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01/<strong>2017</strong><br />

MOTION, DRIVE & AUTOMATION<br />

Schaeffler boots its<br />

standard bearing business<br />

www.engineering-news.net<br />

in cooperation with<br />

Fluidtechnik<br />

Antriebstechnik


MDA Events Worldwide<br />

Join the No. 1 Trade Fair Network for Motion, Drive & Automation<br />

Turkey Istanbul 16 - 19 Mar <strong>2017</strong><br />

Germany Hannover 24 - 28 Apr <strong>2017</strong><br />

China Shenzhen 28 - 30 Jun <strong>2017</strong><br />

Shanghai 31 Oct - 3 Nov <strong>2017</strong><br />

Canada Toronto 25 - 28 Sep <strong>2017</strong><br />

Montreal 2 - 4 Oct <strong>2017</strong><br />

Italy Milan 4 - 6 Oct <strong>2017</strong><br />

USA Chicago 6 - 9 Nov <strong>2017</strong><br />

Chicago 10 - 15 Sep 2018<br />

India Mumbai 22 - 24 Feb 2018<br />

www.hannovermesse.de/worldwide


EDITORIAL<br />

The world has<br />

turned upside down<br />

Dear readers,<br />

the world seems to have turned upside down in these times: In Syria a<br />

bitter civil war has been raging for years. Since 2003 Islamic State,acting as<br />

a terrorist Sunni militia, has not only been active in Iraq and Syria, but has<br />

also spread fear and terror worldwide with terrorist attacks. In Turkey<br />

President Erdogan is gaining more and more power, visibly pushing the<br />

country in the direction of a dictatorship. In Europe, Great Britain has<br />

pitted itself sharply against the European Union with Brexit and by so<br />

doing is stoking the flames for the nascent right-wing populist parties,<br />

which seem to be winning seats in more and more parliaments. And then<br />

there are the two great potentates, Putin and Trump. One casually<br />

annexes Crimea while the other – barely in office – is quickly following up<br />

his threats with actions in matters of protectionist trade and investment<br />

policies. And in general he is behaving like a bull in a china shop – without<br />

regard to existing agreements and treaties.<br />

But getting back to the USA: There is a climate of great uncertainty in<br />

industry, quickly leading to a reluctance to invest. Thus even before<br />

Trump took office, from January to October 2016, exports from Germany,<br />

one of the major trading partners of the USA, declined by 3.4 %. In the<br />

period from August to October, machine exports even fell by 5.8 %. Other<br />

countries face similar problems. The course of further developments is<br />

unclear. It will depend greatly on how the new president implements what<br />

he has announced in actual policy and also whether Congress will simply<br />

wave through all the changes. Thilo Brodtmann, General Manager of the<br />

German Engineering Federation (VDMA, Verband Deutscher Maschinenund<br />

Anlagenbau e.V.), notes confidently, “Isolating the American economy<br />

with tariffs and walls would inevitably hurt not only its trading<br />

partners, but also the United States itself.” After all, US companies are also<br />

tied into global added-value chains and rely on foreign business markets.<br />

How the individual conflicts will be resolved is very difficult to predict. But<br />

we will experience how worldwide industry is responding in the coming<br />

months at some important trade fairs in the near future: The leading trade<br />

fair for the next generation of production starts in March in Istanbul with<br />

WIN Eurasia, while the Hannover trade fair will attract the world to<br />

Germany again in April to the largest event for mechanical engineering in<br />

the world. The most important innovations related to drives and automation<br />

technology will be on display here. This<br />

edition already has a small foretaste of what<br />

you can expect. Here too the world has turned<br />

upside down – not politically, but with technological<br />

innovations.<br />

Wishing you enjoyable reading,<br />

Dirk Schaar<br />

Editorial Director<br />

Meike Sauer<br />

Deutsche Messe AG<br />

MOTION, DRIVES & AUTOMATION<br />

Editorial director:<br />

Dipl.-Ing. (FH) Dirk Schaar<br />

Email: d.schaar@vfmz.de<br />

Editor-in-chief:<br />

Dipl.-Ing. (FH) Michael Pfister<br />

Email: m.pfister@vfmz.de<br />

Editorial board:<br />

Peter Becker B.A., Dipl.-Ing. (FH) Nicole Steinicke<br />

Assistant editor:<br />

Svenja Stenner, Email: s.stenner@vfmz.de<br />

Design/Layout:<br />

Sonja Schirmer, Doris Buchenau,<br />

Anette Fröder, Mario Wüst<br />

Epaper designer:<br />

Katja Rüdell, Mathias Göbel<br />

Managing editor:<br />

Dipl.-Ing. (FH) Winfried Bauer<br />

Publishing house:<br />

Vereinigte Fachverlage GmbH<br />

Lise-Meitner-Str. 2, 55129 Mainz, Germany<br />

Commercial Register No.:<br />

HRB 2270, District Court of Mainz<br />

VAT-ID:<br />

DE149063659<br />

Managing director:<br />

Dr. Olaf Theisen<br />

Publishing director:<br />

Dr. Michael Werner, Email: m.werner@vfmz.de<br />

Correspondent India:<br />

Sushen Haresh Doshi M.Sc.<br />

Advertising sales director:<br />

Beatrice Thomas-Meyer<br />

Email: b.thomas-meyer@vfmz.de<br />

Advertising sales manager:<br />

Oliver Jennen, Email: o.jennen@vfmz.de<br />

Sales representatives<br />

Austria<br />

Heinz-Joachim Greiner<br />

Email: verlagsbuero-greiner@vfmz.de<br />

China, India<br />

Oliver Jennen, Email: o.jennen@vfmz.de<br />

France<br />

Marc Jouanny<br />

Email: marc-jouanny@wanadoo.fr<br />

Great Britain, Ireland<br />

Roberto Tondina<br />

Email: roberto@ts-communications.co.uk<br />

Italy, Switzerland<br />

Hermann Jordi<br />

Email: info@jordipublipress.de<br />

Sweden, Finland, Norway<br />

Malte Mezger<br />

Email: verlagsbuero-mezger@vfmz.de<br />

USA, Canada<br />

Bill Fox, Email: bfox@hfusa.com<br />

Advertising disposition:<br />

Annemarie Benthin, Email: a.benthin@vfmz.de<br />

In cooperation with:<br />

Hannover Fairs International GmbH<br />

Messegelände, 30521 Hannover, Germany<br />

Additional Partners:<br />

Fachverband Antriebstechnik im VDMA<br />

Fachverband Fluidtechnik im VDMA<br />

Fluid Power Association of India<br />

Moskauer Deutsche Zeitung<br />

Internet:<br />

www.en.engineering-news.net<br />

8 th year (<strong>2017</strong>)


TABLE OF CONTENT<br />

EDITORIAL<br />

WORLDWIDE NEWS<br />

TURKEY: OPPORTUNITIES DESPITE<br />

TURBULENCE<br />

WIN EURASIA: BRINGING<br />

INTEGRATED SOLUTIONS FOR<br />

TURKEY’S NEW GENERATION<br />

MANUFACTURING<br />

DIRKS CHOICE<br />

SCHAEFFLER STRENGTHENS ITS<br />

BEARINGS BUSINESS WITH A NEW<br />

PRODUCTION FACILITY<br />

BRAKE TECHNOLOGY 4.0: SAFETY<br />

BRAKES FIT FOR ALL CHALLENGES<br />

NEW GENERATION THERMOPLASTIC<br />

POLYURETHANE<br />

PRODUCT NEWS<br />

SUCCESS IN THE HIMALAYAS<br />

PRODUCT NEWS<br />

MDA SHOWCASES DIGITALIZATION<br />

WITH PREDICTIVE MAINTENANCE<br />

APPLICATIONS<br />

MOTION, DRIVES & AUTOMATION<br />

WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/<strong>2017</strong>


TABLE OF CONTENT<br />

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Find out more at www.FAG-GenerationC.com


Worldwide News<br />

Japan’s Yaskawa expanding strategically<br />

in Europe<br />

Japanese technology group Yaskawa is focusing to intensify<br />

its presence in Europe, with the aim of becoming one of the<br />

leading manufacturers of industrial robots in strategic target<br />

markets. The company plans to expand its production<br />

capacities and open a new robot manufacturing plant and a<br />

new European robotics development centre in Slovenia.<br />

Creating 200 additional jobs in the process. The first Yaskawa<br />

Austrian company NKE completes 20<br />

successful years in the bearings industry<br />

NKE, the bearing manufacturer based in the Austrian city of Steyr<br />

is celebrating its 20 th anniversary. The company, by Heimo Ebner<br />

and Harald Zerobin, produces bearings for all industrial applications,<br />

with engineering, product development, production,<br />

logistics, sales and marketing being centralised at its Steyr<br />

headquarters. The company operates its sales through 12 international<br />

offices and 240 distribution outlets in 60 countries. In its first<br />

10 years, NKE saw rapid growth, with its turnover increasing on<br />

average by more than 20 % a year. To keep up with the growth, the<br />

company invested more than 15 million Euros to build its new<br />

premises in Stadtgut Steyr business park in 2009. This investment<br />

helped NKE double its production capacity. In 2016, the Spanish<br />

company ‘Fersa Bearings’ acquired 49 % interest in NKE. The<br />

resulting group of companies now boasts 3 production sites, 5<br />

distribution centres, and 3 R&D locations. After guiding the<br />

company for 20 years, both its two founders Heimo Ebner and<br />

Harald Zerobin passed the company’s management on to Thomas<br />

Witzler in July 2016. With their expertise and experience they<br />

continue to actively deal with NKE’s vision and strategic planning<br />

for the coming decades.<br />

robots from all-European production are expected to roll in<br />

2018. The factory should satisfy about 80 % of the European<br />

demand for robots. Total investments are estimated to be in<br />

the order of 25 million euros. As one of the top global players<br />

in the industrial robot sector with more than 350,000 units<br />

sold, Yaskawa is pursuing an ambitious expansion strategy in<br />

Europe. The new production and development capacities will<br />

permit faster customized robotic solutions in Europe. This<br />

will also strengthen the cooperation with OEMs in these<br />

markets. Yaskawa is expanding its European activities<br />

through investments in the existing robot business as well as<br />

electric drive technology, industrial control technology and<br />

‘Green Energy’.<br />

www.yaskawa.eu.com<br />

Caption: NKE founders Heimo Ebner (left) and Harald Zerobin<br />

(right) with General Manager Thomas Witzler (centre)<br />

www.nke.at/en/home<br />

NEWS AND MARKETS<br />

Mayr power transmission expands its existing facility<br />

Since the ground-breaking ceremony in mid 2016, much has<br />

happened on the construction site of the new facility at Mayr<br />

power transmission in Mauerstetten. Currently, trapezoidal<br />

sheets are being installed on the roof. Therefore, the roofing<br />

ceremony for the new facility took place back in November in<br />

the presence of numerous representatives from the companies<br />

involved in the construction. Owing to smooth construction<br />

process, it has been possible to cover the site according to plan<br />

before the winter. Over the winter months, the interior<br />

construction will take place, so that it will be possible to move<br />

into the new hall by approximately mid-<strong>2017</strong>. The new<br />

production and assembly hall has a length of 105 m and a<br />

width of 45 m, occupying a total floor area of 4 500 m 2 . The<br />

assembly, dispatch and a warehouse close to the assembly will<br />

be located in the new facility. Around 600 m² office area,<br />

appropriate meeting and engineering rooms have been<br />

planned in the building. Mayr Power transmission is investing<br />

heavily in its Mauerstetten location with this new site along<br />

with the new communications centre simultaneously being<br />

built on the premises.<br />

www.mayr.com<br />

WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/<strong>2017</strong>


KTR Kupplungstechnik GmbH changes its<br />

name to KTR Systems GmbH<br />

Founded in 1959, the KTR group<br />

comprises of 23 subsidiary companies<br />

and 90 sales partners worldwide<br />

along with 7 production sites in<br />

Germany, Poland, USA, Brazil, India<br />

and China. KTR Kupplungstechnik<br />

GmbH, the family-owned company<br />

located in Rheine has strongly expanded over the past<br />

decade in the sectors of drive technology, brake systems,<br />

hydraulic components and cooling systems. Furthermore<br />

the company has intensified its international activities in the<br />

fields of production, logistics and sales substantially. The<br />

product portfolio includes mechanical couplings, torque<br />

measuring shafts, clamping sets and universal joints,<br />

hydraulic and electromechanical brake systems, cooling<br />

systems for industrial applications in mechanical and plant<br />

engineering. Being the legal successor, KTR Systems GmbH<br />

will automatically and fully take on all rights and obligations<br />

from KTR Kupplungstechnik GmbH. Rheine will remain the<br />

company’s headquarters, with only the mail address being<br />

changed from Rodder Damm 170 into Carl-Zeiss-Straße 25,<br />

Rheine 48432. The well-known company logo and the claim<br />

“Made for Motion” will remain unaffected.<br />

www.ktr.com<br />

Nord Drivesystems expands its facility in<br />

Pune, India<br />

Nord Drivesystems has committed to invest 45 million Indian<br />

Rupees (approx. EUR 600,000) to the expansion of its Indian<br />

subsidiary. The investment was used to establish a new service<br />

area at the Nord Drivesystems Pvt. Ltd. facility in Pune. The factory<br />

now boasts a 13,000 m² shop floor and can turn out over 24,000<br />

drives per year.<br />

Since 2005, the<br />

company has<br />

delivered more<br />

than 100,000 geared<br />

motors to customers<br />

across the<br />

subcontinent. Short<br />

delivery times and<br />

fast service are<br />

among the most<br />

important measures<br />

to keep<br />

regional customers<br />

satisfied. Staffed with a team of experienced, highly trained<br />

technicians, the new, expanded service area is crucial to ensure<br />

this for the future. In addition, NORD has launched an initiative for<br />

service vehicles: they serve customers on location, quickly provide<br />

qualified customer service, and are even equipped to offer<br />

training.<br />

www.nord.com<br />

DERANTRIEB■ Reliable<br />

■ Versatile<br />

■ Global<br />

NORD DRIVESYSTEMS:<br />

■ Worldwide available<br />

■ Subsidiaries in 36 countries<br />

■ Agents in 52 countries<br />

www.nord.com/locator<br />

Headquarters:<br />

Getriebebau NORD GmbH & Co. KG<br />

Fon +49 (0) 4532 / 289-0<br />

info@nord.com<br />

Member of the<br />

NORD DRIVESYSTEMS Group<br />

The<br />

Gear Unit<br />

■ Strong bearings<br />

■ Quiet running<br />

■ High power density<br />

The<br />

Motor<br />

■ High efficiency<br />

■ Global standards<br />

■ All operating conditions<br />

The<br />

Drive Electronic<br />

■ Compact design<br />

■ Easy implementation<br />

■ Scalable functionalities


Turkey: opportunities<br />

despite Turbulence<br />

NEWS AND MARKETS<br />

For Turkey, <strong>2017</strong> began on a hurtful note with the<br />

attacks in Istanbul; the entire world expresses their<br />

condolences and support to Turkey and its people. But<br />

in my regards the best way to beat the narrative of the<br />

disruptive forces is by not letting them derail the cycle<br />

of growth and development in the region.<br />

Turkey is a key ally to both, Europe and the United States. A longstanding<br />

member of NATO and a candidate for membership<br />

in the European Union, it has strong ties to the West and has long<br />

served as a bridge to the East in a volatile, yet extremely strategic<br />

region. The collaboration between Turkey and Germany or Europe,<br />

in the context of technology and industry has been progressive ever<br />

since the Ottoman Empire. Since then, a large number of technology<br />

based corporations like Siemens and Schneider Electric have<br />

been the first to introduce many innovative technologies in Turkey,<br />

for example, establishing the telegraph system in mid-1800s, supplying<br />

heavy industry products to the Ottoman Navy, laying the<br />

electricity network in 1914 even during the first world war or bringing<br />

the fiber optic cable on the Bosphorus bridge in 1986. With the<br />

onset of the new millennium, Turkey’s acceptance and integration<br />

with the new technologies has created a massive growth cycle for<br />

the Eurasian region’s industrial development.<br />

Turkey’s economy and role of industry<br />

In the broad frame of economics, Turkey has definitely been a<br />

success story in this century so far. In the last 15 years, Turkey has<br />

shown robust macroeconomic growth with an average annual real<br />

GDP growth rate of 4.7 %. The GDP rose from $ 230 billion in 2002<br />

to more than triple at $ 720 billion in 2015. The country has undergone<br />

profound transformation over the last decade to solidify its<br />

economic foundation. It is the 16th largest economy in the world<br />

in terms of purchasing power parity and the 6th largest economy in<br />

Europe. In 2015, Turkey had global trade volumes totalling to more<br />

than $ 315 billion, of which approximately 40 % was with the EU 28<br />

countries, followed by China, Russia, USA, South Korea and Iran.<br />

The EU is Turkey’s number one import and export partner while<br />

Turkey ranks 7 th in the EU’s top import and 5th in export markets.<br />

Turkey’s exports to the EU are mostly machinery, transport equipment<br />

and engineering goods. (Statistics: European Commission,<br />

Directorate General for Trade)<br />

The Economist Intelligence Unit (EIU) expects an annual average<br />

growth rate in real GDP to be around 5 % in <strong>2017</strong>-18. The OECD<br />

forecasts the GDP growth to pick up to around 3.25 % in <strong>2017</strong> and<br />

3.75 % in 2018, driven mainly by recovering household consumption<br />

and gradual increases in exports. Monetary policy played a<br />

vital role in controlling and bringing down the inflation over recent<br />

years. The rate of inflation in Turkey has stayed under 10 % since<br />

2004 and year-end inflation was capped as 6.2 % in 2012. EIU forecasts<br />

that the average inflation rate will further ease to 4 % by 2018.<br />

The manufacturing industry is one of the main drivers of the<br />

Turkish economy, accounting for roughly a quarter of the total GDP.<br />

According to Turkstat, Turkey’s manufacturing industry has been<br />

growing at a CAGR of 12 % since 2003, exceeding the growth levels<br />

of the GDP and reached TL 220 billion in 2012. Turkey’s increasing<br />

level of disposable income and the high disposable income levels of<br />

its export partners – mostly EU countries, provide a much necessary<br />

boost to the domestic consumption as well as exports.<br />

Author: Sushen Doshi, International Correspondent for World of Industries<br />

WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/<strong>2017</strong>


Turkey 2023<br />

To establish itself as major manufacturing power, Turkey has set the<br />

year 2023 as its target. All the government initiatives and policies<br />

are focused with 2023 in sight. For the machinery and equipment<br />

manufacturing sector, the goal is to achieve $ 100 billion in export,<br />

securing a roughly 2.5 % share of the global machinery market.<br />

Apart from creating more economic value, the country’s industry<br />

aims to create custom-designed, high-quality, affordable and environmentally<br />

friendly products, accelerating Turkey’s transition<br />

from low value-added products to high value-added products and<br />

creating joint R&D centres while increasing R&D spending. Turkey<br />

has signed agreements with the EU ensuring an increase in R&D<br />

expenditure up to 3 % of its total GDP until 2023. Two thirds of this<br />

will be funded by the private sector as is stated in its agreement<br />

with the EU. These incentives that are backed by law will secure<br />

Turkey’s position as a R&D base by encouraging foreign investors<br />

to set up Technology Development Zones (TDZ) in Turkey. TDZs<br />

are organized research and business centres where academic, economic<br />

and social structures become integrated and universities,<br />

research institutions, and industrial foundations work together for<br />

innovation, technology transfer; increasing productivity and reducing<br />

production costs; increasing product quality and standards;<br />

working on product development; supporting technological investments<br />

and entrepreneurship. To further promote the participation<br />

in TDZs, the government offers incentives and tax exemptions to<br />

entrepreneurs operating in this region until 2023 from the income<br />

made from R&D operations and software. Taxes on the wages of<br />

R&D personnel are exempt until 2023 as well. On an average, every<br />

year 4 new TDZs are launched in Turkey.<br />

Demographic advantage<br />

Turkey’s workforce is one of the youngest and largest in Europe with<br />

the necessary education, skills and knowledge. More than 60 % of<br />

the population is aged between 24 and 54, and 25 % population in<br />

the age group of 0-14, which is a huge demographic and economic<br />

advantage for Turkey. Moreover, Turkey has one of the lowest minimum<br />

wage rates in Europe with approximately $ 600 per month in<br />

2016. There are four mechanisms through which the demographic<br />

benefits are delivered:<br />

n The increased labour supply. However, the magnitude of this benefit<br />

appears to be dependent on the ability of the economy to absorb<br />

and employ the extra workers.<br />

n The The increase in savings. As the number of dependents decreases<br />

individuals can save more. This increase in national savings<br />

rates increases the stock of capital in developing countries<br />

already facing shortages of capital and leads to higher productivity<br />

as the accumulated capital is invested.<br />

n The human capital. Decreases in fertility rates result in healthier<br />

women and fewer economic pressures at home. This also allows<br />

parents to invest more resources per child, leading to better<br />

health and educational outcomes.<br />

n The increasing domestic demand brought about by the increasing<br />

GDP per capita and the decreasing dependency ratio.<br />

Free trade and customs agreement with EU<br />

According to the Ministry of Economy, Turkey has free trade agreements<br />

(FTA) with 19 countries and has started negotiations with<br />

another 13 countries. In 1995-96 the Ankara agreement established<br />

a customs union between Turkey and the European Union. Under<br />

the customs union agreement, goods may travel between the two<br />

entities without any customs restrictions. The customs union does<br />

not cover essential economic sectors such as agriculture (to which<br />

bilateral trade concessions apply). Turkey’s main exports to EU and<br />

imports from EU are dominantly industrial. Since 1996, Turkey’s<br />

GDP has increased 4-fold, making it one of the fastest growing<br />

economies in the world. At the same time, however, the foreign<br />

trade deficit of Turkey (between EU) has increased 2 fold. The customs<br />

union is a large factor in both of these developments. In addition<br />

to providing for a common external tariff for the products<br />

covered, the customs union foresees that Turkey is in compliance<br />

with the EU industrial standards.<br />

Apart from FTAs, there are also 19 free trade zones within Turkey<br />

which enable corporate, income and customs tax, VAT and other<br />

exemptions. The Turkish investment incentive program provides<br />

varying tax reductions between 15 to 65 % depending on investment<br />

region, scale and social security support for 2 to 12 years.<br />

Growth despite turbulence<br />

The Turkish economy continues to face geopolitical headwinds<br />

and unsettled political conditions, after having weathered a coup<br />

attempt in July 2016 and engaged in military operations in Syria.<br />

More recently, in the context of high geopolitical uncertainty and an<br />

extension of the state of emergency, a rating downgrade triggered a<br />

weakness in overall business sentiment. Turkey’s main export markets<br />

in Europe and in the region remain subdued. A trade embargo<br />

imposed by Russia in 2016, which is in the process of being waived,<br />

added to the volatility of export markets. Nonetheless, exporters are<br />

highly entrepreneurial and taking opportunity of the exchange rate<br />

depreciation, Turkish firms have increased their share in several alternative<br />

markets in 2016, including in some EU countries. With the<br />

expected normalisation of external trade conditions, real exports of<br />

goods and services are projected to recover gradually in <strong>2017</strong>.<br />

Photographs: Lead photo Fotoliaz<br />

Safety 4.0<br />

ROBA ® -topstop ® —the certified<br />

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with brake monitoring<br />

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your reliable partner<br />

Mayr-Englisch.indd 1 13.01.<strong>2017</strong> 11:09:26<br />

WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/<strong>2017</strong>


WIN Eurasia: bringing integrated solutions<br />

for Turkey’s new generation manufacturing<br />

The Tüyap Fair and Convention Center in Istanbul will<br />

be a very busy place from 16 th to 19 th of March <strong>2017</strong>,<br />

as experts and professionals from the industrial sector<br />

will gather to attend the trade fair, WIN Eurasia. This<br />

international event focuses on latest technology in<br />

areas of automation, electro-tech, hydraulics,<br />

pneumatics and intralogistics.<br />

Istanbul is at the centre of an economic area known as ‘Eurasia’. The<br />

proximity to the Balkans and the rest of Europe as well as to the<br />

emerging markets in Central Asia, the Middle East, and North Africa<br />

creates unique business opportunities. The presence and consistent<br />

growth of numerous global firms consolidates its position as<br />

a dominant investment location and export platform. Turkey is the<br />

leading investor in the Caucasian and Central Asian Republics. Due<br />

to the strong cultural and historic ties, Turkey provides privileged<br />

access and a perfect base to develop business with these countries.<br />

It is an important market for global business to reach over one billion<br />

consumers. And as the economic capital of Turkey, Istanbul is<br />

NEWS AND MARKETS<br />

Author: Sushen Doshi, International Correspondent, World of Industries<br />

10 WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/<strong>2017</strong>


the natural location for an international industrial trade event like<br />

‘WIN Eurasia Automation’. This trade fair represents a real-time, interactive<br />

environment bringing together the supply and demand of<br />

Turkey’s manufacturing industry.<br />

Most influential industrial trade event in Eurasia<br />

Motion, drive and automation are the three keywords of the trade<br />

fair, to be held from 16th to 19th March in Istanbul, Turkey. A large<br />

number of Turkish as well as German along with other European<br />

and Eurasian companies will participate in the event, which is now<br />

to become the most important and influential industrial trade event<br />

in the region. With more and more number of European companies<br />

taking part in this event every year, it aims to increase the knowledge<br />

of latest trends and technology among Turkish operators who<br />

are always keen on innovation. The trade fair also encourages the<br />

gradual development of industrial and commercial cooperation between<br />

European companies and local Turkish companies. The fair<br />

will take place at the Tuyap Fair Convention and Congress Centre in<br />

Istanbul, where the exhibitors with high level of technical expertise<br />

from various sector will be able to show the best of technology and<br />

innovation to the visitors and industry professionals.<br />

As the most influential industrial trade event in the Eurasian<br />

region, WIN Eurasia is expected to attract approximately 70,000<br />

visitors and industry experts from all parts of Turkey. In Istanbul,<br />

visitors shall have an advantage of being able to attend four different<br />

trade shows, namely Otomasyon Eurasia, Electrotech Eurasia,<br />

Hydraulic & Pneumatic Eurasia and CeMAT Eurasia. This event<br />

provides complete solutions for manufacturing industry, focusing<br />

mainly on mechanical engineering, electrical engineering, industrial<br />

IT and digitalization of manufacturing. With more than 1500<br />

exhibitors showcasing their products and intelligent technologies<br />

within a display area of 30,000 m 2 , the show attracts exhibitors<br />

not only from Turkey but 25 other countries, including Germany,<br />

Italy, USA, China, UK, Taiwan, Korea, Japan, Sweden and<br />

the Netherlands. Exhibitors have the opportunity to introduce<br />

their innovations to visitors from Middle East, Europe, Africa, CIS<br />

countries besides Turkey, Bulgaria, Cameroon, India, Romania<br />

and Uzbekistan.<br />

Of all the marketing instruments, international trade fairs and especially<br />

WIN Eurasia, has the widest range of business functions.<br />

It serves as an opportunity to develop and the cultivate customer<br />

relations, it helps in identifying new local partners, distributors,<br />

suppliers and competent personnel from the relevant industry sector<br />

and it helps to increase the company’s market presence and<br />

position as a whole. With so much of technological developments<br />

taking place in Germany, particularly with increasing digitalization<br />

and whole Industry 4.0 revolution, this event serves as a test in the<br />

Eurasian market for new integrated and digitalized products and<br />

hence also functions as market research instrument for innovative<br />

companies. In order to reach the right target audience, WIN Eurasia<br />

provides exclusive sponsorship opportunities to widen the market<br />

and brand exposure of partner companies. This Trade fair serves to<br />

analyze the market situation and to prepare the ground for implementing<br />

market strategies, resulting in increasing the sales. For new<br />

companies in particular it is important to gain an overview of competitors,<br />

their performance, products and after-sales services. Often<br />

a visit to an international trade fair like WIN Eurasia Automation is<br />

all that is needed at an early stage of entering a market.<br />

4 different trade fairs under one roof<br />

WIN Eurasia Automation provides many solutions required for a<br />

factory under a single roof, from cables to fluid power technologies,<br />

drive technologies to software products, robotic arms to unmanned<br />

forklifts. With 4 different trade fairs under one roof, at WIN Eurasia<br />

Automation visitors will be able to see that, Istanbul is the pioneer<br />

for the Eurasian countries in terms of advanced manufacturing,<br />

digitalization and Industry 4.0 technology.<br />

Otomasyon Eurasia: The importance of globalization and productivity<br />

is an ever increasing and urgent demand in today’s world<br />

and that can only be supplied by Industrial Automation. Otomasyon<br />

Eurasia focuses on automation of factories, processes, operations and<br />

industrial buildings. Exhibitors will showcase their quality products<br />

and services, innovations, components and robotic applications of<br />

Industry 4.0. Product category at Otomasyon Eurasia includes: Assembly<br />

& handling systems, linear positioning systems, communication,<br />

networks, and field bus systems, control systems, embedded systems,<br />

Industrial building automation systems, industrial IT & software.<br />

Electrotech Eurasia: By 2023, Turkey is planning to increase its energy<br />

generation capacity from around 40,000 MW to nearly 100,000<br />

MW. To stimulate the level of investment from the private sector in<br />

energy generation capacity and distribution infrastructure, the Turkish<br />

government is making requisite investment to the tunes of tens of billions<br />

of dollars. These huge sums of investment testify to the enormous<br />

scale of Turkey’s commitment to expand and future-proof its energy<br />

sector. Companies wanting to participate in Turkey’s journey to a modern,<br />

diversified energy industry will find the perfect platform for presenting<br />

their technologies in Istanbul – at ‘Electrotech Eurasia’. Product<br />

category at the trade fair includes: Cables & equipment for electric<br />

power transmission, electric and electronic test and measuring equipment,<br />

electric motors & frequency inverters, motor drives, electric<br />

switchgear and equipment for electric power distribution, electronic<br />

and opto-electronic components, gears, mechanical drive systems,<br />

transformers, accumulators, uninterruptable power supplies and generators,<br />

grid management and power quality monitoring systems.<br />

Hydraulic & Pneumatic Eurasia: The hydraulic and pneumatic<br />

systems are among one of the most essential systems for engineers,<br />

thanks to the advantages and increasing number of product range<br />

they offer. The Hydraulic & Pneumatic Eurasia is getting ready to<br />

present outstanding innovations in this field for industry professionals.<br />

In addition to this, also on display will be the Compressed<br />

Air and Vacuum Technology, for the first time during WIN Eurasia<br />

Automation. Product category at ‘Hydraulic & Pneumatic Eurasia’<br />

includes: Hydraulic pumps, motors, gear pumps and gear motors,<br />

hydraulic variable speed drive units, hydraulic and pneumatic cylinders<br />

and actuators, control valves and pressure switches, pipes<br />

and hoses, filters for lubrication systems, compressors and compressed<br />

air preparation equipment.<br />

CeMAT Eurasia: Today, increasing needs of the industrial society<br />

lead to a huge demand for solutions in areas of transport, handling<br />

and storage. Exhibitors from around the world present innovative<br />

logistics systems, cranes and forklift trucks, packaging technologies,<br />

shelving systems, logistics IT and electronic in intralogistics<br />

sector at CeMAT Eurasia.<br />

Photographs: Hannover Fairs Turkey Fuarcilik A.S.<br />

www.win-automation.com<br />

WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/<strong>2017</strong>


Innovations you<br />

definitely shouldn’t miss<br />

at WIN EURASIA <strong>2017</strong><br />

CHOICE<br />

SMC’s new 4-axis step<br />

motor controller<br />

Drive controller in<br />

multi-axis drive system<br />

Low-maintenance<br />

drives for intralogistics<br />

PRODUCT NEWS<br />

Lower device costs, less programming<br />

time, less wiring work and lower space<br />

requirements – are the most important<br />

advantages of SMC’s new 4-axis step<br />

motor controllers JXC73 and JXC83.<br />

These make it possible to control up to<br />

4 electrical actuators for individual or<br />

multiple axes simultaneously. Programming<br />

is done on a PC using a USB<br />

2.0 interface. The new 4-axis step motor<br />

controllers from SMC can reach<br />

entered target positions in 2 ways: for<br />

linear interpolation, only the target<br />

position and the speed of an axis are<br />

required. From this information, the<br />

controllers calculate all of the values of<br />

the X, Y and Z axes that are necessary<br />

for three-dimensional movement.<br />

Alternatively, it is also possible to use<br />

circular movements. If you enter the<br />

coordinates of the target position, the<br />

rotation direction and the centre point,<br />

the controllers use circular interpolation<br />

to calculate all of the X and Y<br />

values required to run the circular path.<br />

www.smc.eu<br />

Under the name of SI6, Stober presents<br />

its latest drive controller in multi-axis<br />

drive system. With a width of only 45<br />

mm, the SI6 has compact design and<br />

requires extremely little space in the<br />

control cabinet. Even more decisive<br />

than the compactness is the omission<br />

of redundant supply units. The entire<br />

series of drive controllers is connected<br />

with a central supply module. The fuses<br />

and cabling for each individual axis are<br />

also distributed from here. The drive<br />

controllers are connected with each<br />

other via quick DC-link modules and<br />

by using double axis modules, unused<br />

power reserves of an axis can be used<br />

for other axes. In regards to acceleration,<br />

the SI6 in combination with the<br />

Stober’s synchronous servo motor,<br />

accelerates from 0 to 3 000 rpm in<br />

10 ms. For the safety concept, Stober<br />

counts on the STO (”Safe Torque Off”)<br />

function that can be controlled via<br />

terminals as well as via Fail Safe over<br />

EtherCAT (FSoE).<br />

www.stober.com<br />

Nord Drivesystems now offers standardized<br />

drive units in 3 versions for<br />

typical requirements in conveying<br />

applications. The line-up of LogiDrive<br />

systems enables a quicker selection of<br />

the drive for a given application. IE4<br />

synchronous motors with 1.1, 1.5, and<br />

2.2 kW rated power are combined with<br />

two-stage helical bevel gears for speed<br />

ranges of 0 to 565 rpm or 0 to 482 rpm.<br />

The transmission is continuously<br />

variable in the range from 1 to 500.<br />

Distributed frequency inverters for<br />

installation on the conveyor frame near<br />

the motor ensure accessibility. They<br />

feature a key switch for disconnection<br />

from the plant control system and a<br />

direction switch for local set-up.<br />

LogiDrives are designed for horizontal<br />

or inclined conveyors. The motors<br />

feature a high overload capability. The<br />

system has all components that can be<br />

serviced separately. This significantly<br />

reduces maintenance costs. Nord<br />

integrates all standard fieldbus and<br />

Industrial Ethernet interfaces directly in<br />

the AC drive.<br />

www.nord.com<br />

WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/<strong>2017</strong>


Automatic torque<br />

limiter<br />

In case of rough operating conditions,<br />

the drives particularly are encapsulated<br />

and therefore hard to access. But these<br />

machines require reliable overload<br />

protection. Mayr, the specialist in<br />

power and torque transmission has<br />

now developed a robust, disengaging<br />

torque limiter which can withstand<br />

Plug and play adapters<br />

for Simatic controllers<br />

For error-free connection of modules<br />

to the Simatic S7- 1500 controller,<br />

the company Phoenix Contact now<br />

offers controller-specific front<br />

adapters as part of the Interface<br />

system cabling range. Due to its<br />

plug-and-play concept, these adapters<br />

reduce the wiring effort to just a few<br />

steps. The adapters are easily swiveled<br />

into the digital or analog I/O cards<br />

and connected to the ‘Varioface’<br />

interface modules via pre-assembled<br />

system cables. They are available as<br />

Servo motors for highprecision<br />

applications<br />

With the new DSH1 series, where “H”<br />

stands for high precision, the drive<br />

specialist Baumüller has created<br />

another derivative in its servo motor<br />

range. The latest product impresses<br />

with a particularly low torque and thus<br />

achieves an extremely high control<br />

high loads and also automatically<br />

re-engage. In case of overload, if the<br />

torque exceeds the value set on the<br />

clutch, a patented disengagement<br />

mechanism of the EAS-reverse torque<br />

limiter, separates the input and output<br />

almost free of any residual torque with<br />

high accuracy.<br />

www.mayr.com<br />

‘passive’ components with various<br />

connection methods including knife<br />

disconnection.<br />

www. phoenixcontact.com<br />

accuracy. The DSH1 high precision<br />

servo motors were developed specifically<br />

for applications with the high<br />

precision e.g. in the handling and<br />

robotics field, including welding robots<br />

that produce components with a<br />

precise and high-quality welding seam.<br />

www.baumueller.de/en<br />

Servo drive even with a<br />

sine wave filter<br />

B&R has made further developments to<br />

the current control loop for its Acopos<br />

P3 servo drives. Users can now<br />

implement a sine wave filter without<br />

having a negetive effect on the drive<br />

control performance. These developments<br />

are aimed at providng the<br />

machines the advantages of a sine wave<br />

filter while the Acopos P3 retains its<br />

usual high performance. By converting<br />

the voltage signal from a square<br />

waveform to a largely sinusoidal one,<br />

sine wave filters help improve energy<br />

efficiency, reduce strain on the motor<br />

and decrease electromagnetic noise on<br />

the motor cable. They also smooth out<br />

the current curve, which reduces both<br />

acoustic noise and motor losses.<br />

www.br-automation.com<br />

OPC UA communication<br />

With a new extension of the OPC UA<br />

specification, which Beckhoff played a<br />

prominent role in developing, the<br />

publisher/subscriber principle is being<br />

introduced into the established and<br />

standardized OPC UA communication<br />

protocol. One particular advantage is<br />

the much simplified configuration<br />

resulting from direct integration into the<br />

TwinCAT 3 environment. Communication<br />

is initiated directly from the<br />

TwinCAT 3 runtime, creating a realtime-capable<br />

communication channel<br />

via OPC UA. Conventional client/server<br />

applications are decoupled from one<br />

another in publisher/subscriber-based<br />

data communication and no longer<br />

need to “know” each other.<br />

www.beckhoff.com<br />

Planetary gearboxes for<br />

better performance<br />

Neugart’s 2 latest products: a high<br />

precision gearbox with helical gearing<br />

and a right angled gearbox with<br />

compact output flange, offer solutions<br />

to the increasingly demanding<br />

challenges the customers face.<br />

Neugart’s ‘PSBN’ is an apt combination<br />

of a precision planetary gearbox and<br />

efficient bearing technology. The<br />

WPLFE, is the right angled gearbox<br />

with compact output flange, and is<br />

extremely helpful when things are tight.<br />

The WPLFE saves up to a third of the<br />

space and has up to 5 times higher<br />

torsional stiffness. Due to its standardized<br />

flange interface, it is simple to<br />

assemble.<br />

www.neugart.com/en-us<br />

WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/<strong>2017</strong>


FAG Generation C Deep<br />

Groove Ball Bearings<br />

Schaeffler strengthens its bearings<br />

business with a new production facility<br />

MACHINE ELEMENTS<br />

Schaeffler expands its business for rolling bearings<br />

with additional production capacities for FAG<br />

Generation C deep groove ball bearings. With an aim<br />

to make this product series even more attractive for<br />

its customers, the company has tweaked its<br />

manufacturing process and the logistics model, therefore<br />

providing an even better price-performance ratio.<br />

Schaeffler, the global integrated automotive and industrial supplier<br />

of high precision components and systems, is now further<br />

expanding its standard rolling bearing business. One aspect of the<br />

new growth strategy is on the FAG Generation C deep groove ball<br />

bearings. The company has made heavy investments in new production<br />

and logistics capacities as well as improved product characteristics.<br />

In the coming months, Schaeffler will put the production<br />

lines at its location in Yinchuan (China) gradually into operation.<br />

This will considerably increase the availability of FAG deep groove<br />

ball bearings. Overall, Schaeffler will double its capacities in this<br />

high volume product series of FAG deep groove ball bearings. In<br />

addition to the new location in China, Schaeffler’s production network<br />

comprises manufacturing plants in Caldas (Portugal), and<br />

Savli (India), where the deep groove ball bearings have been manufactured<br />

for several years.<br />

Strengthening the standard rolling bearing<br />

business<br />

Strengthening the standard production business is an important<br />

aspect of the ‘Core’ program, which was developed to reorganize<br />

Schaeffler’s Industrial division. “Our investments will help us satisfy<br />

the strong demand for standard deep groove ball bearings, especially<br />

from China and the Asia/Pacific region, and meet the specific<br />

requirements of this high volume business in an optimum way.<br />

Our products live up to the highest technical requirements and, at<br />

the same time, offer a cost-effective price-performance ratio” said<br />

Dr. Stefan Spindler, CEO Industrial at Schaeffler. Electric motors,<br />

household appliances, pumps and fans, power tools, and two-wheelers<br />

are the fields of application in which FAG Generation C deep<br />

groove ball bearings are most commonly used. In these fields, highquality<br />

products that meet high requirements, especially in terms of<br />

noise, friction, and sealing are required. “We looked at the product,<br />

production, and logistics, and developed solutions that fulfill the<br />

highest requirements on the market” said Thomas Kreis, project<br />

manager for the deep groove ball bearing, a high volume business<br />

at Schaeffler. “We have optimized our technically advanced product<br />

even further, developed the newest, highly-automated production<br />

processes, and come up with a specific logistics concept”.<br />

Bearings with low-friction and lower<br />

noise emissions<br />

Ever since FAG Generation C deep groove ball bearings were successfully<br />

introduced in 2008, their product characteristics have continu-<br />

WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/<strong>2017</strong>


02 1. Open bearing, 2. New gap seal on both sides (2Z),<br />

3. Lip seal on both sides (2HRS), 4. Lip seal on both sides (2ELS),<br />

5. Non-contact seal on both sides (2BRS)<br />

1 2 3 4 5<br />

01 The FAG Generation C Deep Groove Ball Bearings are<br />

characterized by particularly low frictional torque compared<br />

to other competent competitors in the market<br />

ously improved. In the context of technical characteristics, German<br />

companies have always led the way and have been considered as<br />

a benchmark. When it comes to technical characteristics of the<br />

bearings, Schaeffler is among those benchmark-setting companies,<br />

with its best features as minimum friction and noise. Focusing on<br />

continuously improving its products, the company has also recently<br />

developed two new sealing concepts. Reducing the grease loss and<br />

offering better protection against contamination extends the grease<br />

operating life, which makes the bearings more durable. The new<br />

‘Z’ sealing shield with its innovative labyrinth seal helps to reduce<br />

the egress of grease by 20 %, and prevents contamination by 30 %<br />

in comparison with conventional designs. It optionally comes with<br />

the patented ‘efficient lip seal’ (ELS), which provides maximum<br />

sealing action at low friction and is particularly suitable for changing<br />

axial loads, such as in wheel bearings in motorcycles. The increased<br />

sealing action can be attributed to the innovative lip shape that is<br />

perfectly matched to the ring recess, without any additional friction<br />

loss. Furthermore, the recesses that have been shifted to the interior<br />

of the bearing significantly improve its robustness during handling,<br />

for example during mounting. Moreover, non-contact BRS lip seals<br />

and HRS lip seals, which start at the inner ring, are available with<br />

increased sealing action in the standard program.<br />

The high-quality balls and the noise-optimized cage make the<br />

FAG Generation C deep groove ball bearings run with significantly<br />

less noise compared to conventional deep groove ball bearings. In<br />

addition, the optimized osculation reduces the friction. These characteristics<br />

can be attributed to numerous optimization adjustments<br />

to the raceway parameters in regards to the roundness, waviness,<br />

roughness, and restricted manufacturing tolerances. The friction<br />

which is reduced to an optimum level also means lower energy<br />

costs when in operation.<br />

New production process in China<br />

In Yinchuan, China, where Schaeffler’s new manufacturing plant is<br />

located, the German engineers have come up with a new production<br />

concept, which is fully geared towards the specific requirements of<br />

the high-volume business. This comprises an outstanding level of<br />

quality, availability, and cost-effectiveness. The highly-automated<br />

production lines are optimally designed for these types of bearings<br />

and any variations, so that setup operations and downtimes can be<br />

reduced to a minimum. Schaeffler puts a special focus on cleanliness<br />

in the production process. For this reason, various automatic washing<br />

stations that prevent even the slightest contamination of the<br />

products are integrated into the production process. At the same<br />

time, highly-skilled employees and several automatic inspection<br />

facilities ensure that the highest quality standards are met. Just like<br />

the plants in Caldas (Portugal) and Savli (India), where deep groove<br />

ball bearings have been produced for several years, the plant in<br />

Yinchuan has been certified according to the highest ISO quality<br />

standards for the industrial and automotive sectors.<br />

Improved supply chain ensures prompt delivery<br />

A stockholding and logistics concept that is coordinated worldwide<br />

ensures prompt and reliable delivery to our customers from the<br />

plants in China, Portugal, and India. For Europe, setting up a new<br />

European distribution center (EDC) is of central importance. Operations<br />

at the locations in Northern Europe (Sweden) and Southern<br />

Europe (Italy) have already started. The “Central” logistics center in<br />

Germany is currently under construction and will start supplying<br />

customers in Central, Western, and Eastern Europe as of next year.<br />

In total, Schaeffler has invested approximately 200 million Euros for<br />

expanding and modernizing its logistics network in Europe.<br />

Photographs: Schaeffler AG<br />

www.schaeffler.com<br />

About Schaeffler AG<br />

Schaeffler Group is a leading integrated automotive and<br />

industrial supplier. The company based in Herzogenaurach,<br />

Germany, generated revenues of approximately 13.3 billion<br />

Euros in 2016. With around 85,000 employees,<br />

Schaeffler is one of the world’s largest family owned<br />

companies. The technology group has approximately<br />

170 locations in more than 50 countries with a worldwide<br />

network of manufacturing plants, research and<br />

development centers, and sales subsidiaries. Schaeffler<br />

makes key contributions towards ‘mobility for tomorrow’<br />

with precision components and systems in engines,<br />

transmission and chassis applications as well as rolling<br />

and plain bearing solutions for industrial applications.<br />

WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/<strong>2017</strong>


Brake technology 4.0:<br />

safety brakes fit for all challenges<br />

Mayr power transmission’s approach towards<br />

integrating the industry 4.0 technology with the<br />

braking systems delivers utmost level of operational<br />

and functional safety, at the same time its brake<br />

monitoring modules increase the productivity through<br />

preventive fault detection and maintenance.<br />

The great challenge on the road to a “smart factory” is the digitalization<br />

of the information flow in production and the use of the<br />

collected data, not only to establish intelligent processes, for example<br />

in planning and manufacturing, but also for preventive maintenance.<br />

For safety brakes, this specifically means the realisation of<br />

comprehensive monitoring using sensors. Here, Industry 4.0 comes<br />

up against safety regulations and standards, which already demand<br />

the monitoring of safety brakes with sensors. In addition to the tried<br />

and tested brake control unit Roba-SBCplus, Mayr power transmission<br />

has now developed a new, intelligent generation of monitoring<br />

modules with the Roba-brake-checker and Roba-torqcontrol.<br />

Condition monitoring without sensors<br />

MACHINE ELEMENTS<br />

Mayr power transmission’s brake technology 4.0 with a<br />

advanced friction system and permanent brake monitoring,<br />

making the safety brakes fit for the challenges<br />

of the industry 4.0<br />

The Roba-brake-checker module monitors the tension path reserve<br />

as well as the switching condition without sensors and detects safety-critical<br />

changes in voltage, air gap and temperature. On reaching<br />

the tension path reserve, the Roba-brake-checker sends a warning<br />

signal indicating that the brake can continue to be operated for a<br />

certain amount of time. During this time, the machine owner can<br />

undertake targeted maintenance – in coordination with their work<br />

process. In addition, the module also simultaneously assumes<br />

the control of the brake and therefore replaces a rectifier. Switching<br />

condition monitoring and brake controls are thus combined<br />

in one device. As the Roba-brake-checker works without sensors,<br />

no microswitches or proximity sensors have to be attached to the<br />

exterior of the brake for switching condition monitoring, and the<br />

safety brakes can be employed in their basic design. Furthermore,<br />

additional cables and sealing of the switches and sensors become<br />

obsolete. This therefore ensures full design freedom. Unlike solutions<br />

with switches and sensors, which, due to their installation<br />

position on the brake are exposed to impacts and vibrations, monitoring<br />

with this module takes place from the control cabinet, i.e. in a<br />

protected environment. It works without mechanical contacts and<br />

is highly reliable and wear-free.<br />

For applications, which additionally require braking torque control<br />

as well as status monitoring, Mayr power transmissions provides<br />

the braking torque control module Roba-torqcontrol. It shares the<br />

features of the Roba-brake-checker and can also change the level<br />

of the braking torque in operation by influencing the current and<br />

voltage. As a result, devices and machines can be evenly and gently<br />

decelerated. The Roba-torqcontrol module permits the development<br />

of control loops and brakes movements intelligently – the<br />

ideal basis for its application in smart, interconnected machines.<br />

Even more safety and reliability<br />

One indispensable prerequisite for intelligent, automated processes<br />

with permanently monitored safety brakes is however a reliable<br />

brake technology, as it is of primary importance that brakes work<br />

safely and reliably, and deliver the required torque over the entire<br />

service lifetime. As a result, Mayr power transmission consistently<br />

takes basic safety principles into consideration for development<br />

and manufacture, as defined amongst other things in the standard<br />

EN 13849-2: The electromagnetic Roba-stop safety brakes work<br />

according to a fail-safe principle, and therefore they are closed in<br />

de-energised condition. The braking torque is generated through<br />

the force stored in the thrust springs. When the magnetic coil is<br />

WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/<strong>2017</strong>


01 The Roba-brake-checker<br />

module monitors the<br />

tension path reserve as well<br />

as the switching condition<br />

without sensors, and<br />

detects changes in<br />

safety- critical parameters<br />

like voltage,<br />

air gap and<br />

temperature<br />

02 Engineers at Mayr,<br />

have developed a new<br />

friction lining technology<br />

through which<br />

the brakes achieve<br />

improved torque consistency<br />

and a higher<br />

performance density<br />

energised, a magnetic field builds up, which attracts the armature<br />

disk against the force of the springs and thus releases the rotor<br />

with the friction linings. The brake is released. In addition to the<br />

application of a fail-safe principle, all brake components are reliably<br />

dimensioned and produced only from high-quality, known<br />

and proven materials. The screw thrust springs used are made from<br />

rust-proof steel and are tested for a lifetime strength of 10 million<br />

load alternations.<br />

Advanced friction lining technology<br />

One key factor for the manufacture of reliable brakes is the use of<br />

high-quality friction linings. Mayr’s highly-qualified engineers<br />

and technicians have developed a new friction lining technology<br />

based on extremely complex parameters. A friction lining is not<br />

100 % homogenous, but rather comprises of many components<br />

which react differently to external influences and environmental<br />

conditions. Engineers at Mayr, have managed to create a new friction<br />

lining technology through which the brakes achieve improved<br />

torque consistency and a higher performance density. Influences<br />

caused through environmental conditions, such as air humidity or<br />

temperature, have successfully been reduced, and this is further<br />

supported through the increasing use of enclosed brake designs,<br />

which are protected against external influences. Higher braking<br />

torques can be achieved with the new linings, this means, a smaller,<br />

lighter brake construction size can be selected for higher braking<br />

torques. This takes into account the general trend for machines and<br />

their components, for example engines, to be increasingly compact<br />

in construction, but with greater performance density.<br />

The company observes careful quality checks: This includes quality<br />

assurance measures during the design process and a comprehensive<br />

final inspection. Prior to delivery, all brakes are thoroughly<br />

tested on the test stands and function-relevant values are documented.<br />

An electronic database in which the measurement values<br />

are archived together with the corresponding serial numbers of the<br />

products ensures 100 % traceability.<br />

Controlling the brakes reliably<br />

In particular for applications which have to provide personal protection<br />

according to standards regarding functional safety, Mayr<br />

brakes are perfectly supplemented with the reliable brake control<br />

Roba-SBCplus. Together with the company Pilz, Mayr power transmission<br />

has developed this module which can control and monitor<br />

one or two Roba-stop safety brakes. The Roba-SBCplus module<br />

reliably interrupts the current in the magnetic coil on switching off<br />

the brake. For this purpose, the module operates using wear-free<br />

electronic semi-conductors, and as a result achieves practically unlimited<br />

switching frequency and switching reliability. In addition,<br />

a reliable integrated plausibility check is carried out through the<br />

evaluation of the release monitoring signals. The evaluations of<br />

the switching conditions and the return signal therefore enable<br />

reliable fault diagnosis. As a result, even creeping faults influencing<br />

the switching times, such as increasing wear for example, can be<br />

detected in good time. The reliable brake control Roba-SBCplus has<br />

been prototype-tested by the company TÜV Süd (Southern German<br />

Technical Inspectorate) and can be used up to the maximum<br />

Performance Level ‘PLe’ and Safety Integrity Level (SIL) 3.<br />

Brake technology 4.0<br />

Brake technology 4.0 by Mayr power transmission is a concept which<br />

begins with the smart selection of the products. In order for a user to<br />

find the best or most reliable brake for their purpose, they require a<br />

comprehensive selection of products with the solutions appropriate<br />

for them. The brake technology 4.0 approach means a technologically<br />

leading friction system which, together with safety principles,<br />

stands for reliable braking with extremely high performance density.<br />

Innovative monitoring solutions are firmly integrated into this<br />

system, and as a result, Mayr’s brakes and the corresponding monitoring<br />

modules are able to master all challenges. They ensure the<br />

utmost operational reliability and enable preventive maintenance<br />

in the increasingly compact, higher performance density machines.<br />

Photographs: lead shutterstock/solarseven, 01-02 Mayr power transmission<br />

www.mayr.com<br />

About Mayr Power Transmission<br />

The family-owned company, Mayr power transmission,<br />

founded in 1897, is a leading manufacturer of safety<br />

brakes, torque limiters and shaft couplings. These products<br />

are primarily used for electrically-powered machines<br />

in filling plants, machine tools, packaging and printing<br />

machines as well as in elevators, wind power plants<br />

and in stage technology. Approximately 600 employees<br />

currently work in the Allgäu-based Headquarters<br />

in Mauerstetten, Germany. Mayr power transmission<br />

has over 1000 employees worldwide. The company is<br />

globally established with plants in Poland and China,<br />

sales subsidiaries in the USA, France, Great Britain, Italy,<br />

Singapore and Switzerland and with representatives in<br />

36 other countries.<br />

WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/<strong>2017</strong>


New generation thermoplastic<br />

polyurethane<br />

Within the scope of the Kastas R&D Department<br />

Material Development Division, raw material and<br />

product development activities are two of the most<br />

important factors that affect the performance of the<br />

seal in line, with a design that makes a difference in<br />

different applications. With the new PU8502 material,<br />

Kastas now combines longer service life and higher<br />

performance in pneumatic cylinders, while increasing<br />

the usage rate of thermoplastic polyurethane in<br />

pneumatic systems due to its increased compression<br />

set property.<br />

Polyurethane material is commonly used in fluid power systems<br />

due to its advantages, such as wear resistance, tensile strength<br />

and tear resistance, which enables durable solutions in both<br />

hydraulic and pneumatic systems. Standard polyurethane materials<br />

have superior mechanical properties compared with elastomers.<br />

However, they also have disadvantages, such as low<br />

resistance to different environmental conditions, in particular to<br />

fireproof hydraulic fluids and air, and high compression set value<br />

at low hardness.<br />

One of the most important indicators affecting the performance<br />

of the sealing element in pneumatic systems is the compression set<br />

property. Low compression set value is critical in terms of perfor-<br />

Life test performance<br />

For testing PU8502 at Kastas Test Center, a product named<br />

K59 Pneumatic Piston Seal was produced. The K59 Piston<br />

Seal is made of special PU8502 material and provided<br />

excellent leakage protection and performance through<br />

a 30 000 000- cycle-test. According to results of the test<br />

under 90 cycle/min speed (approximately 0.6 m/s) and over<br />

8 months, it can maintain continuous movement even under<br />

0.13 bars. Examination of seals shows that all abrasion is at<br />

acceptable limits and seals continue to function smoothly.<br />

mance and service life of the seal. Kastas developed a new polyurethane<br />

material, PU8502, for increasing expectations for high<br />

performance for the pneumatic systems and applications requiring<br />

material usage with low hardness. PU8502 provides better compression<br />

set values and resistance to external environmental conditions<br />

compared to standard polyurethane materials, without compromising<br />

its other superior mechanical properties.<br />

Standard polyurethane materials used in pneumatic systems in<br />

the market show high compression set values. PU8502, specially<br />

developed for pneumatic applications, has considerable advantages<br />

compared to standard PU materials with low compression<br />

set values. It also provides long service life<br />

because of its abrasion loss property<br />

and shows high performance at high<br />

temperatures because of its high<br />

Vicat Softening value (153 °C).<br />

MACHINE ELEMENTS


Comparison K50 vs. K59 Pneumatic Seals (PU8502)<br />

K50 Pneumatic piston seal<br />

The K50 is a single acting pneumatic piston seal designed<br />

to have an asymmetrical profile with a shorter and thinner<br />

dynamic lip. Additional advantages of K50 include:<br />

n secure seating due to the longer and thicker static sealing lip<br />

n low friction and good sealing performance due to the seal<br />

geometry<br />

K59 Pneumatic piston seal<br />

K59 ensures easy installation and excellent sealing performance<br />

in a wide range of pneumatic applications. Additional<br />

advantages of K59 include:<br />

n low friction and good sealing performance due to the seal<br />

geometry<br />

n high sealing effect with cushioning applications<br />

0 bar 6 bar 0 bar 6 bar<br />

01 FEA simulation image of K50 under 6 bar pressure<br />

02 FEA simulation<br />

image of K59 under<br />

6 bar pressure<br />

Sealing solutions for hydraulic breakers<br />

Contaminated work environments, constant high speed para meters<br />

and their complex structures make hydraulic breakers a very challenging<br />

application in the construction field. Kastas produces the most<br />

reliable sealing solutions for hydraulic breakers, drillers and crushers<br />

by using the most advanced technology to meet application demands.<br />

Diaphragms<br />

A hydraulic system requires a diaphragm to ensure the continuity<br />

of pressure within the accumulator for smooth operation.<br />

Therefore, the operating performance is directly proportional<br />

with the diaphragm work in accordance with the system used in<br />

About Kastas<br />

With over 500 employees, Kastas is a leading manufacturer<br />

and supplier of sealing technologies. Kastas is<br />

based in Turkey and produces advanced sealing elements<br />

for fluid power and various specific applications. Through<br />

the headquarters in Izmir, Turkey, the European Distribution<br />

Center in Germany as well as sales and service<br />

partners all around the world, the company serves its<br />

customers with high quality, reliable products.<br />

„PU8502 has high hydrolysis resistance,<br />

low compression set value and long service life compared<br />

to standard polyurethanes“<br />

Nihat Öziri, Technical Manager<br />

the accumulator. The diaphragms made out of PU8502 offer long<br />

service life in diverse operating conditions and pressures and<br />

even at high sliding speed. Polyurethane material offers product<br />

advantages such as high coefficient of elongation, high durability<br />

and flexibility. These advantages do not exist in diaphragms<br />

made of elastomeric material. Unlike standard polyurethane,<br />

PU8502 has the ability to provide quick response to shock pressure<br />

changes needed on the accumulator diaphragms by offering<br />

better hydrolysis resistance, compression set and long service life.<br />

Therefore, Kastas offers products distinct from its competitors<br />

through PU8502 polyurethane material.<br />

PU8502<br />

WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/<strong>2017</strong>


TR012015 Pneumatic sealing<br />

elements test rig<br />

Kastas Sealing Technologies contains<br />

the Pneumatic Sealing Element Test Rig<br />

(TR012015) with latest technology for<br />

performing tests such as internal leakage<br />

test, minimum continuous movement<br />

pressure test, life test, guide ring/<br />

bushing life test. As a part of its work on<br />

the Technical Committee of ISO, Kastas<br />

has developed the test rig in accordance<br />

with the ISO 19973-3 standards. The<br />

pneumatic test rigs developed in-house<br />

are redesigned in accordance with ISO<br />

standards.<br />

www.kastas.com<br />

Pneumatic sealing<br />

element test types<br />

n Inner leakage test: 6 bar pressure<br />

is locked between the air<br />

port of the cylinder and pressure<br />

transmitter. Decrease of<br />

pressure depends on the time,<br />

which is monitored.<br />

n Minimum continuous movement<br />

pressure test: The pressure<br />

in the hose connected<br />

to the cylinder’s air port is<br />

gradually increased. The pressure<br />

that the cylinder moves is<br />

determined as the minimum<br />

continuous movement pressure.<br />

MACHINE ELEMENTS<br />

n Life test: Various types of<br />

pneumatic cylinders are<br />

installed to the test rig. When<br />

the internal leakage test value<br />

exceeds the limit set by ISO<br />

19973, testing is finished.<br />

Operating life of the seals is<br />

determined according to these<br />

values.<br />

n Guide ring / bushing life test:<br />

Guide rings and bushings on<br />

the cushioning cylinders are<br />

periodically measured. Subject<br />

to wear over the specified limit,<br />

samples are changed, allowing<br />

the service life of the samples<br />

to be determined.<br />

WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/<strong>2017</strong>


Product News<br />

Compact and highly dynamic small servo<br />

motors with an integrated screw<br />

Wittenstein cyber motor GmbH launches a new series of small<br />

servo motors with an integrated screw for use when the machine<br />

has to be installed in a confined space. The servo motor, spindle<br />

drive, linear guide rail and encoder system form a closed, highly<br />

integrated and ready-to-mount unit. The series is offered in 4 sizes,<br />

each with 2 different screw pitches and two stroke lengths for short<br />

or long-stroke applications. Each of the four sizes achieves<br />

excellent acceleration values, cycle rates and machine throughputs<br />

in a very small space. This is due to the compact design, which<br />

results in much lower mass inertia than is possible, for instance, if<br />

the screw is simply attached to the servo motor. The new small<br />

servo motors with an integrated screw can be configured with<br />

simco drive servo regulators to form high-performance small servo<br />

axes. Multiple connection options are available for these solutions,<br />

which can be integrated<br />

in a higher-level<br />

controller via Canopen,<br />

EtherCAT,<br />

Profinet RT/IRT or<br />

EtherNet/IP.<br />

www.wittenstein.de/en-en<br />

New fan-cooled brushless servo for<br />

increased machine productivity<br />

Moog Industrial Group, a division of Moog Inc. has released a new<br />

series of fan-cooled brushless servo motors. The design offers<br />

additional torque to accelerate and decelerate the load, resulting in<br />

30 % more torque than a naturally-cooled motor. This benefit,<br />

coupled with low rotor inertias, enables higher power density.<br />

Furthermore, the improvement in operating conditions increases<br />

the motor’s robustness by extending the life of the windings. The<br />

new motors are available in size 5 and 6 Compact Dynamic (CD<br />

Series) and Maximum Dynamic brushless servo motors (MD<br />

Series). In addition to the CD and MD Series, fan cooling can also<br />

be added to existing naturally-cooled motors using a separately<br />

mounted fan kit.<br />

Along with the fan-cooled brushless servo<br />

motors, the company also launched its<br />

“Two-You” program. This program<br />

offers Moog’s customers a highly<br />

flexible supply chain, so they can<br />

select among the most commonly<br />

used compact servo drives.<br />

www.moog.com<br />

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Find suitable bearings and calculate their service life online: igus.eu/iglidur-expert<br />

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Whether bronze or sintered bearings, coated metal bushings or needle roller bearings:<br />

Reduce costs and improve machine performance with iglidur ®<br />

polymer bearings. Lubrication-free, lightweight<br />

and wear-resistant for your moving application. Find out all you need to know about replacement of your<br />

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World Maritime Week, Bilbao – Booth B-34 | | abto, London<br />

IGUS-Englisch.indd 1 10.02.<strong>2017</strong> 07:35:16<br />

WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/<strong>2017</strong>


Success<br />

in the Himalayas<br />

Climbing the tops of Himalayan Mountains is a thrilling experience. The elevation at Mount<br />

Everest’s base camp is about 5,200 meters. The oxygen content is just half what it is at sea level,<br />

making even breathing difficult. If you plan on lingering here, you should go through high-altitude<br />

training ahead of time. Otherwise, you face a serious risk of coming down with ‘altitude sickness’.<br />

You would expect to run into mountain climbers in this part of the world, but you’ll be surprised to<br />

meet the employees of Krones, a leading maker of filling and packaging technology, who occasionally<br />

spend time at these high altitudes.<br />

MACHINE ELEMENTS<br />

few years ago, specialists from the company headquartered in<br />

A Neutraubling, Germany, installed a complete beverage bottling<br />

facility in a high mountain valley not far from Llasa, Tibet’s capital.<br />

PET bottles are manufactured there, filled with mineral water from<br />

glacial springs, labeled and shipped throughout the world. Today,<br />

Krones employees handle service and system maintenance.<br />

“The stretch-blow-molding machine used to produce the PET<br />

bottles at the facility is the highest in the world,” said Danuta Kessler-Zieroth,<br />

Head of Press Relations at Krones AG. “The extremely<br />

low atmospheric pressure up there is not just hard on people, it was<br />

a challenge for our development work as well.” For example, in the<br />

Himalayan highlands, a machine designed for pressures at sea level<br />

cannot deliver enough pressure to completely blow-mold PET<br />

bottles and press them into the mold. Moreover, the facility’s touchscreen<br />

operating panels were actually designed for altitudes up to<br />

3,000 meters. Another issue is the bottle design that Krones developed<br />

in concert with the beverage producer. The mineral water<br />

bottles are intended for export, so they should not be deformed<br />

when shipped to lower-elevation regions of the world. That means<br />

the containers must be configured to compensate for the forces<br />

resulting from pressure differences with defined deformation.<br />

Becoming a global company through innovation<br />

“Our innovation potential today is evidenced by our more than<br />

3,730 registered patents and utility models,” explains Kessler-Zieroth.<br />

Since its foundation in 1951, Krones has developed far beyond<br />

classic machine and facility design. “We are able to implement<br />

projects like the one in Tibet because Krones offers the complete<br />

process chain for beverage production from a single source. We can<br />

build a complete turnkey factory on a green field,” she says.<br />

This starts with the planning of the manufacturing spaces and<br />

supply areas and extends to actual equipment production, related<br />

processing technology and in-house logistics, all the way to IT<br />

services spanning the entire factory. For example, the hardware and<br />

software solutions for data processing cover the operation of the<br />

WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/<strong>2017</strong>


equipment, diagnostics to check technologies and monitor processes,<br />

and intralogistics with inventory management, material<br />

flow controls, and yard management. And, of course, the maintenance<br />

and modernization of the facilities are part of the service<br />

package.<br />

About Freudenberg Sealing<br />

Technologies<br />

Freudenberg is one the leading companies in the world in<br />

the areas of sealing technology. The company has sales<br />

revenues of over € 2 billion and employees more than<br />

15,000 people. Its products and services are used in wide<br />

range of applications in areas of automotive, civil<br />

aviation, mechanical engineering, food and pharmaceuticals,<br />

agriculture and construction machinery.<br />

High quality requirements<br />

The food industry also has its own, extremely stringent quality<br />

requirements for production facilities and processes. For example,<br />

the various parameters such as mixing processes, filling and packaging<br />

must be monitored during the entire operation. Facilities and<br />

machinery must meet strict hygienic standards and may not<br />

discharge impurities that could reach the foodstuff at any point in<br />

their lifetimes. “At our company, quality begins right at the machinery’s<br />

development to guarantee maximum process reliability,” says<br />

Kessler-Zieroth. An important cornerstone is Krones’ vertical integration,<br />

which is unusually extensive compared to the competition.<br />

For example, its Evoguard subsidiary was established in 2011 for the<br />

development, design and production of valves and pumps. Details<br />

of safe manufacturing operation are considered alongside the<br />

requirements of hygienic design.<br />

Close cooperation with Freudenberg<br />

Seals are the most important aspect of any valve. Early in the design<br />

phase, the Evoguard development team works closely with experts<br />

from Freudenberg Sealing Technologies to identify the optimal<br />

design in combination with the right material for the particular seal.<br />

At the same time, Freudenberg supports Evoguard in both the layout<br />

and design of the seals and with material-related know-how.<br />

Freudenberg Sealing Technologies’ current product portfolio has<br />

about 1,800 “active” rubber compounds that have been ordered at<br />

least once a year, the largest portion of them as exclusive special<br />

mixtures produced in-house. Evoguard also makes use of Freudenberg’s<br />

materials expertise for damage analyses in the event of valve<br />

and pump failures in customer operation. Freudenberg’s experts<br />

then investigate the reason for the failure and propose solutions to<br />

the problem.<br />

The two companies’ successful partnership dates back to Evoguard’s<br />

very beginnings. Its first valve product portfolio, introduced<br />

in 2011, was equipped with radial shaft and butterfly-valve seals<br />

from Freudenberg Sealing Technologies. “At the time, we went all<br />

out to develop the seals so we could display our production-ready<br />

valve lineup on schedule at trade fairs and exhibitions,” recalls Willi<br />

Wiedenmann, Sales and Product Management at Evoguard.<br />

Another result of this close cooperation is the use of seals made of<br />

Fluoroprene XP instead of the usual EPDM in Evoguard valves. This<br />

premium material is recommended for high stability, its suitability<br />

for hot-steam sterilization and its low risk of flavor transfer from one<br />

food product to the next. Among other products, Freudenberg Sealing<br />

Technologies supplies Krones’ Evoguard subsidiary with shaft<br />

seals, seat gaskets and an entire series of O-rings and butterfly-valve<br />

seals of the highest quality.<br />

Photographs: Freudenberg sealing technologies<br />

www.fst.com<br />

WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/<strong>2017</strong>


Product News<br />

Menzel constructs slip ring motor for<br />

hazardous area<br />

In 2015, a Senegalese cement manufacturer had to install a motor<br />

that provides the plant with fine coal dust to meet the plant’s primary<br />

energy needs. While coal dust offers good caloric properties, the<br />

particles of dust left on slip rings and brushes may cause sparks and<br />

lead to an explosion. The motor therefore required a design that<br />

would reliably prevent dust ingress during all operating stages. To<br />

meet these challenging requirements, Menzel Elektromotoren, the<br />

German manufacturer of custom motors engineered a rugged unit<br />

with IP65 ingress protection.<br />

Since a squirrel-cage<br />

motor requires a high<br />

starting current and has a<br />

lower starting torque, a slip<br />

ring motor was chosen. The<br />

motor construction<br />

featuring special terminal<br />

boxes for the stator and<br />

rotor, a non-magnetic cable<br />

entry plate, and hazardous<br />

area terminal clamps for<br />

the auxiliary terminal boxes was then devised for the application. A<br />

slightly larger motor housing ensures the operating temperature<br />

does not exceed +125 °C. Thanks to these measures, the replacement<br />

motor has received a ‘Ex II 3D Ex tc IIIB T125 °C Dc’ explosion<br />

protection marking.<br />

A new mechatronic drive designed for<br />

horizontal material handling<br />

The m350 mechatronic drive from<br />

Lenze, is an integrated solution<br />

consisting of gearbox, motor,<br />

electronics and software. Yet<br />

Lenze does not just combine the<br />

motor and gearbox, but runs the<br />

two elements together so that the<br />

gear ratio slips far into the motor<br />

housing. The situation is similar for the electronics and software,<br />

with which the fixed motor speed can be easily adapted via the<br />

user-friendly smartphone app with a NFC connection. So, with the<br />

same torque, speeds of 42 to 216 rpm can be freely selected at the<br />

gearbox output – thus considerably simplifying the design. The<br />

m350 is available in three sizes with torques of 25, 50 and 75 Nm.<br />

With just two levels, Basic and Advanced (including brake), no<br />

more than six versions cover a wide spectrum in horizontal<br />

material handling. This drive package is more energy-efficient than<br />

all drives customarily deployed in horizontal material handling. In<br />

addition, integrated ramp functions and brake control options<br />

ensure that conveyed goods are transported smoothly and thus<br />

gently without jerks. Accessories allow the drive unit to be fitted<br />

with an additional torque support, thus customizing it to the<br />

respective machine requirements.<br />

www.lenze.com<br />

PRODUCT NEWS<br />

www.menzel-elektromotoren.com<br />

Compact and integrated motion control<br />

drive with Bonfiglioli’s iBMD<br />

Bonfiglioli, the drive systems specialist with a strong international<br />

presence, has launched its latest product, the iBMD, an integrated<br />

drive with a broad torque range from 2.7 to 30 Nm. It has all the<br />

features of a highly dynamic servo motor as well as those of a<br />

modern drive controller. The iBMD can be used as a stand-alone<br />

drive or as part of a control system. Motion control functions such<br />

as positioning, cam profile, electronic gears and an interpolated<br />

mode are just as intrinsic as the open communication via CANopen<br />

and EtherCAT. Additional features include a broad range of<br />

digital and analog I/O. Integrated in a casing, it significantly<br />

reduces space requirements in the control cabinet and saves<br />

cabling costs. Moreover, the drive can also be combined with the<br />

precision planetary gears by Bonfiglioli. The functional features of<br />

the drive in combination with the highly compact design are<br />

especially useful for packaging, printing and labelling,<br />

as well as for the automation of material<br />

handling system. The dynamic and highly<br />

precise drives are also very popular for<br />

filling systems and machines for<br />

manufacturing in the electronics<br />

industry.<br />

www.bonfiglioli.com<br />

Next generation servo motors from<br />

Kollmorgen<br />

A new generation of Kollmorgen’s AKM series of servo motors is<br />

capable of even more - with its increased power density upto 30 %.<br />

The increased power density with an improved torque-to-speed<br />

ratio is primarily the result of the optimized winding technology.<br />

Kollmorgen has thereby managed to reduce the<br />

copper losses for the windings. This provides<br />

improved energy efficiency as<br />

well as room for more performance<br />

with the same installed<br />

size. The AKM2G, new generation<br />

of synchronous servo<br />

motors will be launched in this<br />

year and will initially feature 6<br />

sizes with performance levels<br />

between 0.3 and 10 kW. The AKM2G<br />

motors can be fitted with different feedback systems and are<br />

primarily provided with single-cable connection technology. As a<br />

result of the modular structure of the range, Kollmorgen is better<br />

able to adapt the 2nd generation motors to the requirements of a<br />

specific application in parallel with series production. Machine<br />

builders are thereby able to use drives that fit without compromise<br />

– especially in combination with the servos from Kollmorgen’s<br />

AKD2G range.<br />

www.kollmorgen.com<br />

WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/<strong>2017</strong>


Tooth Chain<br />

Inverted Tooth<br />

Chain Drives<br />

Made in Germany<br />

Rainer Albes, General Manager Renold Tooth Chain, is<br />

still fascinated even today by the versatility and<br />

added customer value of “Made in Gronau” inverted<br />

tooth chains.<br />

Modern machinery production requires drives that<br />

offer a high degree of economic efficiency and<br />

reliability. Inverted tooth chain drives have unmatched<br />

characteristics to meet these needs. When it comes to<br />

precise, fast, and silent drives, Renold inverted tooth<br />

chains are the ideal choice – even for the high<br />

demands of the automotive industry. The advantages:<br />

long service life, simple assembly, high speeds,<br />

extremely quiet running, and high torques.<br />

Renold GmbH<br />

Zur Dessel 14<br />

31028 Gronau (Leine), Germany<br />

Phone +49 5182 5870<br />

toothchain@renold.com<br />

www.renoldtoothchain.com


MDA showcases digitalization with<br />

predictive maintenance applications<br />

Hannover Messe, the world’s leading trade fair for<br />

industrial technology will be staged from 24 th to 28 th<br />

April <strong>2017</strong> in Hannover, Germany. With its core focus<br />

on “Integrated Industry,” it is the world’s leading<br />

exhibition for the digitalization of production,<br />

maintenance and energy systems<br />

In the world of industries, predictive maintenance is currently<br />

a hot topic and will play a central role at the Motion Drive and<br />

Automation forum at Hannover Messe <strong>2017</strong>. Operators of machinery<br />

and vehicles do not want to wait until a vital component fails,<br />

but they also do not want to replace it ahead of time. And now they<br />

no longer have to, because leading suppliers of power transmission<br />

and fluid technology have developed systems that permit continuous<br />

monitoring of key components such as roller bearings, electric<br />

motors, gears, hydraulic pumps, and compressed fluids.<br />

“Predictive Maintenance is an important part of networked production<br />

and Industrie 4.0. Intelligent components use integrated<br />

sensors to capture and evaluate data in real time. Predictive Maintenance<br />

is a terrific strategy to effectively harness the interaction<br />

between mechanical engineering and IT,” says Peter Synek, Deputy<br />

Managing Director, Fluid Power Division, German Mechanical<br />

Engineering Industry Association (VDMA). This is actually nothing<br />

new: “condition monitoring” was already a main topic at past MDA<br />

shows. What is new, however, is the information that can now be<br />

extracted from condition monitoring systems. With the aid of intelligent<br />

software, the data acquired in real time allows the operator<br />

to carry out servicing or replace worn components at precisely the<br />

right time – with no fixed service interval, and before the part in<br />

question fails.<br />

How Predictive Maintenance works in reality<br />

Roller bearings are a good example of this. The reference variables<br />

in this case are vibration, temperature and speed (revolutions per<br />

minute). These are continuously monitored and analyzed so that<br />

any irregularities can be detected and their effect on the life of the<br />

bearing calculated. At the same time, any bearing that is running<br />

hot can be identified by temperature monitoring. For example,<br />

Schaeffler offers such a service for roller bearings used in wind<br />

turbines and rail vehicles. Schaeffler’s dedicated cloud analyzes the<br />

collected data and generates the results in plain-text format. So the<br />

user or operator no longer needs to have any expertise in analyzing<br />

sensor data, as is the case with condition monitoring. Instead, the<br />

system itself performs the analysis and the condition of the bearing<br />

can be checked from anywhere in the world via the Internet; similarly,<br />

the remaining life of the bearing can be calculated on the basis<br />

of the actual load spectra.<br />

NEWS AND MARKETS<br />

WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/<strong>2017</strong>


Demand for this kind of “micro-servicing” via data-based predictive<br />

maintenance is currently very high, and not only in electromechanical<br />

power transmission. Predictive maintenance systems<br />

for hydraulic drives, for instance, can incorporate particle counters.<br />

Parker will present such a system at MDA – not only at its own<br />

exhibit, but also in the VDMA Forum in Hall 19. Stefan Nilgen from<br />

Parker Hannifin tells us: “With our ‘Total System Health Management’,<br />

we can acquire data from every part of the system, including<br />

peripherals, then analyze it and use it to take the necessary<br />

measures. That way, we can keep an eye on the overall productivity<br />

as well as the total cost of ownership of complex systems such as<br />

hydraulic installations or fluid power transmissions, and can carry<br />

out whatever preventive maintenance might be needed. So ideally,<br />

any corrective measures will become unnecessary, or at least foreseeable,<br />

so that we can plan ahead and avoid the unexpected breakdowns<br />

of the past. For the user, that translates into cost savings,<br />

thanks to a longer service life and higher productivity.”<br />

The predictive maintenance tool developed by Bosch Rexroth<br />

is called OdiN, and it will also be on display at this year’s Hannover<br />

Messe. The acronym stands for “Online Diagnostic Network”,<br />

along with sensor technology and cloud-based applications it also<br />

employs the methodology of machine learning to perform preventive<br />

maintenance – with a high degree of precision. Tapio Torikka<br />

is the man responsible for developing the system: “A human expert<br />

monitoring the installation continuously by conventional means<br />

will detect a fault with 43 % probability. Our system has a fault<br />

detection rate of 99 %.”<br />

Gaining additional momentum<br />

Predictive maintenance has gained additional momentum as a<br />

result of Big Data and other themes associated with Industry 4.0.<br />

It is becoming progressively easier to collect and process relevant<br />

data for servicing and maintenance. This trend is driven in part<br />

by cross-sector collaboration, such as that between manufacturers<br />

of sensors and manufacturers of power transmission systems.<br />

Aventics and sensor specialist IFM are planning to work together<br />

in future to monitor and analyze operating data – e.g. for pneumatic<br />

cylinders – entirely online, and independently of machine<br />

control functions. This is a classic predictive maintenance scenario.<br />

Schaeffler and IBM have entered into a strategic partnership<br />

with the aim of continuously monitoring power transmission<br />

systems in critical applications such as wind turbines and railway<br />

trains using machine learning to optimize performance based on<br />

the data acquired.<br />

Systems of this kind are discussed under the collective heading<br />

of “predictive analytics”. Visitors to MDA forum with a special interest<br />

in this development would be well advised to take a close look<br />

at 7 other trade shows taking place in parallel, namely Industrial<br />

Automation, Digital Factory, Energy, ComVac, Industrial Supply<br />

and Research & Technology. Here, leading companies from all over<br />

the world will be presenting their ideas and visions for Industry 4.0<br />

and the Industrial Internet of Things, including the whole area of<br />

preventive maintenance.<br />

Photographs: Deutsche Messe AG<br />

www.hannovermesse.de<br />

Peter Synek, Deputy Managing Director, Fluid Power Division, German<br />

Mechanical Engineering Industry Association (VDMA)<br />

WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/<strong>2017</strong>


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