MART April 2014

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Setting benchmarks in assembly and handling for over 30 years

Volume 10 Issue 10 April 2014 Pages 52 `100

Elevating Opportunities Flourishing with the Indian Mechatronica Cluster

SCHUNK Grippers

Altering Courses Aerospace Manufacturing in India

• Unleashing Dreams

• Kollmorgen drives the lightweight helpers of Universal Robots

• Onboarding - Your Next Talent Strategy!

• Innovating MIM with enhanced Tool room

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dHi Readers,

A man is but the product of his thoughts; what he thinks, he becomes. - Mahatma Gandhi

I know this twin brothers from Chennai, Karthik and Ramesh who after finishing their Mechanical Engineering started their career together in an engineering company and later ventured into setting up own manufacturing companies separately. Within last 15 years both brothers had become successful in running their establishments, but Karthik is now one of the leading manufacturers and his business is almost 5 times bigger than of his brother. They started almost at the same time, and had everything in common. Even if you take the performance of last two years, Karthik’s company grown steadily compared to that of the other competitors in the market including his brother’s. When I compared Karthik to Ramesh as well as another three entrepreneurs who were almost on same level on education, financial, infrastructure etc I was not able to ana-lyze why he was able to bring success irrespective of market fluctuations. Karthik never possessed any superiority to achieve higher growth and we cannot credit his hard work to luck factor. I was able to spend some time with Karthik recently and I found out it was the way he thought brought him results. He was different from others because he thought ten times bigger than the others around him.

In a day thousands of thoughts comes into our mind – positive, negative, inspiring, depressing, constructive, destructive, innovative; a lot. It’s our choice to select those thoughts which bring positive outcome to our future. Rahul Thakur Singh was like any other teenager in our country, worried about the exam which was scheduled the very next day. A 17 year old engineering student of NITK Surathkal was looking at the pile of untouched books he purchased which he would be using just for couple of hours for the exam. Then this thought came to his mind, why to waste so much money purchasing these books if we can get it on rent in need. At the spur of this moment he co-founded Booksonhired.com with his friend Vivek Aggarwal which aims for making affordable and accessible books on rent to the engineering students. The thought paved the way to the beginning of the journey of a young entrepreneur, who is planning today to widen his network and service across India. We are featuring him in our ON FACE column which is an example of the power of thinking and an inspiration to the budding entrepreneurs.

Aerospace manufacturing in India has grown a long way within the last two decades, but in the global map we are yet to make our mark. With Indian space research programme steadily growing and the recent Mars Mission successfully leaving the Earth’s orbit recently; we are still banking upon imports for the critical components. Our civilian aircraft manufacturing projects are yet to bring constructive results to find out the possibility of commercial manufacturing, a major potential market within India and abroad which should be tapped. In this edition our Roselin Lal has done a research on the Indian aerospace industry and we are featuring it in our special focus this edition. This edition carries an Innovation from Modi Arc, Success story of Grippers from Schunk along with our regular columns on Manufacturing Excellence, Talent Management, MART Update for your update. We look forward your suggestion and guidance to make MART, Smart!

Signing Off,


Saravjit Singh Manoj Kabre P S SatishA S Shetty LD Bhakre Mahesh R P Sandeep HingneJ R Mahajan

Columns

16Kollmorgen drives the lightweight helpers of Universal Robots

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8Altering Courses: Aerospace Manufacturing in India

Onboarding - Your Next Talent Strategy!

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Edited, Printed, Published and Owned by Hari Shanker A G and Printed by him at Lotus Printers Private Limited, No:32/25, 2nd Main Road, Sir M V Industrial Town, WOC Road, Bangalore – 560 044 and Published from No: 217, 3B Main, OMBR Layout, Bangalore – 560 043. Industrial Business Mart is a monthly journal published from Bangalore. Views and opinions expressed in the journal are not necessarily those of the Publishers. RNI No: KARENG/2004/13614

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In the words of Sir George Cayley,”I am well convinced that aerial navigation will form a most prominent feature in the progress of civilization”, the importance of the aerospace industry for growth of a nation is well founded.

The Present Scenario

The current aerospace manufacturing industry has been witnessing great strides in terms of technology, innovation, inventions, and even global tie-ups all in an effort to make India self-sufficient; Hindustan Aeronautics Ltd. (HAL) a government enterprise and a major name in the aerospace industry with its tech partner DRDO keeping true to the above stated recently introduced the much awaited and long-delayed indigenous Light Combat Aircraft (LCA) project for the Indian Air Force .The LCA ‘Tejas’, a fourth generation fighter aircraft is meant to meet the versatile and stringent requirements of the Indian Air Force as its front-line multi mission aircraft.HAL also united in ISRO’s Mars mission by providing satellite structure and propellant tankages delivering seven types of riveted structural assemblies and four types of

welded propellant tankages for the Polar Satellite Launch Vehicle (PSLV-C25).

In the private arena also major players such as Mahindra Aerospace to strengthen India’s place in global aerostructures supply chain have opened a state-of-the art 25,000 sq. m aerostructures manufacturing facility near Bangalore; which exhibits complex, build-to-print parts and assemblies that offer cost-competitive, world-class aerospace manufacturing capabilities.

Changes in the global economy in past years have furthered

in making India a hot spot in the eye of high tech manufacturers who are shifting focus from other neighbouring countries such as China due to the increase in cost of production, banking stress and governmental pressures. The formulation of the Defence Procurement Procedure (DPP) 2013 also clearly sheds light on government initiatives to boost the domestic manufacturing base in India. The DPP (2013) promulgates opportunities for indigenous products, for example one of its clause states that the requirement for prescribed indigenous content should be 30% in the Buy (Indian) category on the overall

cost basis, as well as for the core components i.e. the basic equipment, manufacturers recommended spares, special tools and test equipments taken together. In addition, the basic equipment must also have minimum 30% indigenous content at all stages including the one offered at the trial stage, fostering growth for the local manufacturing companies in India.

One of the key areas to strengthen the aerospace industry still remains to be explored is R&D, this being said the amount of skilled workforce in terms of scientist and engineers India provides is

Altering Courses Aerospace Manufacturing in India

India is steadily moving in the direction to emerge as an ideal destination for manufacturing of aerospace components in the global market. India has the skills and necessary requisites in areas that include engineering, production, etc. These capabilities have been recognized and harnessed by foreign companies outsourcing manufacturing work to India. With around 110 International Aerospace companies headquartered in India. Liberalization in civil aviation policies, a strong domestic manufacturing base, cost advantages and well-educated talent pool are the factors driving the growth of India’s aerospace industry today.

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second largest in the world.

International Role Play

In the international forum Indian aerospace industry continues to face challenges in the global market arising with increase in competition, cost of production and raw materials in addition to a weakening dollar thereby building pressure on the small manufacturing aerospace facilities who are affected the most. To overcome these challenges Tier1 manufacturers and suppliers are leveraging opportunities to India which have arisen from the globalization of the aerospace supply chain through outsourcing technology, components and design manufacture.

India and China buy the largest number of planes but due to the inequalities in opportunities at the home -front and interplay of power forces these opportunities are not accurately tapped by the indigenous manufacturers. The aerospace industry in India is having an expanding consumer base more than ever but this is being sharply contrasted to other factors such as the Indian government policy on FDI (Foreign Direct Investments) standing currently at 26% which hinder the progressive outcome of the growing demand in aerospace.

PWC’s report suggests that India will continue to be the fastest growing country in terms of air travel for the next 20 years.This makes foreign aircraft manufacturers view India’s demand as an opportunity to outsource manufacturing work. This has been majorly responsible for the offset policy which allows foreign vendors to choose their Indian offset partner, private

or public. Air India has already taken a lead in the direction by entering into an agreement with Boeing with a 50 percent offset obligation (allowing indirect offsets also). These policies create an opportunity for Indian manufacturers to enter the high tech arena of aerospace manufacturing with its necessary requirements for safety, quality control and precision.

Opportunities for SME’s and MSME’s

The SME’s and MSME’s generally account for 50 percent of India’s industrial output, with 40 percent of total exports and account for over 90 percent of all enterprises. This suggests the growing need to mitigate challenges in the aerospace sector for them through government intervention, easing banking policies and monitored competition. For achieving an unprecedented growth in the aerospace sector, India is trying to upgrade a notch the policies surrounding SME’s and MSME’s who are crucial to the foundation of the aerospace sector in India, a case in point being the DPP (2013) policy.

Both public and private enterprises as HAL, DRDO; Tata, Mahindra are lending support to increase opportunities for these sectors through their various internal policies. For example DRDO is actively engaged in developing defence technologies and has established an excellent ecosystem with good infrastructure and technology base for defence R&D. It has partnered with both large industries and SMEs in the development of various systems and has more than 100 partner development

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firms for specialist products. DRDO has also constituted four research boards - Aeronautics Research and Development Board (AR&DB), Armament Research Board (ARMREB), Naval Research Board (NRB) and Life Sciences Research Board (LSRB) - to nurture talent in academic institutions, R&D Centers and Industries.

Ministerial Board for MSME’s recently declared plans for setting a new Tool Room in Karnataka to develop an Aerospace Park to enhance the quality of the skills in the region and are now seeking to support clusters development under the SFURTI scheme for micro enterprises which extends programme assistance till 10 crores.

Though in the international picture the presence of SME’s and MSME’s is diluted for a list of factors such as lack of accessing points, capital constraints, and quality issues, but on the home ground there seems to be a positive outlook.

Strides in the Aviation Sector

The Indian Aviation Sector is manifolding itself in the most progressive ways as compared to the last decades. Recent reports indicate that after Saras –India’s first multipurpose 14 –seater civilian aircraft, plans

are being made to introduce India’s very own 90-seater civilian aircraft with the Council for Scientific and Industrial Research(CSIR) saying that, “the strategy for its production has already been evolved” with the design “planned to have unique features like enhanced fuel efficiency, use of bio fuel with low carbon footprint, short to long range haul, shorter air strip requirement and ultra modern avionics”.

Also plans are being made to Pilot project for the Modernization of Airfield Infrastructure (MAFI). At the Air Force Station in Bhisiana (Bhatinda) Air Marshal RK Sharma PVSM AVSM VM ADC, Vice Chief of the Air Staff (VCAS), formally accepted the commissioning of the MAFI pilot project at Model Base; Air Force Station Bhisiana, is a significant milestone towards the much awaited and ambitious air-field infrastructure development project of the IAF, Navy and the Coast Guard.

With the air force accounting for the largest share of the defence capital budget —an approx of 5.54 billion USD, India is accelerating and becoming one of the most sought after aviation industries in the world. With aerospace giants as: Boeing, Gulfstream,

Bombardier, Dassault, and Embraer seeking opportunities for investment in the sector.

Challenges and the way ahead

‘Growth is never equal’, this seems to have been one of the foremost challenges at play in the Indian aerospace manufacturing sector. On one hand where government and private enterprises are continuing to formulate new projects and schemes for the expansion of the sector, the other hand it is seen that no new developments are being nurtured in the indigenous R&D facilities for bringing in new techniques and innovations for an effort to make India self dependent. At present only 1% of India’s GDP (Gross Domestic Product) is spent on the development of R&D, thereby leaving a vast amount of resources untapped and unused. Apart from this because of the irregularities in the global supply chain there is increase of dependency on foreign multinationals investing in outsourcing opportunities in the Indian aerospace sector. The Offset Policy (2012) and The Defence Procurement Policy (2013) have been initiatives on the government’s part to protect the interests of the Indian aerospace manufacturing units against being exploited in the global market.

Another major challenge that the aerospace manufacturing sector faces is the uneven opportunities required to harness the talent pool in the industry. Despite of having 380 -universities, 11,200 colleges, and 1,500 research institutes, there is not enough skilled workforce to support the system. IATA projects that it needs 17,000 trained pilots annually but with less and less students opting for aeronautics

because of less pay packages the gap between the demand and supply is ever increasing. For this reason Corporations both government and private are significantly investing in the training of in-house recruits for the right kind of skills to usher in the aerospace manufacturing market.

The way forward for the growth of aerospace manufacturing sector in India in the right proportions, can only be established if a proper synergy between policy, industry and academia is achieved in the aerospace sector. Aerospace sector is of strategic importance and a key player in development; hence government relaxation on FDI limit alongwith a security policy according to experts can be one way which can strengthen India’s global standing. For MSME’s and SME’s when venturing in the market a good assessment of their strengths and capital savings is a must understanding to avoid risks and failures. Also understanding and opportuning the talent and skills available in the workforce are important to drive India into independency especially if we stand as the second largest in the world population index. Finally, with the aerospace sector facing new intensity in the form of economic slowdown, decrease in defence spending cuts and as such globally it is very important to keep up with the changes simultaneously, and this can be achieved only by investment and growth in R&D areas of aerospace manufacturing both by PSU’s and Private enterprises. In the words of Bill Gates (American inventor, computer programmer and former CEO-of Microsoft),“I believe in innovation, and the way you get innovation is when you fund research and learn the basic facts.”


MECHATRONICS


The term “Mechatronics” was first came to public notion in 1971 by Mr. Tetsuro Mori who was a senior engineer in the Japanese company named Yaskawa Electric Corporation. It is a combination of both electronic and mechanical engineering to help gather knowledge from both fields equally valid and important. It is this vast arrangements of application that deviate Mechatronics from backdated control engineering. But the question that flickers from this issue is that who (either electronic engineers or mechanical engineers) will be responsible for the future development in the mechatronic systems? Usually the answer is silently handled by the companies the engineers work for. In this matter the words from the senior research engineer

Peter Schmidt, of Rockwell Automation’s Advanced Technology Group, can be mentioned here. To quote his lines adequately, “We’re all engineers and we’re doing engineering.”

In the Indian perspective, the leading SME companies in the engineering domain including basically, electronic and mechanical engineering and also computer and control engineering are merged in a cooperative relationship to achieve the highest opportunities in the mechatronics. As we have already learned about the basic technologies involved in our daily used machines to be part of the mechatronics let us acquire more knowledge in the mechatronica cluster in India. The prime factor of the cluster is a mutual relationship

in between the electronic and mechanical engineering for the betterment of the mechatronic technology. In this huge possibility we can only imagine a better future in this multidisciplinary field.

In the last Export Coaching Programme for Engineering Products of CBI, (the centre for Promotion of Imports for Developing Countries), The Netherlands in November 2009, different manufacturers were present from different parts of this field. It is this reason why senior CBI Consultant Mr. Peter van der Sman suggested for an Indian Cluster in this field also. It was expected that this Cluster with

the help of the Companies in ECP for Electronics will bring forth an innovative and creative future in the Indian industry.

The first principle to come across in this matter is to be in a beneficial relationship to advance in a right way to help gather and distribute knowledge. In this system the best ever automation solutions are contributed to their members and supporters. The chief goal is to provide a suitable platform to those companies and institutes to under mechatronical provinces to combine their imagination and creativity for the innovation of new ideas and technology. The world-wide effects of this mechatronics are especially noticed in the fields


The coined term, Mechatronics can be used in a vast range of fields of mechanical engineering, electrical engineering, control engineering and computer science engineering. Simply put that Mechatronic is everywhere in almost all electronic application we find about to fulfill our daily needs. Now if you are still confused to think any specific item then it is time for you to notice the simple and user-friendly coffee makers or washing machines, air conditioning systems, cameras, laser printers, or to think advance technology, automated robotics, as an obvious example we can name Artificial Intelligence or AI and even the highly advanced medical equipments. These are all parts of the huge field represented by “Mechatronics”.

Mechatronica members at Electric Automation Systems and Components International Exhibition and Conference Nuremberg, Germany, 26-28 November 2013

Chandranila Das

[email protected]


of automation, motion control, and robotics.

Mechatronic cluster is an example of effective co-operation between the programmers, designers, planners, thinkers, developers, manufacturers and improvise the most spontaneous solution for the intermediaries and representatives. In this way the Indian foreground in the mechatronic technologies can be made stronger to face the bitter challenges from the International competitions. Most valuable information including the foreign collaboration helps to increase the awareness of the Indian companies and institutions to move forth for the creation of an effective network to confront any possible challenges. It is a vital collaboration of science and engineering for an illuminating future of Indian Mechatronic cluster.

These leading SMEs are engaging themselves in exhibitions, fairs and all other ways necessary to keep track of the latest developments in those multidisciplinary fields. It helps them in experimenting and creating new products and services. It is done solely for the purpose of competing with the foreign challenges. It helps them gain proper international acknowledgements.

This Mechatronic Cluster is fulfilling the vital role playing of encouraging the member Industries about their social responsibilities withstanding their policies, their management, their processes involving their production and also strategies. In this case they always have to keep in mind that international norms are ever-changing, so they have to evolve with the current demands.

Why was Mechatronic Cluster created in India?

In our country there was a need to get awareness about Mechatronic and automations amongst the system users, industries, universities and students. There is a common situation with most of the component manufacturers which are used for system integration. They are scattered and not well connected with each other, due to which indigenized potential was untapped. As India is becoming manufacturing hub for various sectors like auto components, Rubber components, Consumer durables, engineering, electrical etc. it was required to have one common guiding agenda and policies for the system integrators.

What are some of the greatest achievements in the last two or three years in this Cluster?

Rather than competing with each other, with the creation of this Mechatronica Cluster a network is built between many component manufacturers for a common cause and started sharing their thoughts so that tremendous improvement in quality and performance can be achieved. Not just on the national level but also from Europe, this cluster is gaining recognition and their inherent capacity with this cluster collaboration is exposed in the European market.

How is it helping till now in the field of innovation when it is built with leading multidisciplinary SMEs?

The Confidence level is boosted in those constituent SMEs in the Mechatronica Cluster for the competitiveness with European players. Few system integrators have come forward for innovative product development and import substitution, thereby foreign exchange savings are now possible in defense sector.

Why did you think this opportunity to be well-matched for your future development?

As a system integrator and designer, I got very well exposed with newer technology and European business partner which helped my company in improving market share and profitability.

What is the future of this Cluster in India according to your viewpoint?

It will be an Apex body of all India system integrators with regional branches/offices at Delhi, Mumbai, Kolkata, Bangalore and Chennai with more than 1000 members. This cluster will be a bridge between universities and Industries for the Mechatronic innovations.

How do you see the foreign competition, keeping in mind

the betterment of this Cluster?

Already European Mechatronic clusters from various regions are looking at our cluster for partnership, specifically research and developments in the engineering sector.

What would be your advice to those students interested in Mechatronic? How can they pursue their dreams in the Mechatronic division?

In the years to come, Automation and Mechatronic will be the key words in the Indian industries. The requirements of engineers with mechatronic knowledge are going to increase in multifold for which our engineering education system/universities are not ready, even with the basic curriculum at the moment.

Students perusing mechanical or electronics will have to look for taking interdisciplinary subject knowledge if they really want to be mechatronic engineers. On the university level, we must be looking for promotion of mechatronic as an independent subject, branch. As a mechatronic cluster, we will certainly help in achieving this.

More focus on Industry-Institutional interactive programme must be targeted by both.

“Mechatronica Cluster is only the first step towards our goal.”

Ravindra Mahadeokar is the core team member and the Founder Secretary of Mechatronics Cluster. Since the beginning he was helping the president in the establishment and development of the Mechatronica

Cluster on all India bases. He pays strict attention in the membership development in the Cluster. He is also

the Managing Director of Summit Engineers and Consultants Pvt Ltd, Nashik.

Here he talks about Mechatronica Cluster in India.

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INNOVATION

Modi Arc brings innovation to the field of Electrode Welding

Developing of the non-synthetic E9015-B9 type electrode for welding of ASTM A335 Grade P91 material; a step forward to provide welding solutions. U K Sharma, General Manager (Technical) of Modi Arc put forwards the work done at their in-house Research & Development Centre for the development of Non Synthetic, E9015-B9 type electrode for welding of ASTM A335 Grade P91 material; showcasing that the effectiveness of a thermal power plant depends on steam parameters.

To meet power generation requirement of the country and to reduce carbon emission; stress is given to increase efficiency of the power plants.

Modi Arc Electrodes Company part of Group MKM which are in diverse areas such as Welding, Industrial Gases, Paints; Engineering Plastics, Information Technology, and Real Estate, was established in the year 1962 and has a well-equipped plant, spread over an area of approximately 15000 sq. mts located at Modinagar (UP) about 45 kilometers North-East of New Delhi. The welding business of GroupMKM, promoted by Dr. M.K. Modi, has been at the forefront of welding technology in India for over four decades. The group has been engaged in meeting the exacting welding needs of a host of industries, especially in the Infrastructure sector; be it Power Generation, Oil and Gas Exploration, Oil Refining, Ship Building, Railways, Sea Ports, Airports, Road Construction and the like.

With a wide range of electrodes ranging from General Purpose Mild Steel to Stainless Steel Cast Iron to Nonferrous Hard Surfacing to Low Hydrogen being manufactured on modern equipment, they also offer a complete welding solution including Welding Equipment which includes a comprehensive range of Conventional, Thyristor and Inverter based machines for MMA, MIG, TIG, SAW and Air Plasma Cutting processes, which has earned them Quality Management system to standard ISO 9001-2008 in their recent audit.

According to Sharma, the study showed that developing of non-synthetic E9015-B9 type electrode follows that to accompany the principles developing materials having high temperature creep resistance, are alone selected for the components subjected to high temperature and pressure. Material SA335 Grade P9l being one such is selected by designers for its excellent high temperature creep resistance property. The application of alloy steel 91 material is increasingly being used in petrochemicals, refineries and power plants, thereby increasing the requirement of suitable welding electrodes.

Development of the non-synthetic E9015B9 type electrode, specifications of core wire should be of ER90S-B9 grade. Ferro alloys and metal powder need to be used in flux coating arc specified with controlled impurity level so that final weld metal chemistry can be controlled within narrow range. As it is a basic type of electrode, liquid binders have had to been selected accordingly. Electrodes produced in 2.5, 3.15 & 4.00 mm.

Baked electrodes being tested for welding performance in all positions; Pipe joints welded in positional welding like 2G, 3G, 5G, 6G and radiography done to verify the soundness of the welding, showed satisfactory test results.

Chemical analysis of weld metal also done; found all test results as satisfactory.

All- weld assemblies were prepared for soundness and mechanical testing. Preheating and inter-pass temperature

maintained as per ASME Section Il with Part C. Radiography test being done, welded assemblies were subjected for post weld heat treatment at 760°C for 2 hours. Testing of tensile, impact and hardness was done.

Fillet weld testing, coating moisture testing and diffusible hydrogen testing were also done and the results were found meeting ASME Section II Part C and BHEL Trichy specification requirements.

The Creep Rupture Testing is being carried out at 600°C temperature 100 MPa load and is still under continuance on at the M/s. Metallurgical Services, Mumbai, but has completed 12000 hours without rapture.

Modi Arc in the development of this product as a successful test result of chemical, mechanical, usability, coating moisture, diffusible hydrogen and also creep data obtained so far, have exceeded in giving innovative welding solutions to the users of P91 material.

U K Sharma is a science graduate and PGDBM, having a rich experience of more than 30 years in the field of welding. He is Head of R&D centre at Modi Arc, recognized by Government of India, Ministry of Science & Technology. He has developed in-house a number of welding products for welding of Low Alloy, Stainless Steel, Duplex Stainless Steel, High Tensile Steel and Creep Resistant High Chromium Alloy Steel and is an active member of BIS Welding General and its Application Sectional Committee MTD-11 and Metallurgical Engineering Division Council (MTDC) and has presented various technical lectures in welding seminars.

U K Sharma

[email protected]


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ROBOTICS


Universal Robots (www.universal-robots.com) developed the UR5 and UR10 models for small and medium-sized enterprises in particular. The handling units lift a payload of five and ten kilograms, but only weigh 18 and 25 kilograms themselves respectively. This low weight makes it possible to move the units easily without complex subcomponents. The multi-functional robots are just as flexible in operation given their user-friendly software. This multi functionality supports the Danish company with a user-friendly piece of software. Using this, the six-axis lightweight robots are ready for new tasks in no time. No special knowledge of robotics is necessary for the programming.

Modular Design

The exceptional ratio of dead

weight to loading capacity is the result of a sophisticated lightweight construction that does not contain anything it does not need. With the drive technology, this minimalist strategy means integrating Kollmorgen’s frameless kit motors directly into the articulation axes. In so doing the robot takes on the function of the motor housing, while the gear unit simultaneously serves as the primary bearing of the rotor. Viewed as a whole, the components used by UR frequently take on multiple functions, and this ultimately reduces the number of mechanical components such as ball bearings, couplings, or shafts considerably, thus decreasing overall system weight and form factor. In addition, with their high power density, the Kollmorgen motors increase the lifting

capacity of the UR5 and UR10 platforms. With their high power density, the KBM motors increase the lifting capacity of the UR 5 and UR 10 at the same time.

When they are combined with a carbon-graphite mating material, P-V is further enhanced. The ability to closely control the amount of surface texture on the seal face through formulation and processing provides enhanced capability for the seal face combination, in particular hard-on-hard combinations that will exist throughout

The KBM motor series offers advanced electromagnetic designs for optimized torque and minimal cogging and harmonic distortion. These benefits are offered over a large operating speed range. The electromagnetic technology with a high packing density in the stator increases torque and keeps thermal losses low. High strength rare earth magnets are used in the rotor, which allow a continuous torque of 1.45 to 3,445 newton meters along with a peak torque of 4.91 to 12,812 newton meters. “The high quality of these motors was a reason why

we opted for Kollmorgen,” explains Esben H. Östergaard, technical business manager of Universal Robots.

Given that the KBM motors are embedded in the robot housing and directly drive the load, the robots are able to achieve high level of precision in movement and force control. Targeted force control is critical in this regard, because the robots constantly have to move different workpieces perfectly with high variability. In practice they recognize the size and elasticity of the objects and adjust the force to be applied accordingly. This force must be stronger than just 25 newtons to do this. With a precision of

Kollmorgen drives the lightweight helpers of Universal Robots

UR 5 and UR 10 are the names of the two models with which Universal Robots aim to establish the flexibility of articulated-arm robots in industrial production. The focus is on work areas in which conventional robots have thus far been too big, too expensive, and too loud. Due to their low weight they can be used wherever they are needed. A large part of the power density of the six-axis articulated robots comes from specially adapted KBM direct drive motors from Kollmor-gen. Universal Robots was able to embed the motors directly into the articulation axes without need for additional housings.

Ian Young

[email protected]

The six-axis robots are being used in processing and production facilities for example. The robots are easily programmed to accomplish

repetitive tasks. Photo: Universal Robots

The KBM motors offer a great deal of freedom to configure the servo axes in a space-optimized way due to their variable, modular design. Photo: Kollmorgen


± 10 newtons and an accuracy of ± 5 millimeters, the required force and desired position can be programmed and executed for each of the six joints.

Operation without noise but high energy efficiency

Another advantage of the robots is its low-noise and energy-saving operation. From a total-cost-of-ownership perspective, the economical use of resources directly increases the efficiency of the robots overall. The competitiveness of this technology thus increases as a result. An additional benefit of high energy efficiency is closely linked to reduced losses in the motors. As efficiency is high, less heat is produced. This means the motors stay cooler, operate below their maximum ratings, and consequently achieve a longer service life.

The improved temperature behavior also prevents the

entire construction from heating up. “The motors we used in the past became pretty hot when in continuous operation. Because of the lower losses, the KBM motors from Kollmorgen simply stay colder. We can therefore run our robots in continuous operation without derating,” states Östergaard, and he refers to test procedures with long operation periods and comparatively high loads.

The KBM series is an innovative direct drive frameless motor technology provided by Kollmorgen. The frameless kit motors offer mechanical and plant engineering a wide range of solutions for creating applications with a maximum degree of flexibility, power density, dynamics, and durability. In addition to the technical advantages provided by this product, the KBM platform includes 14 frame designs and many pre-

engineered standard options with competitive lead times.

“We can basically order as many motors as we want, when and how we want,” emphasizes Östergaard. This aspect is of particular importance because Universal Robots is growing strongly. “We therefore need a partner in drive technology who is a good fit for us.” In this regard, Kollmorgen was able to impress the Danish robot specialists with delivery reliability and has since established a UR-specific production line at the Czech location in Brno.

For further details on KBM direct drive motors visit

www.kollmorgen.com/hi-in/products/motors/direct-drive/kbm-series-frameless/

Ultimately, the quiet operation and high-quality control of the synchronous servo motors ensure the robots can be used outside of handling applications, too. Up until now Universal Robots’ focus has been to use the robots as a tool for performing simple tasks. “We are therefore not competing directly with other robot manufacturers who deal with more complex tasks. Instead we are saving people from having to perform tiring, monotonous manual work,” stresses Östergaard. As the company

from Odense has developed light constructions without uncontrollable oscillations and vibrations, however, there are new application possibilities; such as with welding and gluing. “We can expand our business channels,” says Östergaard. This development is accompanied by the fact that due to sophisticated safety technology both models are even able to be employed without additional shielding. This opens the path to a safe and comfortable cooperation between staff and technology.

Kollmorgen is a leading provider of integrated automation and drive systems along with corresponding components

for machine builders all over the world. With more than 70 years of Motion Control Design and application experience and profound knowledge of constructing standard and special solutions, Kollmorgen supplies solutions time and again that stand out in terms of performance, quality, reliability, and ease of use. As a result customers can achieve a market advantage which is beyond question.

The author Ian Young is Key Account Manager with Kollmorgen, Ratingen. For further information please contact [email protected] or visit our website www.kollmorgen.in

The UR 5 and UR 10 designs use KBM motors from Kollmorgen. They are integrated directly into the axis joint

Esben H. Östergaard, technical business manager of Universal Robots, values Kollmorgen’s high availability of supply in a constantly growing market.

Photo: Universal Robots

Close partnership with people: the robots from Denmark have been designed for collaborative work in production. Photo: Kollmorgen



ON FACE


Unleashing Dreams

Rahul Thakur Singh, a 17 year old engineering student of NITK Surathkal; co-founder of the domain Booksonhire.in which aims for making education affordable and accessible to engineering students in India, shares his journey from scratch on how he managed to break norms and make it on his own.

“Journey of a thousand miles begins with a single step”. With the entrepreneurial journey I had chosen I wouldn’t want to end it at a thousand mile.

A few of us know that success rate for startups in India is less than 3%, but that never deterred me and Vivek Agrawal (my friend and co-founder) from taking risks because of the unexpected. It was the blessing in disguise. The decision to start up was taken in the spur of a moment. We sat in a room the day before the exam looking at the pile of untouched books thinking we had wasted so much money on them for only using the books a few hours. Deep in pain calculating the amount of money wasted.The thought “What if we could rent books to students only when they needed it?” i.e. for a single semester, that was our Eureka moment! Our grand business plan –‘rent textbooks to students all over India’. After enquiring from friends in many colleges. There was nothing solving the problem; for investment we managed from friends and family expectedly raising about Rs.40, 000. We bought used books from our friends at low prices.

For the E commerce website, we bought the www.booksonhire.in domain and after 2 months of much difficulty we were just in time before the new semester. With a bit

Journey as they say….

of advertising on Facebook and posters we were ready for orders.

With initial murky days, we got our first customer who actually thought that we were into social service, he went on to tell his friends about us and in the next 4

days we were out of stock. We did a business of 1 lakh which was quite overwhelming as a 17 year old.

From taking orders to delivering them personally we did everything, to the point of being teased as ‘delivery boys’. But it did not matter; we got a lot of queries from students. To scale up we went to a lot of start-up events for investors but it were to no avail, which taught us never chase investors but only your customers.

Trying to learn more about the

business of e-commerce, I interned with FlipKart which taught me a lot and helped us pivot from our current business model to something totally different which allows us to expand without much upfront money.

As an entrepreneur I realized there are many bad days than good days but the day you sign a deal or acquire a new customer that supersedes all the bad days. There were challenges but we kept trying; sometimes it’s important to believe in yourself and move along. I owe it to my parents for the support.

The journey I have had is cherished as it taught me to rethink and innovate possibilities when you have nothing to bank upon. It taught me so much which any Ivy League Degree cannot replace,

The experience till now was priceless to say the least.

www.martonline.in 19April 2014 www.martonline.in 19March 2014


MART FEATURE

Increasing Seal Face Capability In Hard-On-Hard Combination

In order to minimise the potential for leakage paths across the faces, flatness is often controlled to fewer than three helium light bands (0.000033-inch). The seal face closing force, typically created by mechanical methods such as springs, and the hydraulic forces that are generated by the seal design itself, hold the faces together, creating an intimate condition ultimately resulting in the wear of one or both faces.

These hard face materials are often used in particularly challenging applications, where they are in contact with each other (i.e. silicon carbide against itself or against tungsten carbide). As operating conditions for the seal become more severe, hard-face materials must continue to efficiently rub against each other to maximise their inherent benefits. Unlike mechanical carbon-graphite, these hard-face materials are not self-lubricating and so are unable to function for extended periods of time without fluid lubrication. Other enhancements therefore need to be made to extend the capability of the hard-face mating pair.

This paper will cover the evolution of the various forms of silicon carbide, their reliability issues in hard-on-hard combinations and the development of hybrid silicon carbide 1.3 Raction

Bonded Silicon Carbide Homogeneous materials such as reaction bonded silicon carbide provide the benefits of low porosity, higher elastic modulus (stiffness) and thermal conductivity, and good tribological behaviour when run against a suitable mating material, such as mechanical carbon. Initially, the costs associated with the processing of this family of materials somewhat limited their use in high-duty applications in less chemically aggressive conditions. These materials required extensive grinding and the free silicon in the structure was susceptible to highly caustic or acidic environments.

This family of materials quickly gained acceptance in a variety of applications as contact pressures could be increased with less face deflection than that would be experienced with metallic materials. Normal protocol was to run a high-duty, hard, mechanical carbon-graphite, often impregnated with antimony, against the reaction-bonded silicon carbide.

1.4 Sintered Silicon Carbide

Sintered silicon carbide (aka self-sintered, direct sintered or less pressure sintered) provides additional options with regard to its production. This material can be formed into specific shapes and then sintered to, or nearly to, the finished

size, limiting the amount of expensive grinding for the finished item.

This reduction in production cost, coupled with the homogeneous nature of the material, enabled its use in highly corrosive environments, along with higher volume applications.

It began to displace other materials such as alumina where higher pressure-

velocity (P-V) capabilities were required. (The P-V parameter is an index of the severity of the application. It is a relative measure of the material pair and is affected by other variables such as the fluid being sealed.)

Unfortunately, this monolithic material does not have all the tribological characteristics of a reaction-bonded silicon carbide, a two-phase material, nor can it run at the highest

Sintered Silicon Carbide w/ Graphite

Relative P-V Capability Hard- face Mating Pairs

RB SIC+G

S SIC+G

R B SIC

S SIC

WC

A1203

0% 20% 40% 60% 80% 100% 120%


While often taken for granted, the composition and design of the mating faces in every contacting mechanical seal are critical in terms of the prime objective of reliably preventing the media on one side of the face from successfully reaching the other. To achieve this objective, different materials are employed, including mechanical carbon-graphite with resin or antimony impregnation, metals and hard coatings, aluminium oxide, tungsten carbide, and silicon carbide. The latter three materials are most often characterised as ‘hard face’ materials, with silicon carbide currently one of the more frequently applied.


ASCENT

duties of that material. Once again, the attributes of the material can also serve as limitations.

1.5 Graphite Loaded Silicon Carbide

Silicon carbide materials have evolved over the years, and now often have the form of a two-phase composite that is applied in the highest duty applications, the most popular being silicon carbide and graphite. These composites are often referred to as “graphite-loaded” silicon carbide since the graphite is integrated (not impregnated) into the silicon carbide structure.

The presence of the graphite creates small reservoirs on the surface that provide a controlled texture for lubrication without creating leak paths. This texture increases the hard face combination’s ability to operate under more rigorous pressure and velocity (PV) conditions and can be tailored to specific applications.

Graphite was initially added to reaction-bonded silicon carbide and quickly exhibited an increase in the performance capabilities of hard face combinations. While strength is reduced somewhat and the ability to handle abrasives is not as good as that of monolithic silicon carbide, tribological behaviour is improved significantly. Using this type of material in at least one of the two hard faces extended the seal life cycle in some cases from minutes to hundreds of hours.

Graphite-loaded sintered silicon carbide has been applied in hard face combinations for more than a decade. This unique family of composite materials has the benefits of sintered silicon carbide while incorporating a second, abradable phase that provides pockets or reservoirs for the

“storage” of fluid.

1.6 Crystalline Diamond Silicon Carbide

Diamond is the hardest material with excellent tribological behaviour, heat conductivity and chemical resistance. These qualities are produced on the surface of a conventional finished silicon carbide ring by growing a crystalline diamond film on the surface. This is created by placing the silicon carbide ring in a chamber where the pressure, gas composition and temperature are accurately controlled. A carbon bearing gas such as methane (CH4) is introduced into the chamber and, under the right combination of processing conditions, diamond crystals grow on the silicon carbide. The process, called Chemical Vapour Deposition (CVD), occurs under vacuum at temperatures around 800°C (1,472°F).

The diamond is not precipitating out from the vapour phase but grows up from the surface of the silicon carbide. As these small diamond crystals grow, they coalesce together and form a continuous diamond surface. Specific processing conditions determine the diamond’s properties, while the high temperature of the process determines the bonding of the diamond onto the silicon carbide. It is also important during the process to maintain the flatness of the seal ring to deviations well below two light-bands of helium. These enhancements offer benefits for applications in harsh operating conditions but come with a significant premium.

2.0 Seal Face Topography

The performance and reliability of a mechanical seal is greatly influenced by the topography i.e. the shape, height and depth of the seal face surface micro-structure. As an example, a monolithic sintered silicon carbide is so homogeneous and

dense that it has no topography that results from its structure. If this material is lapped to normal seal face standards then this hard-on-hard combination may “wring” together creating a very high starting torque and marginal lubrication conditions, both of which may damage the seal faces.

2.1 Matte Lapping

Traditionally a “matte” lap approach, which creates shallow scratches a few microns wide on the seal face to allow fluid into and potentially across the interface, was applied to seal faces to prevent “wringing” and enhance lubrication. But with time the surface would again become polished smooth, re-creating the same conditions that, while theoretically optimal for minimising leakage, are tribologically challenging for these non-lubricating, monolithic hard-face materials. The development of composite graphite-loaded silicon carbides have been developed with graphite integrated into their structure which creates small reservoirs on the seal face surface that provide a controlled

surface for lubrication without creating leak paths. The benefit of the integrated graphite is that it is not just a surface effect, but one that extends throughout the material and produces an enhanced capabilitythroughout the life of the components. It is also possible to control the quantity and particle size of the graphite in the structure for a given application.

2.2 Surface Texture

This control of the surface topography with the size, distribution and depth of graphite is termed the texture; and this increases the hard face combination’s ability to operate under more rigorous pressure and velocity (PV) conditions. As shown below, both graphite-loaded silicon carbide composites running against themselves have the highest relative P-V values of any of the hard-face pairs.

When they are combined with a carbon-graphite mating material, P-V is further enhanced. The ability to closely control the amount of surface texture on the seal

Monolithic “Body” Tribo-Enhanced Running Surface



face through formulation and processing provides enhanced capability for the seal face combination, in particular hard-on-hard combinations that will exist throughout the life of the components. Additionally, this specific adjustment of amount and volume of the texture enables further customisation in the most demanding applications. Increased texture on at least one of the contacting surfaces can significantly extend the life of the seal pair. The final surface finish technique used on a surface texture that is controlled by the level of graphite in the composite can influence the predictability of the mechanical seal’s performance, as shown below.

Texture Ranges Of Composite Surfaces

2.3 Mechanical Properties

The transitions between the silicon carbide and the tribological enhancement are critical so as to not create other operational issues. Specifically, edge breakdown around the boundary can create debris that then damages the interface.

A graphite-loaded sintered silicon carbide composite with a properly configured graphite structure can provide for a smooth transition between the reservoir and the silicon carbide matrix.

The wear rate of composite graphite-loaded silicon carbide can also be influenced by the quantity of graphite in the structure. The table below shows the test results from hard-face mating pairs with differing levels of graphite in the sintered silicon carbide structure, starting with the monolithic material.

The change from a silicon carbide monolith to a composite structure can also result in a reduction in the structure’s physical properties, as shown below. The impact of these properties can limit the use of these tribologically enhanced materials in conditions where modulus and strength have higher importance. There is one characteristic that improves with the addition of a second phase; thermal shock resistance is improved for the composite versus the monolith.

2.4 Composite Silicon Carbides

The graphite-loaded silicon carbide materials enable greater reliability for hard-on-hard seal face material combinations. Not all graphite-loaded composites are the same - the second phase’s integration is as critical as its presence in the matrix. The presence of the second phase reduces key characteristics of the material, potentially limiting its use in some of the highest mechanically loaded

conditions. This limitation has led to the development of a hybrid silicon carbide.

3.0 Hybrid Silicon Carbide

Hybrid composite silicon carbide was developed to improved and sustain the physical characteristics of the homogeneous silicon carbide in the bulk of the material while incorporating the benefits of the graphite addition only on the seal face itself. The integration of the two-phase composite texture onto a homogeneous substrate provides the physical attributes of the bulk silicon carbide and the tribological enhancement of the composite (patent pending).

This development allows the structure of the composite graphite-loaded silicon carbide to be customised for a given application, creating an ability to tailor the seal interface for demanding requirements without affecting the physical strength or other attributes of the material.

The tribologically enhanced surface(s) can be applied to a seal face and/or diameter, depending on the ultimate use of the component, see below. The enhanced surface thickness can theoretically be 0.2mm, although work to date has been approximately 1mm.

Conclusion

The mating rings for a mechanical seal are critical components and silicon carbide remains one of the most popular and cost-effective options. While the physical characteristics of the material matrix can be adversely impacted by the incorporation of tribological enhancing additives such as graphite, the mating pairs’ capabilities are enhanced, specifically in marginally lubricated conditions. A patent-pending development permits the strategic placement of the tribological enhancement in hardface materials, thereby providing thebest attributes of both the monolith and the composite.

Figure 8 EFFECT OF GRAPHITE ON SEAL FACE WEAR RATE

Physical Properties Comparision Monolith vs. Composite

100%

80%

60%

40%

20%

0%

Com

posi

tion

% of

Mon

olith

Val

ue

Compressive

Transverse

Thermal Conductivity

K I C

S-SIC

S-SIC-G

70 BAR -m /sec

46ºC, Demineraized H2O

Matched Graphite Loaded SIC Pairs

Monolithic Sintered Silicon Carbide

Graphite Content IncreasingWear Duration

Wea

r Rat

e (µ

-m/h

r)

Monolithic SIC after < 10 minutes

Test Duration (h)


www.martonline.in24 April 2014www.martonline.in24 March 2014

P S Satish

[email protected]

As a continuation of last article, we will discuss on few more points to manage SME’s better in India

Journey Towards Excellence Managing a SME in India - Part 16

MANUFACTURING EXCELLENCE


28. Practice benchmarking

We often see that children trying to imitate parents like the way father sit, talk etc. This is part of nature. Children do imitation blindly whether good or bad. Because of this, parents have a responsible role to play. As we grow and learn, we try to emulate someone whom we appreciate. It could be their qualities, principles and so on. In the former case, imitation is just trying to copy blindly.

Later case of emulation is an attempt to understand to be equal or excel. Taking the clue from this, what companies should do looking at companies who are successful, have grown in turbulent times and have consistently excelled every year for long time.

Naturally companies have to emulate the best. There is an argument that copying others is wrong. Personally, I do not see anything wrong in this as long as intellectual property issues are taken care.I came across a saying from author Vic Johnson. He says on copying, “I am the ultimate monkey see, monkey do person. What I have become very good at is studying what other people do, then I go out and duplicate it exactly. I don’t violate anyone’s copy write or trade mark laws, I respect that. But what you can’t copy write or trade mark is ideas, concepts and strategies. So if I see someone whose strategies seem to be working, I am going to go study that.”

A word of caution. Evaluate before copying something. If strategy of a company has worked well, it may not work exactly in the same way for your company. You may have to adapt to make it suitable for your specific use. This is normally called as benchmarking exercise.

After world war, economy of Japan was in doldrums. They were committed to rebuild. What did they do? They copied what others were doing but developed their own standards. For example, we know that Toyota sent experts to USA to study how Ford is manufacturing cars. They did not copy blindly but understood the current deficiencies and adapted to suit the Japanese way.

Japan earned respect from the world for the later success. The concept of adapting best practices and improving slowly became a new word called Benchmarking.

Benchmarking is a powerful tool for performance improvements. We know from history how XEROX became successful after benchmarking

with successful Japanese player at that time CANON.

Look at the definition of benchmarking from Dr.Robert Camp who was heading benchmarking exercise in XEROX, “A benchmark is a standard of excellence, or achievement, against which performance must be judged or measured. Benchmarking is the continuous process of measuring products, services and practices against the company’s toughest competitors or those companies, renowned as Industry leaders.”

Every company need to evaluate where they are with respect to a standard or benchmark. When I was heading international purchase of a company, one of leading pressure die casting manufacturer in India came to me and said, ‘ We are the best in India and would like to do business with your company for export requirements ’. I complimented them and asked,’ How many players are there above your Company in the world? Do you know those players by name? With whom you do benchmark? ’

Benchmarking is not Imitating

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organization to develop analytical thinking, ability to ask questions, analysis of Data or Information and so on.

o Internally also department wise bench marking can be done. Example, 5S practice of best department can be benchmarked by others. Healthy internal competition gives very good results.

o Encourage senior management to participate outside seminars, exhibitions, trainings to network with others to get some ideas for benchmarking.

o Benchmarking should not be a onetime exercise but to be a continuous process.

With global competition and challenges, traditional approach of improvements will not work. Practicing benchmarking continuously as a process, Companies have a chance to compare their performance relative to their competitor, hold employees accountable and responsible with better targets, identify areas for improvements ( say OEE compared to industry standard), develop culture of continuous improvements and to understand things that make company successful. If company has to excel every year, benchmarking is one of the means. I want your input to bench mark this article.

I will continue the series of article in the next issue. Please send your inputs,remarks,suggestions to P S Satish, Mentor and Capability Developer, M/s Saraswati Industrial Services, Q 103, MantriParadise Apartments,Bannerghatta Road, Bangalore-560076. Do visit www.satishps.com. Have a good day.

Apparently they did not have an answer and I knew from one of internal studies that this company, claiming best in India, was in sixtieth position or so in the world.

There are many books dealing elaborately on benchmarking exercise. I am giving here some guidelines on benchmarking which can be a starting point for small and medium scale companies:

o Decide on what to benchmark. Is it a product, process, strategy or results ?

o Be clear of why benchmarking is necessary for you. Clarity of purpose will find better ways.

o Do not try to benchmark too many parameters. Focus on one or two. I was consulting a company on marketing. They are into machine manufacture. We found that from the reports of Customer that service level was poor, documentation of service manual was not up to mark, packing of machine was not friendly for customer to unpack. We started looking for best in Industry for these aspects. We picked up good things of two companies to improve.

o With whom to benchmark? It need not necessarily be your competitor. You as an engineering company may benchmark packing methods used in garments if relevant.

o Keep a Databank to note down companies whom and what can be benchmarked?

o Define a process for benchmarking. It can be like planning for collection of Data, analysis of Data, defining goals and action plan to achieve.

o Train people in the

PVC Industry Removes Lumps and Foreign Material from PVC Powder or

Compound for Smooth and Economical Production

Master Batch Industry Removes Lumps /Joined Granules and Dust/Chips for better Product Quality and Appeal

Injection Molding & Plastic Reprocessing

Removes Dust & Chips from Recycled Meterial after Grinding

for better Molding Economy

Polymer Powder Industry Removes Coarse / Underground Meterialfrom Powdered Meterial or Steady Powder Quality

ETA ENGEINEERING SERVICESAhmedabad. (India)

E-mail : [email protected] : www.vibroscreen.com

CONTACT : 09909917170

DESIGNED TO PERFORM

OEM Requirement and Agents Enqiry Solicited


TALENT MANAGEMENT

Onboarding, also known as organizational socialization, refers to the mechanism through which new employees acquire the necessary knowledge, skills, and behaviors to become effective organizational members and insiders - Smart managers know that onboarding is a crucial part of building employee engagement, satisfaction and success.

A review of current research shows a clear correlation between effective onboarding training and improvements in employee performance and reductions in turnover – a recent study by HR.com found that effective onboarding training programmes can improve employee performance by over 11%, primarily because of employee clarity around job roles and responsibilities. Key onboarding activities such

as clearly communicating performance expectations, providing explicit linkages to organizational mission and values, giving feedback, involving co-workers and peers, and providing training, are crucial to employee and organizational success.

Some organizations manage the process better than others. A select few take onboarding to the next level and integrate their onboarding program into their talent management process. The result of this integration is that ‘onboarding becomes a key component of your company’s talent strategy’.

Onboarding involves a special, conscious effort to make a new employee quickly become a productive member of the organization, laying a solid foundation for a long-term relationship.

At the heart of onboarding is careful attention to the success of desirable new employees over a period of time. Transitions are periods of opportunity, a chance to start afresh and to make needed changes in an organization. But they are also periods of acute vulnerability, because new

employees lack established working relationships and a detailed skilling before they assume their new role.

Charged with the task of making new employees feel welcome, establishing their responsibilities, orienting them in their new position

Pavan Sriram

[email protected]

I was reading on the internet that 80% of all new hires decide within the first 6 months whether they are going to stay with their current employers or begin looking for ‘new opportunities’. Whether this figure is result of research or not (or simply overblown), it does point out the importance of new hires in the workplace. From a strategic view, it makes a lot of sense - You have hired the best, now it’s time to ensure that you can fit them into the organization and “ramp them up” as quickly as possible.

Onboarding - Your Next Talent Strategy!

W.K Kellogg, founder of the 100-year old Kellogg Company famously said “I’ll invest my money in people.” In line with this philosophy, in the 21st century Kellogg still sees attracting, selecting, engaging and retaining the best talent as critical to the company’s business success. Feedback from internal surveys indicated a need to improve Kellogg’s onboarding process,

so the company put a transition frame-work in place. The framework includes new ways to add value, connect and build relationships, navigate unwritten rules to get things done, and review performance and progress. Specifically, Kellogg uses new employee onboarding training, new manager assimilations, employee resource groups and a 30-60-90 day checklist.

Kellogg’s transition web site is a focal point of onboarding revitalization. On the web site, employees can assess their own onboarding status by using the onboard-ing track record tool. This tool analyzes potential strengths and weaknesses of past onboarding activities, so it becomes easier to pinpoint areas for improvement of a formal onboarding training plan.

>>> Onboarding on Track



and familiarizing them with the company culture, there’s a lot to cover and the training process is often overwhelming. Onboarding goes beyond orientation to provide an integration program that equips new hires with the resources to become fully engaged and culturally aware members of a productive workforce.

An excerpt from The First 90 Days, written by Michael Watkins, a professor at IMD, Switzerland points out – “employee onboarding, the orientation or mainstreaming process of a new position, is a crucial element in both individual and organizational development and establishes a foundation for future success.”

Re-Think. Re-Engage

When a new employee joins an organization, they spend the majority of their time going through the on-boarding process, mostly with learning and development people like me. So ultimately, L&D is in a unique position to make a direct and measurable impact on employee retention and performance by rethinking the on-boarding process.

Learning professionals need to think beyond the traditional new-hire training programs they typically design and facilitate. These begin during the pre-employment phase of a prospect’s contacts with the employer and can extend to a period that lasts up to a year or more. Researchers have identified four major levers - related to both job roles and social environment:

Leader: Follower Relationship - Most employees leave supervisors, not companies. This means the employee -manager relationship is quite possibly the most important relationship a new hire needs to establish. So the more we can build opportunities for managers to interact with new employees early and throughout the on-boarding process, the better.

Build Employee Self-Confidence: To the degree that a new employee feels confident in doing the job well, he or she will be more motivated and eventually more successful than less confident counterparts. L&D should target specific onboarding programs to help boost

employees’ confidence.

Social integration: Meeting and starting to work within the organizational structure is an important aspect of learning about any organization. In addition, new employees need to feel socially comfortable and accepted by their peers and superiors.

Knowledge of organizational culture: Every company

has a unique culture, so helping new hires navigate that culture - and their place within it is essential. Understanding an organization’s politics, goals and values, and learning the firm’s unique language are all important indicators of employee satisfaction

Successful onboarding is a key part of any talent management strategy. For managers, that means you need to build that culture within your team, and focus on maintaining it particularly

in times of challenge or adversity. For employees, that means you need to look for managers with whom you can have that relationship, not just interesting roles or new parts of the business.

Pavan Sriram is the Founder and CEO of ITTIGE Learning, a performance-based training company that works with c-level executives to improve learning outcomes.

With 12 years of rich experience in management positions at Crestcom International, Dale Carnegie Training, SunGard and MeritTrac-Manipal Education Group and having worked with over 200 clients across industries, Pavan successfully has targeted organizational talent deficiencies associated with performance management, leadership development, ineffective communication, talent management and measurement.

For further details contact Pavan Sriram at [email protected]

Source: Aberdeen Group Report Onboarding 2013


GREEN IN

A more efficient use of energy is becoming an important factor for companies. The GILDEMEISTER energy efficiency GmbH has made it their goal to support companies on their way to energy efficiency. For this purpose they have invented the GILDEMEISTER energy monitor which is especially designed for industrial clients.

From 2016 onwards companies are obliged to set up an energy management system if they want to benefit from top tax adjustments. To complete their product range GILDEMEISTER energy efficiency is introducing the new GILDEMEISTER energy monitor as an efficient and transparent monitoring

system. The GILDEMEISTER energy monitor provides an overview of energy cost and consumption developments, energy reports and payments as well as a detailed load response overview.

Adequate analysis and the user

friendly operation thereby allow an ideal provision and tracing of relevant information for various decision-making levels. In this way, targets can be displayed, monitored and if required adapted continuously. Data collection and transmission is carried out via installed measuring instruments and collected in the GILDEMEISTER energy box. Distribution costs, energy indicators and management reports are provided via computer or iPad and can be generated as pdf-files quickly and easily.

Every customer receives an individually customised service package which is especially suitable for companies that want to analyse their energy consumption and sustainably reduce their energy costs. Due to a variety of requirements and needs, the GILDEMEISTER energy efficiency GmbH offers three different versions of the GILDEMEISTER energy monitor: a Basic, a Professional and an Enterprise Edition. Studies have shown, that only through the installation of one energy

management system up to 15% of potential cost savings can be achieved.

GILDEMEISTER energy solutions

GILDEMEISTER energy solutions comprises the five business units Energy Efficiency, SunCarrier, Cellstrom, Service and Components and offers turnkey solutions for the generation, storage and utilisation of renewable energy for industrial organisations. Together, the innovative solar and wind power systems (SunCarrier / WindCarrier) and the vanadium-redox-flow energy storage system CellCube provide a holistic energy concept for the future. For example, the products can be used for high-speed charging in electric charging stations for efficient e- mobility. The energy solutions business segment is part of DMG MORI´s “industrial services”. Customers benefit from more than 140 years of process- and production-know-how in machine tool production and a high degree of reliability and security of investment.

The new energy management system displays energy costs and potential cost savings

GILDEMEISTER energy solutions presents the new energy monitor


Various software packages of the GILDEMEISTER energy monitor

Overview of the GILDEMEISTER energy monitor

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CASE STUDY

Driving more Ore up the Yangtze

China´s Wuhan Iron and Steel Group (WISCO), one of the largest companies in the nation´s steel sector, has built a new transshipment port to better handle growing quantities of imported ore arriving in the East China Sea. The port consists of several berths and yards where 15 million tons of ore per year can be unloaded from huge ocean-going vessels. Various bulks of handling machinery installed throughout the port by three different OEMs has one thing in common: in all of these super-size loaders, unloaders, and stacker-reclaimers, a total of over 170 geared motors supplied by German manufacturer Nord Drive Systems ensure everything stays reliably in motion.

Now often billed as an island paradise, the Zhoushan Archipelago comprises more than 1,300 scenic isles and islets off the Chinese eastern seaboard. The Zhoushan ports are the region´s chief entrepôts for all sorts of goods. They include industrial commodities such as iron ore, mostly destined for Wuhan Iron and Steel Group (WISCO), China´s oldest steel giant headquartered about 400 miles inland up the Yangtze though WISCO operates a number of mines in China. Hence, the company must source most of its iron from abroad. Water transport on the Yangtze is the obvious, highly efficient, and economic choice, but ore imports for the industrial group usually arrive in the East China Sea in very large ocean-going vessels. Inevitably, these must call at a coastal port, where cargo can be offloaded and

transferred onto smaller ships - even on the lower reaches of the Yangtze, large freighters would be stopped cold at the river bridge in Nanjing. 10,000 dwt ships, on the other hand, can pass under it and make their way onwards to Wuhan.

New port with super-size machinery

Demand for WISCO´s products has grown steeply over the course of the last decade in particular. As raw materials are needed in Wuhan in ever growing quantities, establishing additional unloading and loading bases along the coast - preferably under WISCO´s own direction - had become a pressing issue some time ago. Partnering up with two co-financiers, WISCO eventually came to hold a stake in a new port construction project in the island town

of Wugang, in the south of the Zhoushan Archipelago. All facilities at Wugang Port were built in 2010 and 2011. The German manufacturer of full-scale drive solutions, Nord Drive Systems, supplied more than 170 heavy duty geared motors. As inspections, test runs and approvals for full-scale operation have concluded in mid-2012, Wugang now serves as WISCO´s main transshipment terminal with a cargo throughput of up to 30 million tons of ore per year. The port includes an unloading berth boasting a water depth of 27 m, where huge ships carrying up to 300,000 dwt can arrive. Three loading berths are 15 m deep and can accommodate smaller ships - one will fit a 50,000 dwt class vessel, two are cut out for 10,000 dwt ships. Designed to handle up to 5,000 tons of ore per hour, the

ship loaders, ship unloaders, and bucket-wheel stackers installed along the berths and yards in Wugang Port are all the biggest equipment of their kind for civil use in China.

WISCO´s key requirement for all heavy machinery was extremely high reliability and low maintenance characteristics. It takes at least one hour for a maintenance crew coming from the coast or Zhoushan Zhujiajian Airport to get to Wugang by ship, plus possible delays in bad weather, which might also rule out helicopters as an alternative. In any case, serious problems with machinery would very likely incur staggering costs for repairs and, of course, disturbances of unloading and loading processes due to dysfunctional equipment. Therefore, highly reliable

Reliable geared motors for bulk handling machinery in transshipment port

Jyoti Mishra

[email protected]


Illustration 1: Capable of handling up to 5,000 tons of iron ore per hour, the ship loaders and unloaders at Wugang Port are the largest machines of this

kind for civil use in China

Illustration 2: Large stacker-reclaimers service the iron ore stockyards at the port eliable drive solutions are essential

www.martonline.in 31April 2014 www.martonline.in 31March 2014

crew coming from the coast or Zhoushan Zhujiajian Airport to get to Wugang by ship. Serious problems with machinery would very likely incur staggering costs for repairs and, of course, disturbances of unloading and loading processes due to dysfunctional equipment. Therefore, highly reliable drive solutions are required to ensure that large gantry cranes, conveyors and the like keep moving. Nord Drive Systems was commissioned to supply heavy duty geared motors. Though Nord now has a considerable presence in China that includes several production and assembly plants and a number of regional offices, the German company only set foot in the country a couple of years ago. Still, the superior quality and durability of the drive products as well as the pre- and after-sales services proffered by the drive specialist prompted WISCO to have the bulk handling machinery at Wugang Port equipped with geared motors supplied by the Chinese branches of the German company. Over 170 units were integrated into cranes and conveyor systems sourced from several different Chinese OEMs. All partners cooperated very well, and Nord´s team was readily available for OEM support throughout the project. From the day Wugang port was

drive solutions are required to ensure that large gantry cranes, conveyors and the like keep moving. Nord Drive Systems was commissioned to supply heavy duty geared motors. Though Nord now has a considerable presence in China that includes several production and assembly plants and a number of regional offices, the German company only set foot in the country a couple of years ago. Still, the superior quality and durability of the drive products as well as the pre- and after-sales services proffered by the drive specialist prompted WISCO to have the bulk handling machinery at Wugang Port equipped with geared motors supplied by the Chinese branches of the German company. Over 170 units were integrated into cranes and conveyor systems sourced from several different Chinese OEMs. All partners cooperated very well, and Nord´s team was readily available for OEM support throughout the project. From the day Wugang port was opened, all machines have been used to capacity almost all the time, with the drives reliably doing their duty.

WISCO´s key requirement for all heavy machinery was extremely high reliability and low maintenance characteristics. It takes at least one hour for a maintenance

opened, all machines have been used to capacity almost all the time, with the drives reliably doing their duty.

Geared motors for demanding conditions.

Three very large clamshell unloaders (2,500 t/h) serve the 300,000 dwt berths. These machines incorporate a total of 72 three-stage bevel gear units from Nord. Two massive mobile ship loaders (5,000 t/h) are equipped with 16 three-stage bevel geared motors and a two-stage helical bevel gear unit each. These drives are capable of moving these large systems along the berth on tracks to position them as needed to access various areas of operation. Another 72 three-stage bevel gear units are installed in three bucket-wheel stacker-reclaimers (500 t/h) for the ore stockyards at the port. All geared motors at Wugang feature a heavy duty housing that makes them suitable for outdoor use and severe weather. Well sealed against moisture ingress and fitted with corrosion- and moisture-resistant components, they provide a high degree of protection against the typical challenges of maritime environments. Special paint coats are applied against the salty atmosphere. These units are also tough enough to resist considerable mechanical shock. Most units come equipped with application-specific optional parts, including e.g. dust- and corrosion-protected brakes, micro-switches for continuous brake monitoring, or double canopies serving as drip covers at the motor fans. Such features make these geared motors even more reliable.

Designed to move large loads without fail

All gear units are manufactured from a single housing block - an original Nord development. This design ensures optimal

resistance to axial and radial forces as well as high efficiency, high output torques, low-noise operation and minimal maintenance efforts during a long service life. Solutions for cranes and trolleys feature a wide choice of gear ratios. The manufacturer supplies two or three-stage designs with a hollow or solid shaft as required. Users can choose between models with a foot mount, flange models, and shaft-mounted models. All types are equipped with the same space-saving housing, which allows for easy integration. Though motors used in cranes and trolleys often operate around the clock, some loading facilities may also stand still for certain periods of time. The build standard of the drives ensures that normal operation can be resumed directly after even prolonged phases of this kind, without any special maintenance requirements. Moreover, all models are also available as explosion-protected (ATEX) versions if required.

For further details write to Nord Drivesystems Pvt Ltd, 282/2, 283/2, Village Mann, Tal. Mulshi, Adj. Hinjewadi MIDC II, Pune - 411057 Tel: 09765490890 Visit: www.nord.com


Illustration 3: WISCO had heavy-duty, but low-maintenance NORD geared

motors installed as traveling drives for port machinery

Illustration 4: NORD drives move the loaders on tracks along the berth


SCHUNK grippers are setting benchmarks in assembly and handling for over 30 years

In 1983, SCHUNK the competence leader for clamping technology and gripping systems introduced the world’s first standardized industrial gripper on the market. The “industrial hand, “has been the former designation, and has been the starting point for a fast development of gripping systems which still continues today.

At the beginning of the 1980s, Heinz-Dieter Schunk, the Managing Partner of SCHUNK GmbH & Co KG in Lauffen had a brilliant idea. Inspired by the just starting boom in the in-dustrial robotics he noticed how bulky the individually developed gripping tools on the robots were. Due to the connected pneumatic lines, the modules sometimes had extreme interfering contours. For him it was clear: in order to make robots and other handling systems more successful, grippers are required, which are more compact, lighter, precise, and if possible more cost-efficient than any other solution which was available to date.

In 1983, SCHUNK introduced the world’s first standardized industrial gripper on the market. It was comparably light and disposed of integrated air channels. Graduated sizes enabled the designers to achieve particularly efficient solutions. The “industrial hand“ from SCHUNK has been the starting point for a thirty-year-story of success. SCHUNK grippers are known for precision, longevity and robustness. They are synonymous for process stability and effi-ciency in assembly and handling.

From a simple gripper to an intelligent high-tech module

SCHUNK continually sets new standards for grippers with their pioneering spirit. The pa-tented multi-tooth guidance

which SCHUNK introduced in 2000 is still considered today as a benchmark in gripping technology. Since it is used in modules such as the world’s well-known PGN-plus universal gripper, it is particularly compact, and is also fast and precise. A short time later in 2006, SCHUNK again performed pioneering work, and introduced a pro-gram for mobile gripping systems.

In addition to mechatronic rotary units, and efficient lightweight arms, it comprises the in-dustry-proven SCHUNK SDH dextrous hand, a sensitive three-finger hand, and is suitable for various gripping scenarios, and perfect for applications in the field of service robotics. The latest development of this business unit is a 5-finger hand. It is amazing how it resembles in size, shape, and mobility to its human model.

But SCHUNK also paved the way for new types of grippers in the field of industrial robotics. In 2008, the market leader for gripping systems combined three features lightweight design, mechatronics and modularity to its LEG electric long-stroke gripper. In 2011, the company presented a vast program of electrically actuated modules in the framework of their “Mechatronik3“ initiative on the market: the electric EGP small parts gripper with the world’s most compact performance, the adaptable EGA long-stroke gripper, and

the intel-ligent and sensitive WSG parallel gripper.

The latest gripper generation indicates the direction of this trend. Modern high-tech components allow a unique measure of flexibility at handling processes. With one single module, manifold gripping scenarios can be implemented. The powerful and sensitive modules can handle various components one after the other, and without any set-up time. At every grip the finger position and gripping force are individually adjusted to the workpiece.

The required sensor system, the control and regulation technology, as well as a web browser for communication with the higher-ranking system components are already

SUCCESS STORY

IIndustrial hand 1983: SCHUNK presents the “industrial hand“ on the market. The

world’s first standardized industrial gripper.

PGN-plus 2000: The PGN-plus universal gripper was the first gripper with

multi-tooth guidance.

SDH The SDH combines the advantages of industrial grippers with those of a

human hand.



enormous development step in gripping technology of the past 30 years is obvious. Simple, mechanic components developed to intelligent, powerful, and highly efficient high-tech modules, which allow the users to implement flexible and closely integrated handling processes.

Today, SCHUNK offers more than 10.000 components to the world’s largest standard pro-gram for gripping modules and a module program for gripping systems which is unique in its own way. It comprises grippers and rotary modules, linear axes, speedy Pick & Place units, mobile gripping systems, and compact robot accessories. Over the years, many in-tersections of the SCHUNK clamping technology program were formed, and the user bene-fits from considerable synergies from both business units when using the SCHUNK modules.

For further details do visit www.in.schunk.com

integrated in the gripper. Via intuitively operable programming interfaces, the modules can be easily integrated, controlled and maintained, and no additional software has to be installed via internet.

The world’s largest standard program for gripping systems

When we compare the modern SCHUNK grippers with the industrial hand of 1983, the

• 1983 SCHUNK Industrial hand – the first

standardized industrial gripper

• 2000 PGN-plus – the first gripper with

patented multi-tooth guidance

• 2006 SDH – industry-proven 3-finger

hand for service robotics

• 2008 LEG – a symbiosis of lightweight

design, modularity, and mechatronics

• 2010 MPG-plus – the miniature parallel

gripper with the most compact performance

• 2011 EGP – the electrically actuated small parts gripper with the most

compact performance

• 2012 5-finger hand – almost as talented as its human model

• 2013 CGH – the first standardized lightweight gripper with CFC housing

Milestones of the 30-years-history of SCHUNK grippers:

5-finger hand with LWA 4P The 5-finger hand from SCHUNK (shown here at a

Powerball Lightweight Arm LWA 4P) is almost as talented as its human model.

April 2014

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Innovating MIM with enhanced Tool roomThe current industry trend in the automotive world is to bring about ease in manufacturing and sustain the same over large volumes. This has been felt more into the developing countries, where the production volumes are going up. MIM (Metal Injection Molding) is one of the emerging manufacturing technology that is helping a majority of the OE automotive companies in this regard for manufacturing complex shaped components in steel and stainless steel.

Indo-MIM which is a global leader in MIM technology, has always boasted of open innovation and is an one-stop solution for all technological issues. They are a company equipped with in-house tooling capabilities required for producing the MIM components that could be molded as per the customer need. One of the primary benefits of MIM is the elimination of expensive secondary operations by virtue of achievement of

tight dimensional tolerances through its inherent consistency. Getting this benefit with lead times that allows meeting the aggressive product launch timelines can be a challenge, when sourcing MIM components from a conventional PIM company. However, with Indo-MIM, this is always a dream come true – a mission accomplished. At Indo-MIM, they call it “Mission MIMPossible” .

It is indeed rare to find a

TECHNOLOGY

MIM-house with tooling lead times lesser than 12 weeks. When Indo-MIM was established 16 years ago, it was quick to realize that speed to market is very important to reach the global customers. It didn’t take long to realize that an in-house tool room would be a critical component of meeting the customer’s demanding lead-time requirements. Today, Indo-MIM sports a world-class tool room, capable of delivering 45-50 MIM tools per month!!! In some cases Indo-MIM is able to manufacture tooling and submit samples with leads-times as low as 14 days.

The knowledge and practices on how to do this stay in-house because the capabilities are in-house and the expertise stays in-house. Indo-MIM does not have to wait for the customer to figure out how to reduce the operations as they have teams of product and manufacturing engineers giving out the best MIM design possible at a minimal of cost, through a structures product development process.

Indo-MIM has a full range of state-of-the-art tool making and support equipment which is capable of making MIM tooling for components with weight varying from less than 1gm to over 200gms. Based on the complexity of the tool, the company can run from 1 to 32 cavities thereby helping to ensure that the molding costs per shot are minimized.

Good equipment selection is only half the job of developing a world-class tool-room. Indo-MIM’s real strength is in the hard work and expertise of the tool makers and operators. Constant and systematic training is a part of the ethos of the tool room.

Not only for the tooling capabilities, but Indo-MIM also boasts of the 6-axis robot installed at its molding shop, which is not only responsible for consistency in the molding process, but also doubles the output by going for more number of cavities. The quality of the product remains good and due to the consistency, the part handling damages also get reduced.

Overall, Indo-MIM has helped global product designers realize their dreams in true sense by helping them modify both design and materials, to suit the end customer and application requirement. They have a very closely working and well co-ordinated team effort between the teams at their Marketing, Engineering and Tool Room departments, that ensures the customer to get what he wants and when he wants. The final aim is always “Customer Delight” and it is well accomplished.

Tool Room 1

Tool Room 2

Indo-MIM Robot


“In-house tooling is one of our key strategic

advantage in terms of pushing the boundaries

of what can and cannot be done in MIM.We,

at Indo-MIM, will continue to develop new

materials and increase our forward integration

of secondary machining and surface treatment,

allowing us to deliver shorter lead times

and superior quality products to our global

customers”

Krishna Chivukula Jr CEO, Indo MIM


METROLOGY

New miniature incremental optical encoder is the essential building block of motion systems

Renishaw, the global metrology specialist, launches ATOM™ an innovative non-contact optical linear and rotary incremental encoder system that uniquely combines miniaturisation with leading-edge dirt immunity, signal stability and reliability. The new encoder achieves unmatched performance as a consequence of a design which avoids the many compromises traditionally associated with miniaturised encoders.

ATOM, which is available in sizes as small as 6.8 mm x 12.7 mm x 20.5 mm, is the world’s first miniature encoder to use filtering optics with Auto Gain Control (AGC) and Auto Offset Control (AOC). This advanced technology is found in Renishaw’s proven TONiC™ incremental encoder range and provides excellent signal stability and exceptional dirt immunity.

The ATOM readhead is available in a range of formats and delivers unrivalled metrology performance, offering class-leading accuracy with low Sub-Divisional Error (SDE), low jitter, high signal stability and long-term reliability. ATOM offers speeds to 20 m/s (29,000 RPM on a 17 mm disc) and resolutions to 1 nm (0.004 arc second on a 108 mm disc) with a range of linear and rotary (angle) scales available in stainless steel and glass. The readhead also includes a set-up LED to allow quick and easy installation and an auto-calibration routine to enable faster optimisation.

The ultra-compact ATOM incremental encoder is supplied in hi-flex cable and Flexible-Printed Circuit (FPC) variants with both 20 µm and 40 µm scale options.

The side-exit FPC version reduces the overall package size and allows integration with PCBs. Customers can also choose from a range of high-accuracy linear glass spars to 130 mm in length, stainless steel tape to 10 m and rotary glass disc scales from 17 mm to 108 mm in diameter.

Optional Ti and DSi interfaces support interpolation factors to 20,000 allowing outstanding metrology and unmatched dynamic performance. Designers can also use the sinusoidal signal output from the readhead for

direct connection to analogue drives and controllers. Advanced highly-automated manufacturing processes minimise process variability to assure the highest quality, short lead times and competitive costing.

Applications for ATOM’s ultra-compact readhead include laser scanning, coordinate measurement systems, semiconductor and flat-panel display production, motor drive systems, microscopy and the scientific research sector. The FPC 40 µm format measures just 6.8 mm x 12.7 mm x 20.5 mm and is ideally suited to a variety of space-critical motion control, inspection and metrology applications. ATOM has CE approval and is manufactured in-house by Renishaw under strict quality controls that are certified to ISO 9001:2008, and like all Renishaw encoders is backed by a truly responsive global sales and support network.

For More Information Visit : www.renishaw.com

ATOM cable and FPC readheads

ATOM readheads on various RCDM rotary discs



MACHINE TOOLS

Diamonds Advance Composites Drilling

Hypertherm designs and manufactures the world’s most advanced plasma cutting systems for use in a variety of industries such as shipbuilding, manufacturing, and automotive repair. Over the years, the company has been actively serving the Indian market, providing excellent local support capabilities to local partners and customers.

Custom modular-tip drill with brazed PCD insert.

Carbon fiber reinforced polymers (CFRP), alone or stacked with titanium and aluminum plates, are widely used in aerospace industries worldwide for their high strength-weight ratio and stable material properties in demanding environments. Boeing’s Dreamliner 787, for example, has 80% composites by volume, equivalent to 50% of its weight, eliminating 1,500 aluminum sheets and up to 50,000 fasteners. This achieves 20% better fuel efficiency compared to the Boeing 767. Currently, connection technologies like gluing or welding are still under question so that fixturing with rivets is still a dominating practice. Due to the substantially different mechanical properties of carbon fibers and metals, drilling fastener holes efficiently challenges cutting tools by requiring high wear resistance as well as optimum tool geometries.

Poly-crystalline diamond (PCD) shows great potential for improving machining efficiency compared with traditional tungsten-carbide cutting tools in machining advanced aerospace materials. Brazed PCD drills are being developed and offered by some leading metal cutting tool manufacturers. Such tools combine the PCD as the cutting edges onto a solid carbide drill body. The carbide drill body provides the rigidity and the dimensional accuracy to maintain hole qualities,

Optimum Tool Design Critical

while enabling spiral internal coolant holes and helical flutes to improve cooling and chip evacuation necessary for drilling. The functional cutting edges are PCD, which provides the wear resistance to enhance machining efficiency.

Optimum tool design is critical to generate good hole quality in machining advanced aerospace composites. Many essential factors in the course of tool dimensional design play important roles in affecting hole qualities, such as sharper edge radius and larger rake angle to generate lower cutting forces. Other factors include a smaller point angle to reduce thrust force and fiber delamination, and optimized edge design to improve burr height control. Machine tools, spindle and setup rigidity, tool adaptor, internal or flood coolant, workpiece materials that the drill enters and exits, are also important factors to be considered at tool design. In many cases, customized tools are required to meet various customers’ needs in a timely manner.

Tool development

To develop a premium PCD-enhanced drill requires in-depth understanding of a suitable synthesis approach. Such process development not only determines tool performance, but also influences the tool’s manufacturing efficiency and costs.

There are four main technologies for producing synthetic diamond-based drills for composite materials:

-CVD (chemical vapor deposition) diamond coated drill.

A finished solid carbide drill is coated with CVD diamond. It is a cost-effective solution, however edge sharpness is limited by coating thickness. Also, due to the large hardness difference between the carbide substrate and diamond coating, this solution has low capacity to absorb impact energy. Chipping resistance is also limited.

-Capped PCD drill.

A cone-shaped PCD is sintered onto a small carbide substrate to certain point geometries. The semi-finished component is then brazed onto a solid carbide drill body. This PCD solution is limited in PCD grade optimization due to the necessity of managing high

carbide/PCD interface stresses. Post-sintering processing can also be costly from extra efforts necessary to remove diamonds from non-functional areas and adding internal coolant holes.

-Vein PCD drill.

A solid carbide rod with pre-machined slot is filled with PCD precursor powders and then undergoes extremely high pressure and temperature to synthesize the PCD structure. After the HPHT process, the rod will be cut, brazed onto a drill body and finally ground to designed tool geometries. This vein PCD technology can generate a complex geometry with high positive rake angles and shape, and requires less grinding than the capped PCD. It is limited in size due to applying high pressure and temperature onto complex 3D geometry. In addition, normally high cobalt content is needed, thus reducing PCD’s hardness and wear resistance.



-Brazed PCD drill.

2D is the most established technology for PCD drills (e.g. spade type PCD drills). For smaller sizes, a special carbide sandwiched PCD is used, whereas for the larger sizes individual PCD tips can be used. This solution has serious geometrical limitations as it is difficult to add positive rake angles needed for composite machining. The 3D brazing needs a bulk of PCD block of the desired grade and microstructure to be cut in a helical shape as designed. A corresponding helical-shaped slot is ground in a solid carbide drill to host the PCD blade. Compared with the capped PCD solution, this 3D brazing only applies PCD on functional areas, substantially enhancing machinability. This 3D brazing technology is selected to develop the test PCD drills in this research.

Another important factor for the choice of a suitable PCD grade is machinability of the diamond material. Machinability has been rated by measuring manufacturing times for identical tools made from different PCD raw materials. The focus has been set to all manufacturing steps involving PCD disc erosion and PCD grinding. The results of this machinability test are being displayed in the rating in Table1. The better the machinability, the higher the rating, as faster manufacturing times relate to less expensive manufacturing cost; equally important as tool performance in developing a competitive tooling solution.

PCD brazing

As the tool being introduced in this paper requires a braze joint of a helically cut slice of PCD raw material into a tungsten carbide body, the selected brazing technology needs to prevent graphitization of the metastable poly-crystalline diamond, but also bond the PCD to tungsten carbide. This requires an active brazing

technology. An active braze material usually includes higher melting compounds like titanium. Brazing temperatures are therefore higher, which negatively affects stability of the diamond phase. In order to prevent graphitization, an oxidizing atmosphere needs to be shut out during brazing. State-of-the-art technologies include induction brazing using argon atmosphere and vacuum brazing.

Optimum tool geometry

Choosing the optimum tool geometry for drilling composite/titanium stacks is difficult, as the two cutting materials require different drill features. Drilling CFRP normally employs high helix angles and long cutting edges, as carbon fibers should be sheared along the cutting edge. Long cutting edges are being realized by low point angles. Additionally, drills for CFRP should induce low axial forces in order to avoid exit delamination. All this translates to rather sharp cutting geometries with small wedge angles. Clearance angles go as high as 20 degrees with helix angles around 30 degrees. Cutting titanium can in principal also utilize a sharp cutting edge, however compared to CFRP drilling, a more stable wedge angle is needed. Typical clearance angles for titanium applications are in the range of 8 to 14 degrees. Compared to steel machining, these clearance angles are typically higher (in the presented case around 12 degrees) as heat development on the clearance face should be minimized in order to decrease flank wear. As high clearance angles in combination with typical helix angles of around 30 degrees would weaken the cutting edge too much, the helix angle has been lowered to the range of 15 to 20 degrees in order to counterbalance using high clearance angles. The presented manufacturing technology allows for variable helix angles depending on the tool geometry needed.

This is one of the presented technology’s principal advantages, as typical corner-tipped PCD tools only allow for helix angles up to 8 degrees.

In order to achieve tight hole diameter tolerances, it is absolutely necessary that the drill point have an excellent self-centering capability. From another perspective, point angle also plays a significant role on burr formation. It is known that either below 90 or above 150 degrees, point angles help minimize hole exit burr height. A drill with a point angle of 155 degrees would therefore be suitable for titanium exit needs, but does not have good centering capability. Therefore, a double point angle design is proposed with an inner point angle 130 degrees and an outer point angle with 155 degrees. Overall point height of such a drill is rather short compared to usually used drills with long

cutting edges. This brings the 3rd and 4th margin in contact with the material very quickly, helping to keep hole tolerances tight.

Another advantage of the proposed drill design is internal coolant capability. For drilling pure CFRP plates, internal coolant holes help quickly transport CFRP dust out of drill flutes via compressed air. For cutting CFRP/titanium stacks, minimum quantity lubrication (MQL) can be applied using those sealed internal coolant channels to provide lubricating, and to reduce the tremendous heat generated in titanium machining due to its low thermal conductivity. This makes MQL absolutely necessary when drilling with PCD tools, as otherwise extensive heat at the cutting edge leads to graphitization or TiC formation respectively. This reaction leads to chemical wear in the flute region and finally PCD chipping in flutes.



Experimental study

The developed PCD tools are tested experimentally with the purpose evaluating the most suitable PCD grade and tool geometries for the targeted applications. The test setup and cutting parameters are as follows.

- Test tools: Brazed PCD drills, diameter of 11.113mm (7/16”), with three different PCD grades (G4, KD1415, and KD1425) and an uncoated solid carbide drill with the same geometry.

- Test coupon: Test coupon consists of an 8.7mm (0.342”) thick commercially purchased CFRP (Isocarbon 3K) plate securely stacked with a 10.8mm (0.425”) thick Ti-6Al-4V plate. Test tools drill through holes, entering the CFRP side and exiting from the titanium side.

- Machine tool and coolant: A CNC machining center (Heckert CWK 400) with a horizontal spindle and through-spindle MQL coolant (Vascomill MMS FA2) is applied.

- Cutting parameters: Cutting parameters of 20 m/min (65 SFM) cutting speed and 0.05 mm/rev (0.002”ipr) feed rate for both CFRP and titanium. No pecking cycles were used.

-Tool inspection: To monitor tool wear progression, test drills were inspected under microscope after drilling of every 4 holes. Wear mechanism inspection was conducted under SEM after drilling of 24 holes.

-Hole measurement: After all machining tests, test coupons were cleaned and marked. All drilled holes were inspected. Hole diameter was measured at four depths of each hole (two in the CFRP layer near the entry and exit surfaces, and two in the Ti layer in the same manner). Hole exit burr height on the Ti bottom surface was also measured.

Results and analysis

A long, predictable, and

consistent tool life is the key factor deciding a tool’s success. In drilling of CFRP/Ti composite matrix, several requirements must be met simultaneously to accept a good hole. Hole size must be within a tight tolerance to fit a fastener, and exit burr must be controlled within certain height to ease or eliminate deburring. To avoid potential hole damage by tool’s catastrophic failure and try to keep the tool reconditionable, corner chipping must be minimized and monitored. The following criteria are chosen to decide where the test tool reaches end of life:

a)Hole size tolerance of 11.113 + 70µm (H10);

b)Burr size of 0.2 mm;

c)Corner chipping occurrence.

Test results show corner chipping was the primary failure mode for the PCD drills at the end of life; and the carbide drill failed by exceeding burr height specification. Hole quality requirements could be met for all drilled holes in this test.

Hole size

Figure 1 shows the hole diameters exemplary for one tested PCD tool. For each inspected hole, hole diameter was measured at four different positions; two in the CFRP section and two in the titanium section, close to the hole entry surface and the bottom exit surface respectively.

It can be seen that the hole diameter in the titanium layer is very well within the middle of the specified tolerance fluctuating in a small range of 10μm. Hole size at the entry of the Ti layer is pretty close to the size at the hole exit. In the CFRP layer, however, there is a relatively large difference in hole size between entry and exit. This difference is the result of chips scratching the hole wall during evacuation. Improved chip control is essential to reduce chip scratching and

enhance hole size consistency. It is difficult to solve the chip control issue by tool design alone. It is proven in practice that adding pecking cycles or vibration-assisted drilling will help to control chip length and decrease the scratching effect.

The results indicate that the proposed new drill point design is capable of creating holes in H10 tolerance. Using optimized machining conditions even H8 hole tolerance levels are achievable with good process reliability. A dependency of hole quality on cutting edge material could not be seen. PCD and carbide tools with the same drill point geometry create similar hole quality results.

Burr height

A clear dependency on drill cutting edge material can be shown when discussing drilling results in regards to burr height control and wear mechanisms. Figure 2 shows the burr height progression versus hole count exemplary for a carbide and two PCD (grade KD1415 and G4).

It can be seen that a carbide drill creates excessive titanium exit burrs after only 14 holes, whereas the first hole out of specification for the two PCD drills are at 57 and 117 holes, respectively.

In theory, burr height progression should be a function of corner wear of the cutting tool. This can be shown between carbide and PCD due to the big difference in material hardness and therefore the slower progressing corner wear on PCD tools. The PCD drill has much less corner wear than the carbide drill. The difference in the wear progression among the three PCD grades seems to be minor. The dominating wear pattern of PCD grades is the cutting edge/corner chipping.

Table 1 gives an overview of the tool life results of the three

tested PCD grades. As can be seen G4 and KD1415 are very similar in regards to average tool life. KD1415 shows more consistent tool life as well as the best machinability to reduce manufacturing cost, therefore chosen as the most suitable grade for this application.

Conclusions

Brazed PCD solid carbide drills with three different PCD grades and optimum tool geometries were developed and tested. The conclusions of this work are as follows:

1) 3D brazing technology allows manufacturing of PCD tools with flexible helix and therefore large rake angles. Compared with capped PCD solution, 3D brazing enhances machinability by removing less PCD from functional faces;

2) With the optimum tool geometry (double point angle, helical flutes, internal spiral coolant channels, large rake angles), the developed PCD drills were able to generate good hole qualities (hole size diameter and burr height control).

3) Compared with uncoated solid carbide drills, PCD drills show significant improvement in tool life.

4)All tested PCD drills have the same wear pattern which starts off from micro fractures in the rake face, and finally ends with catastrophic corner chipping.

5) KD1415 outperformed G4 and KD1425 in consistent tool life and better machinability. Therefore, KD1415 was the most suitable grade for this application.

For more information write to [email protected]



Haas Machine Number 150,000!

At a special handing-over ceremony to

mark the occasion, Haas Automation

Europe’s managing director Alain

Reynvoet attended the Manufacturing

and Automation Expo 2014, Stockholm,

to meet the owners of Swedish company

Claesson Engineering - a general, precision

engineering business founded by three

brothers, and to present them with a

commemorative plate to mark the occasion

of their purchase of this very special

machine tool.

“Installation of the 150,000th machine is

a signal event for Haas Automation,” said

Mr. Reynvoet. “The fact that it has been

bought by a European company – in the

relatively high-cost region of Scandinavia,

is further proof that our new generation of

products, combining value, performance,

reliability and support are the right ones

for any market, however tough the trading

conditions.”

Growing aggressively, and currently

posting annual revenues of around

$1billion, Haas Automation continues to

introduce new machine tool products

on a very regular basis, expanding its

already impressive range by applying the

same tried-and-tested engineering logic

to continually improve productivity and

reduce running costs.

As recently as June 2007 Haas celebrated

Haas Automation is celebrating building and supplying its 150,000th CNC machine

tool: a DS-30SSY dual spindle turning centre with Y-axis.

building and

installing its

75,000th CNC

machine tool,

purchased

by a family-

owned

machining

business

in Baden-

Wurttemberg,

Germany.

Not bad

considering

the California-

based

company only started to build CNC

machine tools just 20-years earlier.

Incredibly, the company has since

build and supplied an additional 75,000

machines in around one third as long as it

took to build the first 75,000. More than

50% of that production has been exported

to customers in overseas markets.

“The Haas DS-30SSY CNC turning centre

is one of our latest-generation machine

tools,” adds Mr. Reynvoet. “It was

designed to provide affordable high-

productivity to companies around the

world wishing to machine complex parts in

as few set-ups as possible.”

The DS-30SSY combines dual-spindle

turning with Y-axis, C axis, and live tooling

to create

powerful

‘done-in-one’

machining

solutions.

The opposed

spindles

support fully

synchronized

turning and

allow on-the-fly

part pass-off

to reduce

cycle times.

The machines

provide 102 mm of Y-axis travel (±51 mm

from the centerline) for off-centre milling,

drilling, and tapping, and come standard

with high-torque live tooling and a servo-

driven C axis for versatile 4-axis capability.

As its name suggests, the machine installed

at Claesson Engineering also benefits from

Super Speed configuration.

Haas CNC machine tools are sold

worldwide through the company’s 170+

Haas Factory Outlets (HFO’s) – dedicated,

independently owned Haas resellers who

have reached the high-levels of service and

support demanded by Haas Automation.

The 150,000th Haas CNC machine tool is

supplied and supported by the Swedish

HFO, Edströms Maskin AB, Jonkoping, one

of the longest-serving and most successful

HFOs in the world.

“It’s a great honour for us to be part

of these celebrations,” says Edströms

company owner and CEO, Ola Andersson.

“Claesson Engineering is a valued customer

and has already invested in several Haas

machine tools over the years, since it was

founded in 2000. The celebration was a

wonderful opportunity to recognise the

achievements of all those involved. But, the

truly important thing is that the Haas DS

turning centre will give the customer many

years of profitable, reliable service.”

MART UPDATE

www.martonline.in 41April 2014 www.martonline.in 41April 2014

www.martonline.in42 April 2014www.martonline.in42 January 2014www.martonline.in42 April 2014

High-resolution light grid BLAIdentify parts and determine positions

Third Consecutive Year Kennametal Named “The World’s Most Ethical Company”

Kennametal Inc announced that for the third year in a row, it has been named one of the World’s Most Ethical Companies by The Ethisphere Institute, a leading independent organization dedicated to advancing and recognizing best practices in business ethics.

Through in-depth research and a multi-step analysis, Ethisphere honored 145 companies from three dozen industries worldwide. Kennametal is one of just seven industrial manufacturing companies chosen for this year’s honor.

“The entire community of World’s Most Ethical Companies believe that customers, employees, investors and regulators place

a high premium on trust and that ethics and good governance are key in earning it,” said Ethisphere’s Chief Executive Officer, Timothy Erblich.

Kennametal’s ef-forts in past years have included a number of new records for the company

• Employee engagement, exceeding peer comparisons with a record 91 percent employee participation consistent

increases in engage-ment levels measured in the company’s Voice of Employee survey

• Talent development, delivering nearly 100 technical training programs to more than 2,500 people, including customers and dis-tributors through The Kennametal Knowledge Center

• Safety, including key

milestones as more than half of the compa-ny’s facilities achieved the aim of keeping all employees and visitors 100 percent safe, 100 percent of the time

• Commitment to Integrity, with 100 per-cent participation globally in the company’s quarterly business ethics and compliance training modules

• Community stewardship, including more than 2,100 hours donated by more than 1,200 employee volunteers worldwide and record contributions to community organizations such as the United Way

• Innovation, consistently exceeding 40 percent of sales realized from new products that offer customers at least 20 percent performance improvement.

“To be recognized for a third time as one of the

world’s most ethical companies is an outstanding

honor and speaks volumes about the dedicated,

talented team we have at Kennametal. Our

employees consistently demonstrate the values

and beliefs that set Kennametal apart as a

leader in industry, enabling us to give our best

to our customers, shareholders, communities and

everyone we serve.”

Carlos Cardoso

Chairman, President & CEO, Kennametal Inc

“It is an honor to be recognized for the third

time as one of the world’s most ethical companies.

This honor is a tribute to our more than 14,000

employees around the world who consistently

demonstrate the values and beliefs that set

Kennametal apart as an industry leader.”

BC Rao

Managing Director, Kennametal India Limited

Balluff has developed a new, high-resolution light grid for optical object detection with a width of 50 mm and a range of up to 2 meters. Consisting of a transmitter with a high-performance redlight laser and a receiver, the device works completely self-sufficiently, without additional accessories such as PC or special software. All settings can be made via a display in the receiver.

The high resolution of 0.01 mm opens up many application possibilities. Evaluated are not only the light quantity of the especially homogeneous red laser light, but also the location and position within the light grid. In addition, the emitter

and receiver are encased in a rugged industrial housing and can be easily and quickly aligned using the live graphic display on the integrated multi-function display. The user can teach-in up to six different objects using the buttons and can hide obstructions in the measuring field (blanking).

This way different objects can be reliably detected, compared and sorted based on minimal differences in size. Other applications include presence and height checks. The result of the inspection is then available at two analog and three digital outputs. Starting in May 2014, there will also be a variant

with an IO-Link interface.

For further details visit www.balluff.co.in


www.martonline.in 43April 2014 www.martonline.in 43March 2014 www.martonline.in 43April 2014

New Code Readers Open up Wide Range of Applications Reliable readings on reflective surfaces using polarization filter

First products in Anybus® CompactCom™ 40-series

Offer fast communication to EtherCAT, POWERLINK, EtherNet/IP, PROFINET and PROFIBUS

The Anybus CompactCom range of embedded communication solutions from HMS Industrial Networks have provided automation devices with connectivity to any fieldbus or industrial Ethernet network for more than a decade. With the new Anybus CompactCom 40-series, HMS now introduces a new technology generation.

Built on solid and proven experience

The existing Anybus CompactCom 30-series (based on the Anybus NP30 network processor) has been installed in millions of automation devices and systems around the world and is tailored for general purpose automation such as AC drives, weigh scales, valves, barcode scanners, sensors, HMIs etc.

The new CompactCom 40-series is based on HMS’ Anybus NP40 network processor and is especially suitable for high-end industrial applications that require fieldbus or real-time Ethernet connectivity. Offering close to ”zero delay” between devices and real-time networks, the 40-series is ideal for high-performance applications such as servo drive systems, which require

fast network cycles and synchronization capabilities.

The CompactCom 40-series will support all major industrial networks, and the first release in April 2014 includes connectivity to EtherCAT, POWERLINK, EtherNet/IP, PROFINET and PROFIBUS.

The same hardware for all Ethernet networks.

Like all CompactCom solutions, the 40-series covers all types of industrial networks — traditional fieldbuses as well as industrial Ethernet. Device manufacturers that choose to use CompactCom get access to all networks through one single development project, during which the user simply integrates the generic Anybus interface (hardware/software). After this, any CompactCom

40-series product can be connected, offering instant connectivity to industrial networks.

The CompactCom 40-series extends the level of flexibility even further since it uses a common reprogrammable hardware to support several Ethernet networks. For example, it is possible to install the CompactCom 40-series Ethernet hardware into an industrial device and simply download ready-made firmware to connect to the desired network (for example POWERLINK, EtherNet/IP, PROFINET IRT or EtherCAT).

For more details visit www.hms.se

A new series of camera-based code readers now comes equipped with special polarization filter technology, which significantly expands the devices’ application area. This is because the barcodes and Data Matrix codes are often located on shiny, reflective surfaces, which can significantly interfere with the read operation. The new code readers are reliable at suppressing these kinds of reflections and even enable fast, reliable readings on metallic material.

The new OPC120W and OPC120P Series 1-D code and 2-D code readers from Pepperl+Fuchs cover an exceptionally broad range of applications. The OPC120W models offer an excellent cost-benefit ratio and are all-rounders suitable for a host of standard applications at standard speeds. The OPC120P model is perfect for more difficult tasks: It can handle high-speed applications with movements up to

10 m/s or 100 readings/s, and is equipped with unique polarization filter technology. Reliable code reading is guaranteed on highly reflective surfaces, such as metals, plastics, PCBs, under films, and on curved surfaces. Other highlights offered by this device include a rotary encoder input for path synchronization and the ability to read barcodes up to 200 mm in length through multiple image capture. The high depth of focus enables readings over a long distance without needing to make parameter changes. Moreover, the code readers are available in a range of interfaces that include PROFINET, RS232, and Ethernet.

The OPC120 Series devices read the DataMatrix, Code 2/5, Code 39, Code128, EAN13, and Pharmacode code symbologies. In addition, they can detect varying textures, expiration dates, and the presence and position of logos. The code readers are characterized by many other

features: These include outputting the code quality, automatically saving fault patterns, formatting the output string, and the match code function. These functions can be applied to up to four separate regions of the captured image. Its wide variety of features and protection category IP67 mean that the new code readers are suitable for a broad range of applications and industries.


www.martonline.in44 April 2014www.martonline.in44 January 2014www.martonline.in44 April 2014

Elscint offers Vibratory Bowl Feeder for CondomsPune based Elscint Automation recently supplied a special vibratory bowl feeder for feeding of condoms in 4 rows. The speed or feed rate achieved was 75 condoms per minute per row in 4 rows. Elscint Model 630 was used for this purpose. Further a one meter long four track linear vibrator (Model Elscint IV) was used to convey the condoms forward. The major problem with condoms is that they are rubbery and lubricated, making them slippery. This results in the speed being very less as the friction between the condoms and the

bowl track is reduced, which does not allow them to move forward properly. However, Elscint provided a special type of bowl made of stainless steel for this purpose.

Full welding was done at all areas to ensure that there were no crevices for dust accumulation. Another important point is that the mounting of the bowl has to be from outside to ensure that dust does not get accumulated in holes made for the screws required for

bowl fixing. Hence, Elscint ensured the mounting was on the outer side on 12 screws. There being 4 outlets, proper overflow of parts was required and this too was taken care off.

The condoms being in

various shapes, another possibility is that of overlapping and jamming. However, Elscint has perfected appropriate tooling for this type of bowl which eliminated this problem totally. Thus the feeding is very smooth without any overlapping or jamming. The fabricated bowl was having a diameter of more than 1300 mm.

For further details do write to [email protected] or visit www.elscintautomation.com

“This was a very difficult requirement as a total

of 4 lines were required and the parts being

fed were condoms which were being fed for

packing, hence quality requirements were very

strigent.”

Monish Shete

CEO, Elscint Automation

Haas Factory Outlet - CNCSSIPL Nashik Demo Day to showcase VF-3 and ST-10Y

Visitors to the Haas Factory Outlet- A division of CNCSSIPL, Nashik Demo Day, scheduled for May 7th, 8th and 9th, at the Nashik Engineering Cluster, MIDC Ambad, will have the opportunity to see live cutting demonstrations on two of the company’s best selling CNC machine tools: A Haas VF-3 CNC vertical machining centre; and a Haas ST-10Y CNC turning centre.

The Haas ST-10Y is one of the latest-generation, high-productivity machines from the Haas ST range of completely redesigned CNC turning centres. Equipped with C-axis and live tooling, customers can turn and mill complex parts and perform multiple operations in one set-up, increasing throughput, reducing handling and improving accuracy. Like its larger siblings in the ST range, the Haas ST-10Y provides a small-footprint, economical solution but with many full-size, productivity-enhancing features.

The ST-10Y is equipped with a 12-station BOT turret that indexes tools in 0.5 seconds, helping to reduce cycle times. The machine provides a maximum cutting capacity of 228mm x 355mm and boasts 101 mm of Y-axis travel (±50,8 mm from

the centerline) for off-center milling, drilling, and tapping, and comes standard with high-torque live tooling and a servo-driven C axis for versatile 4-axis capability. The ST-10Y’s A2-5 spindle nose has a 58mm spindle bore and a bar capacity of 44mm. It is equipped with a 165mm hydraulic 3-jaw chuck. The machine’s 11.2kW vector dual-drive spindle turns to 6000 rpm, and provides 101 Nm of torque at 1300 rpm.

The Haas VF-3 CNC vertical machining centre has travels of 1016mm x 508mm x 635 mm (xyz), uses a 40 taper spindle driven by a 22.4 kW vector drive motor delivering high torque through to 8100 rpm. The machine boasts a 20-station carousel tool changer and 25.4 m/min rapids.

Haas Automation made its name in the global CNC machine tool industry by

building the most affordable, reliable, hardwearing vertical mills the industry had ever seen. True to its roots, the VF-3 is a Haas workhorse and one of the company’s best-selling products, globally. It is designed to give years of service in job-shops or production environments, cutting everything and anything from resins to aluminum, cast iron to tool steel.

Like all Haas CNC machine tools, the VF-3 and the ST-10Y are built at the company’s one and only factory, in California, USA. A global network of local Haas Factory Outlets (HFOs) supports all Haas products, each one employing factory-trained engineers and stocking official Haas spare parts, ensuring customers’ machines are kept running with minimum disruption.

www.martonline.in 45April 2014 www.martonline.in 45April 2014

New Generation of ROMER Absolute Arm from Hexagon MetrologyHexagon Metrology announced a new generation of the ROMER Absolute Arm, featuring optimized ergonomics and stability, creating the best ROMER Absolute Arm ever.

This portable measuring arm is now more user-friendly than ever before, thanks to a completely new wrist design that improves handling and provides immediate acoustic and haptic feedback. A modified counterbalance also improves the movement of the arm when it is in use, enhancing user experience.

The new ROMER Absolute Arm is a versatile all-purpose metrology tool. It is designed for tactile and non-contact measurement of a huge variety of parts in an almost unlimited number of industry sectors.

An enormous range of touch probes, non-contact probes (for tube and hose measurement) and laser scanners are available, allowing users to always use the best solution for their measurement needs, whatever the task at hand. A repeatable probe mounting means that

users can swap probes as they work without the fussy calibrations normally associated with other competitive measurement arms.

New copper cathodes for existing HiFocus plasma cutting units

After launching the HiFocus neo technology with optimised plasma cutting units and new copper cathodes now users with existing HiFocus power sources can reduce their costs as well: As of now Kjellberg also offers powerful copper cathodes for cutting mild steel with older HiFocus plasma cutting units.

The consumable upgrade does not require any modification of hardware. Customers using the plasma torches PerCut 200/201/210/211 or PerCut 440/450/451 can easily exchange former cathodes for the new copper cathodes. Thus, the users can benefit from substantial cost advantages:

Cost advantages now also for users of older systems

Acquisition costs are lowered due to the significantly lower price for the new copper cathodes compared to former cathodes. Moreover, the costs per cutting metre as well as tied up funds for stockage are reduced with the more economic consumables. The conservation of resources because of the copper material is a further advantage.

With the HiFocus technology Kjellberg sets the standard in plasma cutting: The constriction of the plasma beam by a swirl gas that rotates with high speed leads to laser-like quality with nearly rectangular cut surfaces. The plasma cutting units of the HiFocus series cover a wide cutting range from 0.5 to 160 mm. Due to new consumables and the revision of the power sources under the

designation neo plasma cutting becomes even more efficient: Long-living copper cathodes and the low gas consumption reduce process costs. neo is standard in the plasma cutting units HiFocus 130 neo, HiFocus 161i neo, HiFocus 280i neo, HiFocus 360i neo, HiFocus 440i neo and HiFocus 600i neo.

Kjellberg Finsterwalde is the oldest manufacturer of plasma cutting technique in the market and is the world market leader in this area today. In particular, the HiFocus series with its excellent cut quality is evidence of the company’s competence. For further details visit www.kjellberg.de

“Our new copper cathode in HiFocus neo series are price

effective, having higher cutting speed & longer cutting

life than competitive product available in India, which

make it more attractive for Indian buyer who can enjoy

highest cutting quality with lowest running per meter cost

in plasma cutting.”

Vishal Deore

India Technical Manager

Kjellberg Finsterwalde Plasma und Maschinen GmbH

For scanning applications the ROMER Absolute Arm is available with a completely integrated high-performance laser scanner or, for the most challenging scanning jobs, the external laser scanner CMS108. They are the only truly verifiable portable scanning systems on the market today.

Through Hexagon Metrology’s worldwide sales network, the ROMER Absolute Arm is available immediately.

For further details visit www.hexagonmetrology.in

“We are pleased to announce this new enhanced

portable measuring arm now available in the India

market. It is a result of our commitment to offer

improvements in the product features in line with

market expectations.”

Anup Verma

Managing Director, Hexagon Metrology India


Vector award presented at Hanover

Exciting, unusual and exemplary. Every two years igus GmbH accords the vector award in recognition of special applications with energy chain systems. This time among them were interesting solutions from around the world showing the immense diversity of applications with energy chains. The winners from the 195 submissions from 28 countries were presented at the Hanover Show 2014.

The great variety of applications in mechanical and plant engineering submitted for the fourth vector award, even featured a small and delicate low profile chain in a CNC hybrid machine right through to a large heavy-duty energy chain with 500 metres of travel in a coking plant. The jury, consisting of representatives of

specialist media, business and research, had the difficult task of choosing the winners from among the 195 entrances. Applicants from Canada to South Korea display the versatile and high-power potentials of plastic energy chains. The vector trophy and prize money of 1,000 to 5,000 Euros were distributed as awards at the Hanover Show.

Extraordinary storage and retrieval unit is gilded

The winner of the golden vector this year is the University of Duisburg-Essen. A high-bay warehouse system was developed that works fast, saving space. A transport platform with a gripper moves from one point of the shelf to the other via eight wire ropes clamped in a parallel motion. In order to prevent the required cables from interfering with the rapid movements, they are wound and unwound on an e-spool and securely guided within the energy chain.

Silver vector for high-speed application

This time the silver goes to the company FronTone from Austria. In this lightning-fast application, one to two high-speed cameras with up to 750 m/s² acceleration reached a speed of 21 m/s on a carbon carrier system. This is necessary due to the cameras being used in crash tests of vehicles and vehicle parts thus the motor, feedback and camera cables can be carried smoothly.

Bronze for metalworking

The Otto Bihler Maschinenfabrik GmbH & Co. KG was awarded the 2014 bronze vector for its servo-controlled punching

and bending machine. Here a number of different igus energy chains with reverse bending radius are used, which protect the cables routed to the individual units from dirt and damage caused by punching slugs.

Special vector for a special stage show

A special mention was granted by the jury to the submission of Wicreations from Belgium. The company’s spotlight installation was used during the South American tour of the Mexican singer Alejandro Fernandez. These so-called “Venetian blinds” consist of five individual boxes, each with three moving spotlights. The individual boxes that can be adjusted separately,are also dynamic and interconnect by zigzag chains from igus to supply energy and data to the spotlights.

All information about the competition and the whole range of all submissions - including those from the past few years - are available at http://www.vector-award.eu

The winners of the 2014 vector award: Harald Nehring, igus GmbH, Dieter Bencer, igus Austria (silver vector),

Dr. Tobias Bruckmann, Universität Duisburg-Essen (golden vector), Norbert Muche, Otto Bihler Maschinenfabrik

GmbH & Co. KG (bronze vector).

Gold for storage and retrieval system


Every two years, the igus GmbH presents the vector award in recognition of special applications with energy chain systems. A total of 195 participants from 28 countries participated in 2014.

HDP 125 and HDO 125

new intermediate sizes for parallel and bevel helical gearboxesThe Bonfiglioli heavy duty parallel and bevel helical gearboxes HDP and HDO are now more competitive thanks to the incoming new 125 size. HDP 125 and HDO 125 are available in 2, 3 and 4 stages, with a range of reduction ratios from 1:9 to 1:500.

They feature an output torque above 49kNm. It improves both series in the torque area between 40KNm (HDP 120) and 70kNm (HDP 130), which is fundamental for the applications of Bonfiglioli customers like feed screws,

lifting systems, pumps, conveyors, mixers and mixer-stirrers, etc.

The 125 size also features the well-known robustness and reliability of the HDP and HDO series. It shows a brand new external design that will be applied to the whole series in the future.

The new size has just been presented for the first time to customers at the Hannover Messe in Germany. A sample of HDP 125 has been shown to customers and visitors.

For further details write to [email protected]



Vector award presented at Hanover

Red Lion introduces PXU Series of PID Controllers

Red Lion Controls, the global experts in communication, monitoring and control for industrial automation and networking, announced last month the launch of its new PXU series of proportional-integral-derivative (PID) controllers. The PXU series, which is the latest addition to Red Lion’s portfolio of industrial automation solutions, is designed for machine builders, systems integrators and commercial equipment manufacturers. The PXU series enables tighter, more reliable control over a wide range of processes, including temperature, flow and pressure, from a single model.

Capable of being deployed in precision

Compact Design and Universal Input Options Provide PID Control for a Wide Range Temperature and Process Signals

process applications within the food and beverage, plastics, packaging, energy, gas, heat-treating, commercial and medical industries, the PXU series offers 1/16, 1/8 and 1/4 DIN size models to provide a range of space-saving options.

“The PXU series of PID controllers gives customers compact PID controllers with large, easy to read displays,” said Jeff Thornton, director of product managementat Red Lion Controls. “The range of sizes and universal input coupled with our award-winning Crimson software make these controllers


a must-have for OEM machine builders and commercial equipment manufacturers.”

For more information about Red Lion’s new PXU series, please visit www.redlion.net/PXU.

EEC One: Automation of documentation increases engineering efficiency

The new version of EPLAN Engineering Center One (EEC One) has arrived. Detail engineering and hence engineering times can be drastically reduced with comprehensive frameworks. Now available in 17 languages, the software supports important interna-tional standards and norms for the global market. What started with English, Spanish, Russian and Chinese at the Hanover Trade Fair in 2013 is now being expanded: EEC One, the automation software from solutions provider EPLAN, is now available in all 17 platform languages. The newly integrated dictionary function also ensures direct access to the EPLAN diction-ary and hence to translations of the entire documentation of the schematics in all possible languages. At the same time it ensures consistency in the descriptions

due to the use of uniform terms, phrases or special characters. Language barriers are removed and the efficiency level of the software usage increased. In particular, interna-tional companies with sites in multiple countries will appreciate this benefit.

Excel environment for automation

Efficient engineering is not only reflected in streamlined, automatic processes but also in the user-friendliness of the software. Furthermore, EPLAN continues to use the tried & tested Excel environment with the EEC One, which allows intuitive use. New colouring supports the error search function. Additionally, in the current version a fixed value can be specified for the position of macros with respect to the predecessor macro. This supports rapid and clear positioning.

Integrated instead of just linked

The deep connection to the EPLAN Platform is also reflected in the integrated parts selection. The EEC One directly accesses the EPLAN parts database and transfers parts and their reference data. Transmission errors can be avoided due to the automated data transfer, and efficiency can be increased at the same time. Moreover, the new EEC One version

is compatible with the current EPLAN Platform 2.3 and the predecessor version 2.2.

First stage of automation

Nowadays, efficiency in engineering is no longer a supplementary benefit for most companies, it is neces-sary to remain nationally and internationally successful. Software tools that relieve the user from routine tasks are an important building block on the way to the efficient engineering process. This leaves more time for innova-tive developments and problem solving. Based on the macrotechnology that already offers options for stan-dardisation within the EPLAN Platform, the creation of schematics in electrical and fluid power engineering can be automated via EEC One.

For further details visit www.eplan.in

With its new multi-lingual functionality, EEC One provides even better interaction of automation in the international arena.

Separate user environments in EEC One support the user in selecting macros and specifying parameters.

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Control Techniques empowers CMC Packaging MachineControl Techniques Servo Drives and Motors chosen for Unique Box Packing Machine

Control Techniques, part of Emerson Industrial Automation, an Emerson (NYSE: EMR) business, is supplying Digitax ST servo drives and Unimotor FM servo motors for a new design of packaging machine, Cartonwrap, manufactured by Italy-based CMC Machinery.

Cartonwrap machines use an inexpensive corrugated cardboard roll to make boxes to pack any kind of product, adapting the container to the size of the item to pack. Products are fed into the packaging machine on a conveyor and the box is formed around them.

The Digitax drives use multi-network management via central PC and Ethernet for coordination of all production menus

and motion parametric equations on the individual process components. CMC machinery uses SM Applications Plus modules in each drive - these are automation controllers with integrated fieldbus communications and I/O. Using the modules avoids the need for an external PLC allowing reduced wiring which increases communication speed. The modules are running bespoke software that has been designed specifically for Cartonwrap machines with the assistance of software engineers from Control Techniques.

Each Cartonwrap machine uses 22 Digitax ST servo drives and 075U2C / 095U2B Unimotor FM servo motors, as well as six

Unidrive SP and 5 Commander SK drives, also from Control Techniques. For further details write to [email protected]

Dr. Sunita awarded ‘Amazing Global Indian’

Pediatric cardiologist Dr. Sunita Maheshwari was awarded the prestigious ‘Amazing Global Indian’ by Mahindra Rise in association with Times Now. Teleradiology Solutions co-founder and Chief Dreamer, Bangalore based Dr. Sunita Maheshwari was named and presented the ‘amazing global indian’ award by the Speaker of Lok Sabha – ‘Smt. Meira Kumar’ at an inspirational event organized by Times Now in New Delhi, among


Magzter Founders in Fortune’s 40 under 40!!

Magzter Digital Magazine founders, Girish Ramdas, CEO and Vijayakumar Radhakrishnan, President get listed in the prestigious Fortune’s 40 under 40.

Magzter the world’s largest and fastest growing cross platform of global digital magazine store and news stand have achieved many a milestones : the very recent being listing of its Founders under Fortune India’s 40 under 40 which recognizes India’s next generation entrepreneurs and managers under the age 40 who have worked their way up to make enterprise a valid career choice.

What the Chennai pair took up as a stirring initiative in 2011 to be the news stand which would revolutionize digital publishing; Magzter since then hasn’t looked back, pushing boundaries with technology and staying perseverant to the cause of digital publishing. Today it has to its credit 3500 titles from a 1000 publishers to it’s a name and a readership reaching out to 18 million users worldwide. Mart is digitally available through Magzter.com .

Vijayakumar Radhakrishnan (Left) Girish Ramdas

the category of Global Indians who have returned to India and done amazing work for the country.

With co-founding ‘Teleradiology Solutions’- in the United States and globally alongside ‘Telerad Rxdx’ clinic and ‘Telerad Tech’- a technology healthcare company; she and founder Dr. Arjun Kalyanpur have charitably furthered their proceeds of entrepreneurship in funding playgrounds for poor children through People4People – a trust fund for playgrounds in Karnataka and to take Tele-Diagnostics to remote parts of India. The award acknowledged that, over the years she has installed over 125 playgrounds in Government Schools at Karnataka positively impacting over 25000 children every year.

Dr Ramadorai conferred ‘Life Time Excellence Award’

The Indian Institute of Welding (IIW), at the occasion of 8th Weld India Expo 2014 in New Delhi conferred Dr. S. Ramadorai- Chairman of National Skill Development Corporation (Govt. of India) with the ‘Life Time Excellence Award’ for his dedication and contribution towards Manpower & Skill development.

Dr Ramadorai ensured help from the Indian Government for the skill up gradation of ordinary welders to be prioritized and

Skill Development Institutions in Welding receiving necessary support for the same.



THE LAST LEAF

Dear All,

Innovation is about implementing change and ideas, and just because you have an idea that does not mean that you can make it a reality. These are the thoughts of Fredrik Haren, the author of The Idea Book, that was featured in “The 100 Best Books of all Times”. You need more than a seed if you want to grow a plant.

Auto parts exports grew by 4.4 % to touch $ 9.7 billion in 2013, as per data issued by ACMA. This is a result of growing credibility of domestic component makers which has led to many global companies and OEMs to set up their sourcing centres in India.

Boosted mainly by the government’s 9% stake sale in Axis Bank, a large chunk of which was bought by foreign investors, and also the buyback of forex which was given to oil companies last year, India’s foreign exchange reserves jumped a massive $5 billion during the week ended March 28 to go past the $300 billion mark after over two years. This also incorporated the effects of appreciation of the rupee against the dollar, and also against other major currencies. The figure was last above this mark in December 2011.

Bandhan Financial Services is now the country’s biggest microfinance company. It ranked second in the world in the list of world’s top MPFIs, by Forbes magazine in 2007 It got recently an approval for a bank licence from RBI. This transformation would help its 52-lakh borrower base get savings and deposit products.

India is inching closer to the mission of creating their own version of the American GPS, owing to the efforts of ISRO. Indian Regional Navigation Satellite System (IRNSS) will give India its own indigenous air navigation system, which would provide information on location and time in all weather conditions. IRNSS-1A has already started functioning from its designated orbital slot after extensive tests. The second of the seven planned satellites for this system, IRNSS 1B was successfully launched on 4th April. Now, it needs to launch at least four of the seven satellites to start operations of IRNSS.

IRNSS is similar to US’ Global Positioning System, Russia’s Glonass and Europe’s Galileo. China and Japan too have similar systems named Beidou and Japanese Quasi Zenith Satellite System respectively; IRNSS’ applications include terrestrial and ma-rine navigation, disaster management, vehicle tracking and fleet management, integration with mobile phones, visual and voice navigation for drivers.

As always, we need your input on the industry news, views and any observation about the industry around you. Your feedback will be useful to us to better inform our reader’s about tomorrow’s manufacturing solutions.

Till then, Happy Technology!

Manoj Kabre Member, Editorial Advisory Board (EAB)


RNI No.: KARENG/2004/13614 Regd. Regn. No: KRNA/BGE/1016/2012-2014 Posted at MBC, Bangalore GPO, Bangalore - 560001 on 15th of every month

MART April 2014

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