VDW organized on behalf of its member bodies, Nika Nowizki from the University of Stuttgart analysed the running times of 578 multi-spindle automatic lathes with a total of 3951 spindles using mostly standard PLC controllers. These produced not a single safety-related accident in over 93,333,000 machine hours of operation evaluated since 1992. “We were happy to see that our gut feeling was scientifically reconfirmed” smiles Eberhard Beck, Head of Machine Con-trol Design at the lathe manufacturer Index in Esslingen, Germany. “It shows that our

high safety level is attributable not only to single components, but to our long-term empirical design principles according to product safety stan-dards, which are proven-in-use.” Still, many safety subjects need further insights. For example, the recent development of turning operations on milling centres is causing uncertainty among manufacturers and their customers as to whether the proven-in-use argument for machine tools remains valid for the future. An intermediate con-clusion is that this is only possible when the suppliers of clamping devices are involved. Another subject is market surveillance. Machine tools are complex products, usually custom-built, and too large and expensive for lab testing. This means it is difficult to determine on-site if the design is compliant with safety regulations. In particular, market surveillance authorities lack qualified personnel and time to investigate. One concept to help market surveillance authorities in doing their job is the CE Guides on Machine Tool Safety published by Cecimo, the European Machine Tool Association. In simple words, with instructive illustrations, they spotlight the impor-

EMO Hannover 2017 – the world’s premier trade fair for the metalworking sector From 18 to 23 September 2017, international manufacturers of production technology will be spotlighting “Connecting systems for intelligent production” at the EMO Hannover 2017. The world’s premier trade fair for the metalworking industry will be showcasing the entire bandwidth of today’s most sophisticated metalworking technology, which is the heart of every industrial production process. The fair will be presenting the latest machines, plus efficient technical solutions, product-supportive services, sustainability in the production process, and much, much more. The principal focus of the EMO Hannover is on metal-cutting and forming machine tools, production systems, high-precision tools, automated material flows, computer technology, industrial electronics and accessories. The trade visitors to the EMO come from all major sectors of 34

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tant aspects involved. “If we want to have a level playing field with all market participants, we need to assist market surveillance authorities in doing their job better”, points out Maitane Olabarria of Cecimo. After sawing and EDM machines, the recently finished safety stan-dard for milling machines, ISO 16090, triggered the publication of a new guide to be presented at EMO Hannover. “The proximity to the EMO exhibition makes it possible to see how the design concepts of modern machine tools have been enhanced once again”, Mr. Mödden concludes. As a consequence, not only the aspects of machine manufacturers are to be discussed, but also the vital connection to the equip-ment suppliers, as well as the reflections of occupational safety executives arising from their field experience. The expected conclusion of the EMO Safety Day is also an appeal to all worldwide manufacturers to ensure that machine tools which are being de-signed in accordance to the relevant product safety standards and which are also being operated in accordance with their intended use can be considered safe!

industry, such as machinery and plant manufacturers, the automotive industry and its component suppliers, the aerospace sector, precision mechanics and optics, shipbuilding, medical technology, tool and die manufacture, steel and lightweight construction. The EMO Hannover is the world’s most important international meeting point for production technology specialists from all over the planet. In 2013, the fair attracted more than 2,130 exhibitors, and around 143,000 trade visitors from more than 100 different countries. EMO is a registered trademark of the European Association of the Machine Tool Industries CECIMO. You will find texts and images relating to the EMO Hannover 2017 on the internet at in the Press section. You can also follow the EMO Hannover using our social media channels

At a glance What: When: Where:

EMO Safety Day for Machine Tools Tuesday, 19 September 2017, 10.00 a.m. to 14.00 p.m. Hannover Exhibition Grounds, Convention Center


Welcoming Address Dr. Alexander Broos, Director of Research and Technology, VDW (German Machine Tool Builders Association) Machinery Safety and Market Surveillance in the EU: A Success Story Continues Safety of Grinding Machines - Secret of the Success of ISO 16089 and Residual Risk

Felicia Stoica, Policy Officer Machinery Directive, European Commission, Director-ate-General for Internal Market, Industry, Entrepreneurship and SMEs Christian Adler (BGHM, expert committee woodworking and metalworking of the Ger-man social accident insurance scheme), Health and Safety Expert on Grinding Ma-chines; Collaborative impact tests

The new Safety Standard ISO 16090 on Milling Machines Dr. Lukas Prasol, Fabio Meister, Scientists, Technical University of Berlin Christian Neumeister, Managing Director, German Standardization Commitee for Machine Tools DINNWM

CE Guide for Milling Machines - A Checklist for the Market Surveillance Authorities Ms. Maitane Olabarria Uzquiano, Manager Technical Regulations, Ce-cimo (European Association of the Machine Tool Industries) Safety of Workpiece Clamping Devices Heinrich Mรถdden, Technical Expert in Safety, VDW Impact Tests on Guards and Simu-lation Dr. Luca Landi, Full-time researcher, University of Perugia Proven-in-Use: Safety of Standard-PLC in Turning Machines Nika Nowizki, Scientist, Stuttgart Uni-versity Seminar language: English Attendance fee: 185 Euros plus VAT Registration: Contact: Ingrid Kirchner,

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CONTINENTAL USES STRONG CORPORATE BRAND TO TAP INTO NEW SALES MARKETS FOR SURFACE MATERIALS BeneckeKaliko and Hornschuch are becoming Continental: The technology company is gathering speed in this integration and, in the future, Continental’s strong corporate brand will be used to tap into new sales markets for surface materials and to expand awareness in existing markets.


technology company Continental is gathering speed in its merger of Benecke-Kaliko and Hornschuch. In the future, the strong corporate brand will be used to tap into new sales markets for surface materials and to expand awareness in existing markets. “With this new image, we are ensuring we have a consistent identity across the world, generating a high level of recognition among our customers and reinforcing the common identity of our employees without losing sight of our long-standing traditions. At the same time, we are consistently expanding the image of the Continental brand outside of the automotive industry,” explains Dr. Dirk Leiß, head of the newly renamed Benecke36

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Hornschuch Surface Group business unit. The integration of Hornschuch began on March 1 after approvals were received from the antitrust authorities and is expected to be completed by the end of 2018. More than 90 employees are driving a smooth and effective merger of all the company divisions.

such as Acella, d-c-fix, laif and skai, will remain unchanged. “This will be an extremely positive step for our business partners and employees alike. Our new unified image reflects the combined high performance and sovereignty of a company that has evolved from a variety of cultures,” emphasizes Leiß.

Integration in the brand world of Continental is changing the market image. Benecke-Kaliko and Hornschuch are becoming Continental. Visual elements are already being changed step by step to comply with the corporate design of the Continental corporation. This means that, in the future, the image will be characterized by Continental yellow. However, well-known product brands,

The global team of researchers and developers, engineers, sales employees and designers understands the markets and requirements of the customers, thereby laying the foundations for innovative, intelligent and environmentally friendly surface solutions in high-quality and creative designs. After all, innovation and progress have been tradition

Company at Benecke-Kaliko and Hornschuch for almost 300 years. Independently of each other, both companies have enjoyed success on a global level in the technical implementation and design of surfaces, as well as an image that stands for tech-

nological competence, design, quality and service in the furniture, construction, automotive, commercial vehicle and DIY industries. With a strong network comprising 11 production locations, 20 sales offices and joint representatives

in more than 80 countries, the surface specialist is based locally for customers across the world, allowing it to provide the best possible services for globally operating customers.

BeneckeKaliko and Hornschuch are becoming Continental: The technology company is gathering speed in this integration and, in the future, Continental’s strong corporate brand will be used to tap into new sales markets for surface materials and to expand awareness in existing markets.

Continental develops pioneering technologies and services for sustainable and connected mobility of people and their goods. Founded in 1871, the technology company offers safe, efficient, intelligent and affordable solutions for vehicles, machines, traffic and transport. In 2016, Continental generated sales of €40.5 billion and currently employs more than 227,000 people in 56 countries. As a division in the Continental Corporation, ContiTech is one of the world’s leading industrial specialists. Its customers can be found in key industries such as machine and plant engineering, mining, the agricultural industry, and the automotive industry. With around 46,000 employees in 44 countries, the company uses its development and material expertise for products and systems made of rubber, polyamide, metal, textile, and electronic components to combine these with individual services. ContiTech always thinks in terms of customer-friendly and environmentallyfriendly solutions – going well and truly beyond its roots as a producer of rubber products. With sales of approximately €5.5 billion (2016), this international technology partner is active with core branches in Europe, Asia, North and South America. Machine - Automation & Electricity / EMO 2017




BMW Group subsidiary Designworks collaborates with Shell to improve the customer experience in hydrogen refuelling.

BMW Group subsidiary Designworks and Shell have collaborated in the development of an innovative hydrogen dispenser that will improve the refuelling experience. Hydrogen vehicles have proved to be increasingly suitable for everyday use and offer the potential to become an important low carbon transport option for the future. The new dispenser design will create a seamless experience for hydrogen drivers on the forecourt and help to encourage the adoption of hydrogen as


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a transport fuel of the future. Designing for a new way of refuelling. BMW Group subsidiary Designworks, a design studio well acquainted with the challenges of designing for the future of mobility, was commissioned by Shell to develop the design of a new hydrogen dispenser. Designworks approached the project applying BMW’s innovative and holistic research and design process “Fixstern” (fixed star). This pioneering

approach to innovation creates a future vision, a focal point that all stakeholders can share in common, align to, and drive benefits of the Fixstern process, is its power to create commitment for a common goal by providing a tangible vision that multiple project partners can work towards”, says Sonja Schiefer, Director of the Munich studio of Designworks. Oasis:







Hydrogen dispenser models currently on the market are based on those designed for conventional fuels. To inspire a world of clean energy, Designworks created Oasis, a dispenser concept that departs from the “H” or “L” shaped fuel dispensers presently on the market. It introduces a new product typology with an “I” shaped, pillar-like design with a friendly appeal. Oasis takes inspiration from natural forms and elegantly rises upwards creating a beacon both from close up and from a distance.

screen and an innovative nozzle for refuelling. The light concept helps guide the overall flow of cars on the forecourt by providing precise and clearly visible information about the dispenser´s occupancy and the remaining fueling time. A concise graphical communication concept wasdeveloped for the interaction screen on the front of the dispenser, to provide clear and easily accessible information. It allows users to keep track of their refuelling time and price, request maps to check route details or dive deeper into the world of hydrogen.

The Shell dispenser design is clean and remarkably simple with all mechanical parts made invisible. When approaching the dispenser, the user will experience a light guidance system, a generous information

For the refuelling nozzle, the design team created a new pick up and mount mechanism, which provides a highly intuitive way of removing and returning the nozzle. To make the refueling experience even more

Company comfortable, a screen was integrated directly into the nozzle guiding the user through the refueling process step by step. Beyond offering an innovative refuelling experience, the new dispenser concept, with its clean design language and easy to use functionality, makes a clear statement about the future of hydrogen. Oliver Bishop, Hydrogen General Manager at Shell said “Customers are at the heart of what we do. We are pleased to have collaborated with Designworks in the development of a new hydrogen dispenser that will allow us to provide customers an improved hydrogen experience. It will not only make refuelling seamless, it will also help make hydrogen fuel an even more attractive option in the future”.

Machine - Automation & Electricity / EMO 2017


Hannover Messe 2017

VDW’S MALAYSIA SYMPOSIUM OPENS UP MARKET OPPORTUNITIES Contact platform for machine tool manufacturers and Malaysia’s indus-trial sector

Author: Alexander Schneiders, VDW Press and Public Relations

Contact platform for machine tool manufacturers and Malaysia’s indus-trial sector The business talks in the context of the VDW Symposium in Kuala Lumpur (Malaysia) enabled German machine tools manufacturers to establish contacts in the Malaysian industry.

Despite the currently weak-

ened vigour of its economy, Malaysia remains an attractive export market for German machine tool manufacturers. Admittedly, the forecasts for machine tool consumption in 2017 are only very cautiously optimistic, but as from 2018 annual growth rates of around 3 per cent are again being predicted. In the long term, too, Malaysia offers attractive scenarios for machinery vendors, since the country is in this category largely dependent on imports.


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Malaysia’s import market is currently dominated by Asian vendors, chief among them the Japanese. But at least Germany ranks fourth, behind China and Taiwan, with scope for improvement – after all, manufacturers from Ger-many have hitherto operated rather cautiously in Malaysia. The VDW (German Machine Tool Builders’ Association) accordingly arranged a symposium for the ASEAN nation. “Its primary purpose is to give member companies a feeling for the Malaysian market,” is how Klaus-Peter Kuhnmünch describes the motiva-

tion for this multi-day event. As the organiser of the VDW’s symposia abroad, he has for years now been accompanying representatives of German machine tool manufacturers to attractive markets all round the world. This time, the companies availing themselves of the opportunity were Alzmetall, Chiron-Werke, DMG Asia, FFG Europe & Americas, Hermle, Index-Werke, Liebherr-Verzahntechnik, Mauser-Werke and Open Mind. The majority wanted to be-come better acquainted with the market and make new contacts. Others

Hannover Messe 2017 made the journey already resolved to gain partners or representatives in the region. And several of them came along because in the past they had already learned to appreciate the VDW’s symposium format. Keen interest from Malaysia’s industrial sector The main event, entitled “Innovations in Production Technology – Machine Tools from Germany in Kuala Lumpur” on 11 July was supported by the Ger-man-Malaysian Chamber of Industry and Commerce (AHK Malaysia). There, the German participants had an opportunity to spotlight their corporate profiles among users and potential partners with their presentations. Daniel Bernbeck, Executive Director of the AHK Malaysia, rates the symposium as a great suc-cess. “The high number of business meetings held under the aegis of this event underlines the keen interest displayed by Malaysian entrepreneurs in German technology. The symposium is a consummate example of cooperation between the VDW and the AHK in market entry consultancy, from which small and mid-tier German companies can derive especial benefit.” Modernisation remains dependent on machinery imports

Insights into the status of production technology were provided by visits to in-ternational branch operation under the aegis of the symposium. In and around Penang, the Bosch, Osram and Infineon companies invited participants to in-spect their production facilities. “These visits made it clear that high-tech is also represented in Malaysia,” is how the symposium’s host Klaus-Peter Kuhnmünch describes his impressions. However, Malaysia’s production tech-nology across the nation as a whole is very far from equalling the level attained by highly developed industrialised nations. “The expectations and results in regard to Malaysia are mixed” is how Roland Merz, Asia Sales Manager at Chiron, for example, assesses his experiences in business meetings there as follows: “Manifestly, the main business here still involves triaxial machines. But high-end solutions sometimes seem quite a long way off.” That, however, also opens up longterm opportunities, because in order to catch up technologically, Malaysia needs imports. The country will not be able to postpone the industrial sector’s renewal for much longer, since their sophis-ticated sectors (like aircraft manufacturing) are increasingly dependent on tech-

nologically advanced machinery. These developments, for example, are a major focus for symposium participant Martin Winterstein, Business Develop-ment Director at the gear system manufacturer Liebherr Verzahntechnik: “For us, Malaysia has definite potential, thanks to its growing aerospace industry, but also its automotive, oil and gas sectors. This is why we’re looking for a representative there. I am very satisfied with the VDW’s symposium, and will al-ready be taking specific customer inquiries back home with me. And we at Liebherr are already planning another visit to Malaysia in the autumn”. It’s not only the German participants who benefited from the event, but also representatives of Malaysia’s business community. “An excellent initiative”, comments an enthusiastic Helmi Sheikh Mahmood, for example. He is the CEO of Sapura Industrial, part of a group of companies active in all of the re-gion’s key industries. The symposium, he says, offers Malaysia’s business community a unique opportunity at a single location to establish personal con-tacts with quite a few representatives of Germany’s technologically sophisti-cated machine tool industry.

Background: For thirteen years now, the VDW has been organising German technology symposia in important growth markets. They aim to assist the German machine tool industry to penetrate these markets and to showcase for the users there the sector’s professional competence and corporate capabilities. So far, symposia have been organised in Brazil, China, India, Mexico, Poland, Romania, Russia, Thailand, Turkey, Iran, Malaysia, Indonesia, Vietnam and South Korea. In line with sustainability thinking, the symposia are repeated at certain intervals.

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A+ A +

BASIC REQUIREMENTS OF PEOPLE - FRIENDLY DESIGN OF THE WORLKPLACE About the Author: Ralf Pieper, Prof. Dr. rer. pol., Wuppertal University, Specialist Area Safety Technology / Safety and Quality Law

W hat is Ergonomics? The invented term ergonomics

was coined in 1857 by the Polish natural scientist Wojciech B. Jastrzebowski from a combination of two Ancient Greek words  ergon meaning “work” and  nomos meaning “principle” or “law” as the “science of activity”. In this context Jastrzebowski made a distinction between the “science of damaging acFrom 17 to 19 tivities” and a “science of useOctober the ful activities”. He focused his international further definition on “useful trade fair A+A activities” and set out a series 2017 featur- of further correlations such as ing the 35th  “Labour”, International  “Entertainment”, Congress for Occupational  “Thinking” and Safety and  “Devotion”. Occupational These attributions which can Medicine more easily be associated with offers a comprehen- an anthropological and cultursive range of alistic viewpoint, which were information also charged with a religious on the topic connotation by Jastrzebowski, of ergonomics and work- are without any social considplace design. eration. This means that they In conjunction at no point reflect the spirit of with a defini- industrialisation that occurred tion of the in 1857 in the first generally term “ergonomics” and perceived world market crisis. its sub-topics With Jastrzebowski one seeks this line-up in vain for a description of the will be eluci- industrial or other working dated below conditions and the social and according to thematic focal political climate of workers or points by Prof. an examination of the forms Dr. Ralf Pieper of power and hegemony, conof Wuppertal flicts and resistance in labour University. relations. After long disciplinary development ergonomics now focuses on the design  of products including software ergonomics  working conditions as part 42

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of employment relationships. Overarching requirements made of ergonomics arise from the digitalisation of living and working conditions, the requirements of age and ageingappropriate, inclusive and nondiscriminatory design as well as eco design. Here ergonomics is integrated into company and inter-company labour and wage policies of social partners. Norms1 play a key role here as does the Commission for Occupational Health and Safety and Standardization (Kommission Arbeitsschutz und Normung – KAN)2 funded in this context by social partners, the state, statutory accident insurance and the German norms board DIN. In terms of the discipline itself a differentiation is made between  physical/corporeal (especially anthropometry, bio-mechanics, physical forces, perception and sensory perception),  cognitive (especially information processing) and  organisation-related (especially labour organisation, workflows, working hours, working environment) ergonomics3 where the systemic, activity-related contexts between these sub-sections is pointed out with a view to the necessary general overview of physical and mental health4. Ergonomics as an Operational Support Task Since 1974 the German Occupational Safety Act (Arbeitssicherheitsgesetz – ASiG) has stated that it is a specific and, at the same time, general task of employers to appoint expert support in the form of works physicians, safety engineers and other specialist staff for occupational safety

 when designing the workplace, workflows and the working environment,  in occupational-physiological, occupational-psychological and industrial hygiene questions, in particular working rhythms, working hours and break time regulations as well as  in other ergonomics issues. This basically describes what areas of activity in occupational prevention the field of ergonomics covers5 and, at the same time, what the central areas of research for work science are. This joint task of works physicians and occupational safety specialists, who by law must be independent of company instructions, can be seen in the light of the goals to be achieved by appointing them in accordance with § 1 of the German Occupational Safety Act (Arbeitssicherheitsgesetz – ASiG):  Application of regulations serving safety and occupational health corresponding to specific occupational conditions  Realisation of established occupational health and safety findings to improve occupational safety as well as  Achievement of the highest possible level of effectiveness of the measures serving occupational safety. Organisational Fields of Ergonomics and Ergonomics as a General Employer Obligation Employer obligations arising from the German Occupational Safety Act (Arbeitssicherheitsgesetz – ASiG) in terms of ergonomics and their related support tasks are clearly laid out and defined in  the Working Hours Act of 1994,

A+ A +  the Occupational Safety Act of 1996 and  Workplace Ordinance 1976/2004/2016,  The working appliance usage ordinance (= Industrial Safety Ordinance 2002/2015) and  Ordinance on Occupational Healthcare 2008/2013. Here the corresponding occupational safety measures to be determined, laid down and implemented by the employer, as defined in § 2, Section 1 of the Working Conditions Act (Arbeitsschutzgesetz – ArbSchG), comprise the prevention of accidents at work, work-related health hazards (i.e. work-related illnesses and occupational illnesses) including measures for people-friendly workplace design. This also particularly applies to the humane operational organisation (for instance with a view to forms of business autonomy and mobile professions) as well as working hours. Consequently, employers must establish an overarching works prevention policy pursuant to § 4, No. 4 of the Working Conditions Act (Arbeitsschutzgesetz – ArbSchG) when planning occupational safety measures. Ergonomics when Designing Work Systems and Using Work Appliances When providing and using work appliances the employer must, pursuant to § 3 of the Industrial Safety Ordinance (Betriebssicherheitsverordnung – BetrSichV), taking into consideration all hazards that arise from the work appliances themselves, the working environment and the working tools/equipment in relation to all activities (industrial work, services, healthcare, education, training etc.). This means a series of aspects relating immediately to ergonomics must be taken into consideration such as fitness for use of working appliances including ergonomic, age and ageing-appropriate design, the safetyrelevant and ergonomic contexts between the workplace, working appliances, work procedures, work organisation, workflow, working hours and work tasks as well as the

physical and mental burdens of employees that arise when using working appliances. In Technical Rules for Industrial Safety 1151 (Technische Regel Betriebssicherheit TRBS 1151) these aspects to be taken into consideration by the employer are laid down with presumption of conformity. Fundamental concepts of ergonomics are anchored in their definitions: work system, interaction and the stress-strain model (“Belastungs-Beanspruchungs-Modell”)6. On the basis of the hazard assessment pursuant to § 3 of the Industrial Safety Ordinance (Betriebssicherheitsverordnung – BetrSichV), included in the judgement of working conditions pursuant to § 5 of the Working Conditions Act (Arbeitsschutzgesetz – ArbSchG), measures must be laid down pursuant to § 6 of the Industrial Safety Ordinance (Betriebssicherheitsverordnung – BetrSichV). In accordance with this the employer must ensure that the working appliance is used safely and that the principles of ergonomics are observed. The use of working appliances must be set up and organised in such a way that stresses and incorrect strains that might endanger the health and safety of employees are avoided or, if this is not possible, reduced to a minimum. The employer must ensure employees are in a position to use the working appliance without endangering themselves or other persons. In addition, § 6 of the Industrial Safety Ordinance (Betriebssicherheitsverordnung – BetrSichV) requires that, for instance, principles of humane workplace design are respected. This means the working appliances including their interface with humans must be adapted to the physical characteristics and abilities of the employees and biomechanical stresses must be avoided during use that might have damaging effects on users. To be taken into consideration here is the working environment, the location of access points and the centre of gravity of the working appliances, the necessary posture, body movement, distance to the body, necessary per-

sonal protective equipment as well as mental strain of the employees. Furthermore, employees must have sufficient freedom of movement. Working speeds and work rhythms must be avoided that could lead to endangering the employees. Moreover, operating and supervising activiti es must be avoided that require unlimited and lengthy concentration. Ergonomics, Workplaces and Work Stations When setting up and operating workplaces employers must, pursuant to § 3a, Section 1, of the Workplace Ordinance (Arbeitsstättenverordnung – ArbStättV) 2016, implement corresponding occupational safety measures and take into consideration the current state of development of technology, works medicine and hygiene, ergonomic requirements as well as technical regulations. This relates to all work stations, in particular monitor-based and teleworking stations (specifically in this context compare the requirements made on working conditions as well as on monitor-based and teleworking work stations in No. 3 and No. 6 of the Appendix of the Workplace Ordinance (Arbeitsstättenverordnung – ArbStättV)) taking into consideration the Industrial Safety Ordinance (Betriebssicherheitsverordnung – BetrSichV) relating to working appliances and the Load-Handling Ordinance (Lasthandhabungsverordnung – LasthandhabV) aimed at physical strains (handling of loads). Focus Theme “Workplace Design” A focal theme in Workplace Design is the ergonomic design of workplaces and work processes in production and at the office, in particular the communication of good practice taking into consideration the criteria of people-friendly workplace design, man-machine interfaces, prevention and economic efficiency. Health impairments due to bad working conditions and the associated drops in performance and downtimes also impact companies’ economic results. Over the past few years good and healthy work has therefore come increasingly to the fore in the discussion of the Machine - Automation & Electricity / EMO 2017


A+ A+ role of human capital in a company. Current topics now also include, for example, age-appropriate arrangement of workplaces, interface design, lighting, climate and acoustics. As part of the special shows exhibitors will be presented with a contribution on the stage in Hall 10. There will be simultaneous interpretation for all lectures. Co-Determining Ergonomics The Works Constitution Act (“Betriebsverfassungsgesetz”) of 1972, which lays down the rights of employees to elect works councils that represent their interests towards employers within the company, contains its own paragraph on the central fields of ergonomics, entitled “Fourth Paragraph – Design of the Workplace, Workflows and Working Environment”). The involvement, participation and co-determination of the works council is a key design instrument here. The same applies to staff councils. Rights and obligations of individual employees are laid down by the Working Conditions Act (Arbeitsschutzgesetz – ArbSchG). Ergonomics as a Manufacturer’s Obligation The law on technical working appliances of 1968 already obliged manufacturers and importers of technical working appliances to observe work safety and accident prevention regulations. At that time consumer protection relating to household appliances and toys was already included and today this is comprehensively anchored in the Product Safety Act (Produktsicherheitsgesetz) in conjunction with European single market laws (Product Safety Directive and, for instance, the Machinery Directive as well as norms) as well as in other legal provisions. This means inherent safety as well as principles for inherent ergonomics are required when placing products on the market (incorporated in risk assessments, operating instructions). Ergonomics and Health Promotion in the Workplace and Living Environments Already by virtue of its context ergonomics relates to fitness for use and product ergonomics as well as to the design of working conditions in the 44

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workplace and also to the conditions of all forms of activity in other living environments. Ergonomic principles therefore have to be appropriately linked to measures for both living environment-oriented and workplacecentred health promotion. This in particular applies to fitness for use as well as the related “user experience” from the perspective of humane design of working and living conditions. Ergonomics and Qualification The overarching requirements of physical, cognitive and organisational ergonomics have to be included in appropriate qualification measures. Consequently, pursuant to § 2, No. 7 of the Working Conditions Act (Arbeitsschutzgesetz – ArbSchG) employers must issue appropriate instructions. When transferring tasks to employees employers must, pursuant to § 7 of the Working Conditions Act (Arbeitsschutzgesetz – ArbSchG) and depending on the type of activities, take into consideration whether employees are able to observe the provisions and measures relating to safety and health protection when fulfilling tasks. Pursuant to § 12 of the Working Conditions Act (Arbeitsschutzgesetz – ArbSchG) a suitable instruction must be given. Ergonomics, Inclusion and Anti-Discrimination Ergonomic principles must be observed when carrying out measures for groups of employees in particular need of protection pursuant to § 4, N. 6 of the Working Conditions Act (Arbeitsschutzgesetz – ArbSchG). Measures also have to be adopted for the elimination and prevention of discrimination (c.f. § 12 of the General Equal Treatment Act (Allgemeines Gleichbehandlungsgesetz – AGG), for instance from the point of view that, pursuant to § 4, No. 8 of the Working Conditions Act (Arbeitsschutzgesetz – ArbSchG), directly or indirectly gender-specific provisions are only permitted if this is imperative due to biological reasons and also in view of an age or ageing-appropriate design of working conditions. Ergonomic principles have to be ob-

served if the employer has to fit out and operate the workplace in the event of their employing disabled persons pursuant to § 3a, Section 2 of the Workplace Ordinance (Arbeitstättenverordnung – ArbStättV) in such a way that the special health and safety concerns of these employees are taken into consideration. Ergonomics and Digitalisation The digitalisation of working and living conditions will comprehensively alter the requirements for risk assessment as well as the technical, organisational and person-related measures. For this reason, ergonomically oriented yardsticks of social technology appraisal have to be integrated into the assessment. This will, for instance, apply to monitorbased and teleworking work stations as well as mobile activities. Work system design including software ergonomics as well as data protection are particularly important here. Pursuant to No. 6.5, Section 5, Appendix of the Workplace Ordinance (Arbeitsstättenverordnung – ArbStättV) labour supervision may not be carried out in terms of the qualitative or quantitative results without employees knowing. This is enshrined in the fundamental right to informational self-determination and in employees’ data protection in accordance with current data protection provisions. Ergonomics and Sustainability According to Germany’s Federal Environment Agency, eco design aims to find solutions within an integrated life cycle analysis to reduce the environmental impact of a product overall. Consequently, this adds eco-friendliness to the classic line-up of requirements in product development such as functionality, safety, ergonomics and value for money. Eco design is therefore a comprehensive design task of sustainable corporate management. Current information on A+A 2017 and the 35th International Congress for Occupational Safety and Occupational Medicine can be found online at and

Hannover Messe 2017

Machine - Automation & Electricity / IMT 2017



Blurry Box, the Unbreakable Software Protection Technology

Blurry Box, the latest software encryption technology from WibuSystems, remains undefeated at the 2017 Global Hackers’ Contest

K arlsruhe, Germany – Hundreds of participants from

all corners of the globe have taken part in a hackers contest aimed at cracking a game protected with Blurry Box®, the pinnacle of encryption recently launched by Wibu-Systems. The outcome: No one could break the latest software protection technology introduced by the leading provider 46

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of secure license management in the industrial world. The contestants tried frantically for three weeks; two of them submitted their results to the independent jury consisting of IT security scientists from the Horst Goertz Institute (HGI) and the Institute for Internet Security - if(is). Their exploits were proven to be not correct, resulting in a voluntary award of €1,000 each against the total

sum of €50,000 that was originally at stake for a complete hacking solution. Instead, it will go towards further research and development. Wibu-Systems has been focusing on the protection of digital know-how for almost thirty years, leading to the birth of CodeMeter, its flagship solution for safeguarding software publishers and intelligent device manufacturers from intellectual property pira-

cy, product counterfeiting, software reverse engineering, and code tampering. One of the essential components of CodeMeter is its encryption mechanism: The AxProtector module conveniently encrypts the compiled software in a fully automated fashion; the IxProtector module, later integrated in AxProtector, extracts and encrypts individual functions for higher protection against typical cracking techniques. Still, some complex and sensitive software need stronger protections. In 2014, Wibu-Systems, the Karlsruhe Institute of Technology, and the research center FZI took the first prize at the German IT Security Awards for Blurry Box. Since then, the encryption scheme has been integrated into CodeMeter and is now publicly validated through the global challenge. It extracts, duplicates, modifies, and encrypts individual functions, selects variants, and takes the flow of the program into consideration. Traps and decryption delays stop brute force attacks. With such a robust design, hackers would have an easier time rebuilding the

software protected with Blurry Box from scratch. Oliver Winzenried, CEO and founder of Wibu-Systems, who was just named Top Embedded Innovator of 2017, shares his excitement: “In today’s world, wars are shifting towards a digital battlefield. Industrie 4.0, IoT applications, and digitized services will have to be hardened with the most stringent security measures. Our mission is to put our greatest business and private life values into safe hands”. Prof. Dr. Norbert Pohlmann, one of the contest jurors and Director for Internet Security at if(is), adds “In my mind, it is a great idea that developers let ‘hackers’ take on their products in a public competition. It gives us transparency about how secure and trustworthy they are, and the contest is a great opportunity for the participants to learn about IT security.” Prof. Dr. Thorsten Holz, another of the contest jurors and Deputy Director of HGI and Professor for Systems Security, declares “In 2014, Blurry Box won the 1st prize in the German IT Security Awards, the most prestigious awards for IT security in Germany. Our constant work on refining

Fair the concept and the recent success in our hackers’ contest are a perfect match with the mission of the awards, and it is great to see a concrete product coming out of it. The German IT Security Awards are entering their next round in autumn 2017, and I am very hopeful about repeating our performance in the future.” Prof. Dr. Jörn Müller-Quade, Head of the Institute for Cryptography and Security at the Karlsruhe Institute of Technology and one of the partners that have organized the contest, states “It is great to see the results of the hackers’ contest, because however careful your analysis is beforehand, true security depends on whether the theoretical models can stand the test of actual reality. We can only know this by trial and observation, which is why even the theory needs a hackers’ contest. The IT security research done at the KASTEL center of competence sees systems holistically and includes many different disciplines and methods for the purpose. Blurry Box is a perfect example of this.”

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EISENWARENMESSE - International Hardware Fair 2018 almost fully-booked: Early bird result convinces with excellent quality and quantity After the end of the first registration phase (31 May 2017) EISENWARENMESSE - International Hardware Fair has recorded an excellent result: According to the status at the beginning of June 2017, 90 percent of the exhibition space is already booked. 64 percent of the registrations are from abroad, including big brands of the hardware industry as well as many returnee exhibitors. In the coming spring EISENWARENMESSE - International Hardware Fair nternational Hardware Fair 2018 will be already laid the foundation for held from 4 the excellent result in the event to 7 March at year 2016: Through numerous the Cologne fair grounds. conceptual innovations such as the DIY Boulevard and the E-Commerce Arena, it excelled with an outstanding field of participants and visitors. In 2018, the event is building on this success. The exhibitors that have already confirmed their participation include Alfred Schellenberg, Altrad Lescha, F. Reyher, Gedore, Hazet-Werk Hermann Zerver GmbH & Co. KG, Pferd Rüggeberg, Schäfer



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& Peters, STAHLWILLE Eduard Wille GmbH & Co. KG and Tox Dübel. The fact that the organisers were able to record the return of Stanley Black & Decker Inc. was a particularly notable success. The international significance of the leading trade fair for the hardware industry is once again being underlined by the general strong interest from abroad. Exhibitors from 49 countries have already secured their exhibition space. The successful new formats at the previous event are going to be continued and further developed in 2018: In cooperation

with the manufacturers association, Haus & Garten e.V., EISENWARENMESSE - International Hardware Fair will be presenting innovations by the metre on the DIY Boulevard in Hall 5.1 for the second time. After the great interest in the E-Commerce Arena in 2016, the organisers are extending the format into a 2-day E-Commerce Summit. As an international industry meeting point, EISENWARENMESSE - International Hardware Fair is thus once again offering its exhibitors and trade visitors orientation and concentrated information.




Shvabe Holding of Rostec State Corporation will demonstrate about 70 developments in the field of photonics at Laser World of Photonics 2017, the he key exhibits in the HoldInternational ing’s exposition will be: an Trade Fair for Photonics active element made of neoComponents, dymium phosphate glass, an Systems and SWIR camera, the MBS-16 Applications. stereoscopic microscope, hoThe event will take place on lographic optics, etc. These June 26-29 in products are used in the aerospace and microelectronics Munich. industries and other fields. “Shvabe is a leader and a systems integrator in Russian innovative photonics. The Holding is currently developing several areas in this field, including lasers, optic materials and photodetectors. In Germany, we are going to present samples of these products, including knowhow – a brand-new element base for superpower laser stations. It is a real breakthrough in Russian optic science and technology, which will allow us to create energy centers of the future,” said Sergei Popov, the First Deputy CEO of Shvabe. One of the most advanced developments of the Holding is a



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circular active element made of neodymium phosphate glass designed for large-sized highprecision active elements. Its unique composition amplifying laser irradiation is protected by several Russian and foreign patents and won the Russian Federation Government Prize in Science and Technology in 2016. It is going to be the key exhibit in Munich. In addition to optics for lasers, the Shvabe exposition will feature a new stereoscopic microscope, the MBS-16, designed to examine 3D, thin-film and transparent objects. The exposition will also include 17 types of diffraction optics, single- and multimode optic fiber, monocrystals and nanocrystalline material for laser Q switches, as well as aiming and ranging equipment – a total of approximately 70 developments. Rostec is a Russian corporation that was established in 2007 to promote the develop-

ment, production and export of high-tech industrial products for civil and military purposes. It is comprised of over 700 organizations which form 9 holding companies in the military-industrial complex and 6 in civilian industries, as well as 32 organizations under direct management. Rostec’s portfolio includes such well-known brands as AvtoVAZ, KAMAZ, Concern Kalashnikov, Russian Helicopters, VSMPO-AVISMA and others. Rostec organizations supply to and operate in over 70 countries. The consolidated revenues of Rostec companies in 2015 exceeded 1.14 trillion rubles (over 19 billion USD). According to the new Rostec strategy, the main objective of the corporation is to provide a technological advantage to Russia in highly competitive global markets. The planned investment volume for the development program until 2025 is over 4.3 trillion rubles (over 70 billion USD).

Aventics Machine - Automation & Electricity / IMT 2017




D espite the German phaseout from nuclear power, this

technology still plays a major role in Europe. Due to this fact, it is all the more important for Germany to be able to assess the condition of international nuclear power plants. In a nuclear power plant (NPP) an average of 25,000 cables with a total length of 1,500 km are installed. These cables are partially exposed to harsh environmental conditions such as increased temperature or radiation: Under these circumstances, the cable insulation deteriorates with the risk of cracks occurring as a result of embrittlement. How can nondestructive procedures detect possible fatigue processes of the cables at an early stage? And how can these procedures be brought in line with practical aspects? A team of engineers and scientists at Fraunhofer IZFP in Saarbrucken is working on these questions. Within the framework of an EURATOM project funded by 52

Machine - Automation & Electricity / EMO 2017

the European Union which focuses on both research and innovation, the Fraunhofer Institute for Nondestructive Testing IZFP will contribute to the determination of the exact state and age of the cable insulation. The institute is part of a consortium of 13 partners from Germany, Finland, France, Italy, Poland and Czech Republic. Currently, the cables are replaced preventively on the basis of experience, but without reliable information on the actual condition. Thus, the actual condition can vary in a wide range: Maybe an expensive replacement is not yet required, but maybe a critical condition has already been reached before the scheduled replacement. To date, few nondestructive methods have been used to investigate cable insulation. However, the economic and safety-related benefits could be significant. This will be examined in detail by Fraunhofer IZFP within the framework of the EU project “TeaM Cables”,

and the results will be transferred to the application-oriented practice in the long term. “Using an enhanced terahertz approach on the basis of highfrequency electromagnetic waves, we are going to identify the aging state and the condition of the insulation,” explains Christopher Stumm, responsible project engineer at Fraunhofer IZFP. Additionally, these terahertz-based examinations provide information which allow for revision scheduling and timely inspection of the cable insulation. Hence, brittle cables can be replaced promptly while sound cables can stay in operation safely. This way, Fraunhofer IZFP has a significant share in increased safety and cost savings – also in the context of nuclear decommissioning – at increased economy and competitiveness. The “TeaM Cables” project has a total duration of 4.5 years with 682,000 € of research funding for Fraunhofer IZFP.


Machine - Automation & Electricity / IMT 2017




EMO Hannover 2017 augurs well for rising orders in the year’s second half

Dr. Wilfried Schaefer

Iorder n the second quarter of 2017, bookings in the German machine tool industry fell by 7 per cent compared to the preceding year’s equivalent period. Domestic orders were down by 27 per cent, while export orders rose by 4 per cent. In the first half of 2017, total order bookings shrank by 1 per cent, with domestic orders decreasing by 15 per cent. Order bookings from abroad were up by 6 per cent. Forming technology is performing better than metal-cutting machinery. “With the mid-year figures, we’re well on course of our expectations,” com-ments Dr. Wilfried Schäfer, Executive Director of the sectoral organisa54

Machine - Automation & Electricity / EMO 2017

tion VDW (German Machine Tool Builders’ Association) in Frankfurt am Main. Ex-port orders continued their uptrend, with the Eurozone nations still constituting the principal drivers. Their orders rose twice as steeply as orders from the rest of the world. Following the substantial growth of last year, driven primarily by project business with the international automotive industry, the high level achieved is predicted to continue through 2017. “Domestic demand, however, was a disappointment in the year’s first half,” says Wilfried Schäfer. This remained weak, due not least to a base effect owed to the high growth achieved during the first half

of 2016. This effect, however, is now coming to an end. For the second half of 2017, significantly better figures are anticipated. This reflects the optimistic mood in the business community, the rising cyclical indicators for Germany, and the macro-economic forecasts, which pundits have only recently revised upwards. “Moreover, we’re anticipating a huge boost from the EMO Hannover 2017,” emphasises Wilfried Schäfer in conclusion. The world’s premier trade fair for the metalworking sector, he adds, is very well booked, will be showcasing nu-merous innovations in all technical categories, and will thus be providing a major boost to capital investment.



Order Intake of the German Machine Tool Industry Strong demand for German machine tools Index, nominal 240 12-month moving average original values



120 Order Intake, %-change to previous year 1Q 2017 Total +6 Domestic +2 Foreign +8



0 1998




















Note: Index basis shipments 2010=100, data until March 2017, Sources: VDMA, VDW VDW | Order Intake |

O rders received by the German machine tool industry in

the first quarter of 2017 were 6 per cent up on the previous year. Domestic demand rose by 2 per cent, while overseas orders grew by 8 per cent. “Orders received by the German machine tool industry have therefore been stronger than expected,” said Dr. Wilfried Schäfer, Executive Director of the VDW (German Machine Tool Builders’ Association) in Frankfurt am Main, commenting on the result. International demand remains consistently high. The euro countries rep-

resent a reliable market. There was a disproportionately high increase of 23 per cent in orders for machine tools from there in the first quarter in comparison to the same period last year. “Furthermore, the increase in demand from the key Chinese market is now broader based,” reported Schäfer. Orders rose last year by more than twenty per cent, primarily due to large international automotive industry projects in China. The strong development has continued, however, in the first quarter of 2017. There was a 13 per cent increase in metal forming tech-


| Page 1

Solid support from eurozone countries - China business picking up

nology orders. This rise in demand came both from home and abroad. Machining equipment orders, however, which represent about 70 per cent of the total, only rose by 3 per cent. The main source of growth here was foreign markets, which posted an increase of 6 per cent. Domestic demand, by contrast, fell by 4 per cent. “The German machine tool industry continues to perform stably and at a high level, undeterred by the many crises and uncertainties affecting different parts of the world,” said VDW Executive Director Schäfer.

Machine - Automation & Electricity / EMO 2017




Sandvik Coromant is exclusive tooling sponsor for seven skills competitions

C utting tool and ing system specialist,

ing CNC Milling, CNC Turning, Manufacturing Team Challenge, Industrial Mechanic Millwright, Polymechanics and Automation, Prototype Modelling and Plastic Die Engineering. The skills challenges take place from 15 to 18 October 2017.

The global hub for vocational skills, WorldSkills hosts a championship every two years to showcase talented students who come together to compete in a wide range of competitions. Looking to win medals in their chosen skills, these students inspire thousands of young people to take up vocational careers.

“The dedication and talent these students possess is inspiring to us all. We congratulate them on their selection to compete at this high level and we wish them luck in their competitions,” notes Brett Cline, Head of Marketing Execution at Sandvik Coromant.

toolSandvik Coromant, is the official sponsor and exclusive tooling partner for seven skills competitions at WorldSkills Abu Dhabi in October 2017.

Sponsoring these competitions brings attention to vocational education and training that is imperative to closing the skills gap around the world. This year’s competition includes student representatives from 77 countries and regions from around the world competing in 51 skill competitions. Sandvik Coromant is sponsoring six of those competitions includ56

Machine - Automation & Electricity / EMO 2017

At WorldSkills Abu Dhabi, Sandvik Coromant will give students a glimpse into the future by showing the CoroPlus® platform at booth H10-014. Students will see how cloud-based analytics and data collection can improve machining operations. “As digital natives, it’s important to show students about the future of manufacturing, not just what is happening now,” says Scott Lu, Sales

Tools Manager, Digital Machining R&D at Sandvik Coromant. “CoroPlus® monitoring solution will show students a connected shop floor from cutting tools to software solutions and IoT devices.” Visit to get more information about WorldSkills Abu Dhabi. Looking ahead, Kazan City, Russia will be the next host of the 2019 WorldSkills Competition.


Sandvik Coromant

Part of global industrial engineering group Sandvik, Sandvik Coromant is at the forefront of manufacturing tools, machining solutions and knowledge that drive industry stan-

dards and innovations demanded by the metalworking industry now and into the next industrial era. Educational support, extensive R&D investment and strong customer partnerships ensure the development of machining technologies that change, lead and drive the

future of manufacturing. Sandvik Coromant owns over 3100 patents worldwide, employs over 8,000 staff, and is represented in 150 countries. For more information visit www. or join the conversation on social media.

Machine - Automation & Electricity / EMO 2017



SANDVİK COROMANT AT EMO 2017: DİGİTALİSATİON AND TURNİNG CONCEPTS REMAİN THE FOCUS a more profitable and sustainable production. “Digitalisation is transforming our world and the manufacturing industry is no exception. We atSandvik Coromant want to use the opportunities this transformation has to offer in the best interest of our customers and make these opportunities available to them. Our goal is to tap the full potential of digitalisation with the help of new innovative ideas and intelligent concepts,” says Nadine Crauwels, President Sandvik Coromant.

Digital solutions enable connection of design, planning and metal cutting as well as effective process analysis and improvement

A t EMO 2017, Sandvik Coromant will be presenting innova-

tive solutions for more efficient manufacturing processes. The future of machining and production is to take centre stage at the company’s booth, spanning 528 square metres in hall 5, booth B18. True to the motto “Together we shape the future of manufacturing – Let‘s connect!”, Sandvik Coromant aims to bring machining operations to the next level by offering new digital solutions and enabling the connection of processes, with the focus on optimising the machining process and decision making to increase profitability.


Machine - Automation & Electricity / EMO 2017

An international team of 40 specialists will present the company’s innovations and answer any questions visitors might have on the latest trends in machining. Among this year’s highlights is the new PrimeTurning™ method and its corresponding CoroTurn® Prime turning tools, the industry’s first solution for turning in all directions offering improved machining flexibility, productivity and tool life. In addition, the emphasis is on further developments of the CoroPlus® solutions made ready for Industry 4.0. It allows for linking-up of the different process steps operations planning, process planning and machining as well as for an extended production analysis in order to secure

Thanks to the cooperation with numerous machine manufacturers, the company’s stateof-the-art tooling solutions will not only be shownat its own booth in Hanover, but also be presented at many places all over the show floor. In addition to that, the proven and trusted service team will support and advise exhibitors before and during EMO. The 20-strong team will already be on location a week before the trade show opens its doors and can be found at pavilion P35. Last but not least, the media will be able to get exclusive insights on the latest technological and corporate developments at the press event which will be taking place on September 19 at the press centre. Find out more at www.sandv i k . co ro m a nt . co m /e n - g b / products/news/Pages/default.aspx#new-turning-tools

Ziehl Abegg

Machine - Automation & Electricity / IMT 2017




he registration deadline for AMB 2018 expired on 30 June 2017. This means that the project team must now examine the registrations which were received and prepare placement proposals for the exhibition stands. “Since AMB exhausted all the capacities of our trade fair centre in the last few years, it was impossible to take account of every exhibitor request. Another 15,000 square metres of gross exhibition space will be available with the new Registration deadline for AMB Paul Horn Hall (Hall 10). We will be able to satisfy the 2018 / Increased therefore demand by exhibitors and increase amount of exhibi- the attractiveness of the trade fair tion space for our visitors by presenting even opens up new more products and innovations,” possibilities said Ulrich Kromer von Baerle, President of Messe Stuttgart. The additional space will also enable us to optimise the assignment of the existing exhibition areas. AMB 2018 will be thematically


Machine - Automation & Electricity / EMO 2017

restructured: the L-Bank Forum (Hall 1) and Hall 3 will contain machining tools and chucking tools. Hall 4 and Oskar Lapp Hall (Hall 6) will focus on lathes and automatic lathes. Hall 5 will feature grinding machines, tool grinding machines and everything relating to them. Alfred Kärcher Hall (Hall 8) will present the innovations in sawing and cuttingoff grinding machines, surface technology, marking systems, hardening and heating machines, lubrication and cooling, and safety and environmental engineering. Halls 7, 9 and the new Paul Horn Hall (Hall 10) will round off the exhibition programme with milling machines, metal-removing process machine tools, measuring systems and quality assurance, as well as flexible production cells/systems, machining centres, gear cutting machines and drilling machines. Companies which registered before the closing date on 30 June 2017

will receive the first placement proposals from autumn 2017 onwards. The AMB 2018 website contains a film with detailed information on the new layout of AMB 2018 and the topics that will be presented in each hall. “Digital Way” will be staged for the first time during AMB 2018 and will be devoted to increasing digitalisation in production. “The new concept comprises a congress, an accompanying exhibition and showcases. Visitors will be able to experience real applications and best practices here live. The associated plans are already in full swing. Over the course of the year we will launch specific offers for participation in the accompanying exhibition and the conference,” said Gunnar Mey, Department Director Industry at Messe Stuttgart.


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TOOL, PATTERN AND MOULD MAKERS HAVE A HOME Talready he première in 2015 was a success, but the 2nd 763 exhibitors, 14,000 visitors: 2nd edition establishes Moulding Expo as the international marketplace for an innovative industry

Moulding Expo (MEX) at the Stuttgart Trade Fair Centre from 31 May to 2 June 2017 raised the successful concept to the next level. With 763 exhibitors who attracted more than 14,000 visitors from all over Germany, Europe and many other countries of the world to Stuttgart, the trade fair is becoming established as the most important European meeting point for the tool, pattern and mould making industry. 39 per cent of exhibitors came directly from this core area. Every leading supplier in the industry also presented their products and services. MEX therefore underlined its status as a trade fair by the industry for the industry. Stuttgart proved to be the perfect stage for the topics in the industry Thomas Seul, President of the Association of German Tool and Mould Makers (VDWF): “MEX is characterised by a very special ‘spirit’. The profile of the trade fair in the industry is very pronounced. Tool makers came to Stuttgart and presented their company on their marketplace.“ Companies are able here to gain an ideal overview of the innovations, trends and developments in their market environment. The trade fair location of Stuttgart is predestined for this. The region around the state capital of Baden-Württemberg has the highest industrial density in Germany and Europe. It is also home to one of the most productive clusters of tool, pattern and mould makers in the


Machine - Automation & Electricity / EMO 2017

world. Southern Germany also contains a large number of traditional user industries such as plastic and metal working enterprises and automotive component suppliers. The growing international interaction at Moulding Expo produces inspiration for innovation and the necessary cooperation network for the success of the industry. Ulrich Kromer von Baerle, President and CEO of Messe Stuttgart: “The second MEX demonstrated what the European and, in particular, the German hightech tool, pattern and mould making industry can actually do.“ The organisers of the trade fair also managed this year to give Moulding Expo, despite its size and internationality, an unmistakeable positive atmosphere in which exhibitors and visitors equally felt at home. The formative topics and trends during the four-day trade fair were very clear: Nothing is preoccupying companies in the industry as much as digitalisation, an area which is posing great challenges for medium-sized enterprises in particular. This is also closely linked to the increasing internationalisation of business processes. During his tour of the trade fair Winfried Kretschmann, Minister-President of Baden-Württemberg, underlined the “impressive inventive and creative spirit” of tool, pattern and mould makers, and wished the companies courage on their road to the digital future. “It is easier to connect IT to our industrial world than the other way round. I know that tool, pat-

tern and mould makers are stretched to the limit here, but also that they will achieve this objective.” The exhibitors at MEX included many important companies who are assuming key roles in digitalisation with their products and services. Trade visitors were also able to obtain an extensive picture of the generative technologies, which are now changing the entire industry, and find out how 3-D technology and additive manufacturing methods can be integrated in their own process chains. Florian Niethammer, Team Director for Moulding Expo at Messe Stuttgart: “A large number of visitors to the trade fair came with specific requirements, even with project drawings, in order to discuss their concerns and problems on the spot with exhibitors. Intensive discussions were held and projects were also concretised right away. This represents something special.” Exhibitors and visitors both rate MEX as positive “Key to markets” is the motto of Messe Stuttgart. In the opinion of the exhibitors, this did not promise too much. They regard MEX as the perfect platform for the industry, and all of them awarded the trade fair good marks. Exhibitors unanimously mentioned good and lengthy business discussions. According to Franz Tschacha from the company Deckerform in Aichach, MEX is a “distribution and sales trade fair for German tool makers, which rightly exudes confidence.” Jörg Vetter (Hermann Hauff, Pforzheim) believed that the event “hits the nail on the

head” while Andreas Sutter (Meusburger, Wolfurt/Austria) made the following comments: “The mood at MEX was fantastic and cannot be topped.“ The concentrated and productive atmosphere at Moulding Expo was reflected in the results of the official survey of exhibitors and trade visitors. Overall, the exhibitors were impressed by the excellent organisation and the quality of the contents of MEX, They awarded the average mark of 2.0 for the expertise of trade visitors. Isabell Oerder, who is responsible for marketing and communication of NCSimul at the software developer Spring Technologies GmbH, was representative of many suppliers when she concluded: “What we really liked about the trade fair was the mixed hall planning where software, control units and machines were placed together rather than being separated. With Industry 4.0 we are moving closer towards integrated solution approaches - something which is positive for both exhibitors and visitors.“ The participants were therefore confident that MEX will become even more relevant for the industry in future. MEX also went down very well with trade visitors: Out of the more than 14,000 visitors, 83 per cent said they would recommend the trade fair to other people while 93 per cent of them already knew that they would come back to the third edition of MEX in 2019. Markus Heseding: “The high expertise and the length of stay of the visitors were noticeable at MEX.” The Managing Director of the Precision Tools Association in the German Engineering Federation (VDMA) highlighted as an “ideal synergy” the large number of accompanying events, e.g. the guided tours of the trade fair for the participants in the Buyers’ Forum of the Federal Association of Materials Management, Procurement and Logistics (BME), which was held concurrently at the Stuttgart Trade Fair Centre. Meeting point for an international industry network One important task which was given

to the MEX team by the advisory boards was to increase the internationality of the trade fair. “We are on the right track here,” said Niethammer. “The companies in which the visitors work come from Europe and all over the world.“ 31 per cent of exhibitors came from abroad - an increase of 7 per cent. The international proportion of visitors also rose from 11 to 14 per cent. Dr. Wilfried Schäfer, Managing Director of the German Machine Tool Builders’ Association (VDW), was pleased with this development: “The large number of international joint stands and the growing interest among visitors are confirmation of the market position of the trade fair!“ The just under 2,000 foreign guests travelled to Stuttgart from 52 countries: visitors from Austria (15%) and Switzerland (13%) formed the largest group, followed by guests from Italy (10%), Turkey (7%) and the Czech Republic (6%). “Interested parties from all over the world examined Moulding Expo at close quarters,” said Florian Niethammer. “The delegations of trade associations from Estonia, France, Japan, Spain, Turkey, Croatia and the USA were able to forge contacts and were supplied with valuable information.” In addition to guided tours of the trade fair, there was, for example, a tour of the Mercedes-Benz plant in Sindelfingen with the emphasis on the press and tool shop. Niethammer emphasised here the successful partnership with the world association, i.e. the International Special Tooling and Machining Association (ISTMA), which participated in the trade fair for the first time. Bob Williamson, President of the Association, underlined the importance of Moulding Expo as an international meeting point: “Not only German tool, pattern and mould makers meet here in Stuttgart, but also entrepreneurs from throughout the world. Anyone wanting to enjoy success in the industry must communicate - also with potential competitors on the market.” And precisely this “positive co-opposition”, as Williamson put it, can be seen and felt everywhere at MEX.

MEX Theoretical and practical highlights in the extensive accompanying programme Up to date and compact: first-class speakers provided insights into the important developments from the world of tool, pattern and mould making. “The seminars, talks and workshops were ideal occasions to exchange information, carry out further training and hold constructive discussions on technical topics. Experts from many different business areas in the industry met here,” said Florian Niethammer. Another highlight was the MEX special exhibition on the promotion of young people with detailed information on training and advanced training. “I am very satisfied and grateful for this event. I am especially pleased with the positive feedback on the Young Professionals’ Forum,” said Peter Gärtner from the Information Centre for Company Management in the Federal Association for Pattern and Mould Making (BVMF). Under the motto “Get your future into shape!” the industry associations presented the most important training occupations in tool, pattern and mould making. School classes exchanged information directly with trainers and apprentices, and became acquainted with the work areas in the industry during guided tours. The career starters and every trade fair visitor were fascinated by the live production processes during the trade fair give-aways, i.e. the eating tool “3-2 eat”, and the Polyman learning component or the presentation of the Innonet plastics processing chain. “That was handson tool, pattern and mould making,” concluded Ulrich Kromer von Baerle, President of Messe Stuttgart. Outlook: after MEX is before MEX No sooner had MEX 2017 finished at Messe Stuttgart, than the preparations for the third edition of the trade fair started. The trade fair organisers have resolved to continue establishing Moulding Expo as the leading European trade fair for the Machine - Automation & Electricity / EMO 2017


MEX industry. “We are pleased that our still young trade fair is now already a permanent fixture in the calendar of European tool, pattern and mould makers,” said Ulrich Kromer von Baerle. He also clearly defined the next steps: “MEX 2017 has strengthened our conviction that we are on the right path together with the industry. However, organising trade fairs also means that we must continually develop and learn. We will therefore meet with the advisory board in autumn and determine the key topics and date of Moulding Expo 2019.“ Overview of the Moulding Expo 2017 figures: Exhibitors: 763 companies, of whom 530 came from Germany and 233 from abroad, occupied a net exhibition area of 21,620 m² (gross: 42,000 m²). 61% of exhibitors generally rated Moulding Expo 2017 as good to very good. 94% of exhibitors rated the location of Baden-Württemberg as good to very good (average mark 1.6). Exhibition areas: Tool, pattern and mould making (39%) Contract manufacturing and services (25%) Machine tools, measuring technology and special machines (24%) Components and accessories (19%) Software (13%) Systems for additive manufacturing (3%) Trade visitors: 14,015 visitors, 14% of whom came from abroad. 84% of visitors generally rated Moulding Expo 2017 as good to very good. 93% of visitors were intending to come back again. The average length of stay was 5 hours or 1.3 days. Visitors came from 52 countries. Main countries: Austria (15%) 64 Machine - Automation & Electricity / EMO 2017

Switzerland (13%) Italy (10%) Turkey (7%) Czech Republic (6%) France (5%) Portugal (5%) Economic sectors of visitors: Industry (73%) Page 5 of 6 Craft trades (14%) Services (11%) Universities, technical colleges, vocational schools (6%) Commerce (5%) Training, consulting (3%) Authorities, civil service, associations (2%) Industries of visitors: Automotive and automotive component supply industry (41%) Tool construction and mould making (29%) Mechanical engineering and plant construction (23%) Plastics industry (15%) Pattern making and prototyping (11%) Metal working and processing industry, and metal production (11%) Visitors were involved in the following task areas: Manufacturing, production (18%) Development (14%) Business, company and operations management (10%) Design (11%) Sales and distribution (12%) 75% of visitors said they had an influence on purchasing or procurement decisions. Investment or purchasing intentions of visitors (multiple nominations possible): In the next 6 months (46%) In the next 12 months (26%) In the next 24 months (17%) At the trade fair (7%) In the next 18 months (6%) You can find selected comments by exhibitors, videos and other highlights of Moulding Expo 2017 at

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