WORLD OF INDUSTRIES 01/2019

01/2019
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EDITORIAL
Editorial Directors:
Dirk Schaar, Email: d.schaar@vfmz.de
Winfried Bauer, Email: w.bauer@vfmz.de
The golden years seem
to be over for now
Dear readers,
For many years, Turkey was known to be one of the up-and-coming
economic regions. The country on the shores of the Bosporus was undoubtedly
regarded as one of the future growth markets. This positive
rating was certainly substantiated by the fact that the gross domestic
product of Turkey really only moved in one direction over the last few
decades. However, this has all changed now. Following the crash of the
Turkish lira in the summer of 2018, many experts predicted that Turkey
would have a severe economic crisis – yet the national currency is gradually
recovering, inflation is decreasing and the government has declared
that all of its problems are over. Although skeptics in Ankara believe this to
be a political flash in the pan. Many everyday consumers are having to
tighten their belts. Finance minister Berat Albayrak, who is also one of the
son-in-laws of President Recep Tayyip Erdogan, is trying to combat the
rate of inflation by reducing the tax on furniture, household appliances,
and new cars and is also appealing to Turkish companies to reduce their
prices by ten percent. A significant increase to the interest rate by the
central bank has also helped. According to Albayrak and Erdogan, the
government has thus been able to combat the attacks on the Turkish
economy. In Ankara, the difficulties the country is facing are not seen as a
consequence of any of their own mistakes but as a conspiracy against
Turkey. The USA has particularly been pinpointed as one of the offenders
in recent months. However, the crisis is not going to simply disappear.
Recent favorable developments of the inflation rate
and exchange rate of the Turkish lira could give
false hope.
Right in the middle of this difficult situation,
WIN Eurasia will be held in Istanbul between
March 14 th and 17 th . More information about
the trade fair is provided on pages 8 and 9.
Traditionally, mechanical engineers,
automation and intralogistics
specialists from all around the
world meet at WIN Eurasia to
discuss new technologies,
products, and systems. We can
only hope that these discussions
will have a positive impact on
the Eurasia region.
Winfried Bauer,
Editorial Director
World of Industries
Editorial board:
Peter Becker (Editor-in-chief),
Email: p.becker@vfmz.de
Nicole Steinicke (Editor-in-chief),
Email: s.steinicke@vfmz.de
Manfred Weber, Email: m.weber@vfmz.de
Svenja Stenner, Email: s.stenner@vfmz.de
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Svenja Stenner, Petra Weidt
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Winfried Bauer
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Internet:
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WORLD OF INDUSTRIES 1/2019 3

TABLE OF CONTENT
14
10
20 24
NEWS AND MARKETS
03 EDITORIAL
06 NEWS AND MARKETS
08 THE ‘MUST GO’ INDUSTRIAL TRADE
FAIRS FOR 2019
10 TURKEY WILL BOUNCE BACK, AS IT’S
INDUSTRY’S FUNDAMENTALS ARE
STILL ALIVE AND STRONG
AUTOMATION
18 LASER MODULES PROVIDE
IMPROVED EFFICIENCY FOR
THIN-FILM SOLAR MODULES
20 TAKING A LOOK INTO OUTER SPACE
21 HOW TO CHECK PRESENCE AND
POSITION SIMULTANEOUSLY
22 PRODUCT NEWS
MOTION AND DRIVES
12 DRIVING THE INNOVATION
OF ELECTRIC MOTORS FORWARD
WITH HIGHLY EFFICIENT TEST BENCH
14 ELECTRIC DRIVE SYSTEMS FOR
OFFSHORE CRANES
16 PRODUCT NEWS
LOGISTICS
24 FULLY SERVICED IN EUROPE
4 WORLD OF INDUSTRIES 1/2019

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W RLDWIDE NEWS
One of the world’s largest machine tool
trade show is creating a new record
Taipei International Machine Tool Show, known as Timtos, is jointly
organized by TAITRA and TAMI and will be opened in Taipei on
March 4-9, 2019. 1,230 exhibitors from 26 countries to use 7,000
booths, creating a new record high in the show’s history, and
making it the world’s 3 rd largest machine tool trade show. In
response to the development trends of global industry, Timtos will
focus on “Industry 4.0 & Smart Manufacturing” and “AI
Technologies”. Visitors will be able to see a number of digitalized
solutions that integrate machine tools, industrial robots, sensors, IoT,
machine learning and more. You too should not miss this event.
www.timtos.com.tw
Head Lyko Group AB invests in
SSI Schaefer`s warehouse solution
NEWS AND MARKETS
The Swedish company Lyko Group AB, a leading Omni
channel specialist for haircare and beauty products in
the Northern countries, trusts the general contractor
SSI Schaefer with the realization of their new
automated distribution center in Vansbro, Sweden. The
turnkey project includes the high-performance shuttle
system Cuby, ergonomic work stations and the logistics
software Wamas. SSI Schaefer is going to realize a
state-of-the-art warehouse for Lyko in a 10,000-squaremeter
facility including a 5-aisle shuttle system that will
provide Lyko`s customers with around 50,000 different
beauty products. A bin and carton conveying system
will connect the different warehouse areas efficiently.
Furthermore, the Wamas logistics software from
SSI Schaefer is going to coordinate the transparent
warehouse processes. The system is scheduled to go
live in the beginning of 2020.
www.ssi-schaefer.com
Australian retailer to build automated
logistics centers with Witron
Major Australian retail
company Coles has
selected Witron to deliver
two new ambient
distribution centers as
part of a supply chain
modernization
program that will
improve availability
for customers while
lowering costs. Coles
and Witron have now
executed definitive
contracts for Witron to
develop two new automated
ambient distribution centers in the states
of Queensland and New South Wales. The distribution centers
will respectively supply a full range of ambient grocery lines to
more than 240 Coles supermarkets in New South Wales and
more than 170 supermarkets in Queensland. “The
modernization of our supply chain will provide a safer working
environment for our team members, lower supply chain costs,
enhance our overall business competitiveness and make life
easier for our customers”, said Coles CEO Steven Cain (right).”
Witron’s CEO, Helmut Prieschenk, said the company was very
pleased to be working with Coles on Witron’s first Australian
project.
www.witron.de/en
6 WORLD OF INDUSTRIES 1/2019

Hannover Messe: Arno Reich
named Senior Vice President
Effective immediately, Arno Reich (47) has taken
over management of Deutsche Messe’s portfolio of
industrial, energy and logistics trade fairs, the most
prominent of which is Hannover Messe. As senior
vice president, his core tasks
include the strategic
further development of
this tradeshow
portfolio both in
Germany and
abroad, i.e.
throughout Europe,
Asia and North and
Central America.
Hubertus von
Monschaw (42) has
assumed the position of
project manager for Integrated Automation,
Motion & Drives (IAMD) and Digital Factory and
Worldwide Events on 1 January 2019. Von
Monschaw has been with Deutsche Messe since
2003 and was previously responsible for ICT &
Business and Communications & ICT
Infrastructure as well as Energy at Hannover
Messe.
Wibu-Systems
extends its
worldwide reach
In the fourth quarter 2018,
Wibu-Systems celebrated the
official opening of its new wholly
owned daughter company, Wibu-Systems
K.K., in Tokyo, Japan, together with the German-Japanese
delegation and local industry luminaries. The new Far
Eastern stronghold adds to the existing subsidiaries in
Europe, U.S., and Asia Pacific that Wibu-Systems has created
over the last 30 years.
Photo (f.l.t.r.): Marcus Schuermann, Managing Director of
AHK Japan, Peter Altmaier, German Federal Minister for
Economic Affairs and Energy, Oliver Winzenried, CEO of
Wibu-Systems AG, Yasukazu Irino, Executive Vice President
of Jetro, and Tomoki Maruyama, Representative Director of
Wibu-Systems K.K. (source: Manfred Knopp)
www.wibu.com
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WORLD OF INDUSTRIES 1/2019 7

The ‘must go’
industrial trade fairs for 2019
NEWS AND MARKETS
Industry 4.0 is changing industries, markets… and
even trade shows. In many cases, the top two
leading trade fairs have combined in order to create
one new annual event. Manufacturers are looking
for cross-sector and cross-platform solutions, as well
as digitally integrated products, in order to meet
the ever-changing demand of their customers. Let’s
take a look at the top industrial trade fairs of 2019,
and the latest technological trends that will be on
display worldwide.
Author: Sushen Doshi, International Correspondent, World of Industries
WIN Eurasia: Let’s start the year in the historic and beautiful
city of Istanbul with WIN Eurasia. For centuries, Eurasia has
been an highly active and an important region in terms of trade and
industry, and Istanbul has been at the center of all the action.
Located at a key juncture of world’s most important trade routes
and energy routes, Istanbul has become a thriving trading hub and
an attractive base for all sorts of industries. For more than 25 years,
WIN Eurasia - the international trade event involving six industrial
trade shows under one roof, has been the pioneering event in terms
of level of technology for the manufacturing sector. As the most
influential trade event in the region, WIN Eurasia is prepared to
lead the companies in ongoing industrial revolution. For visitors
this event provides a 360 degree view of the Eurasian manufacturing
sector by merging six trade fairs. This merger creates a synergy
and brings together a wide range of technologies, products and
services from the entire manufacturing domain under one roof.
This international event is to be held from 14 th until the 17 th March
2019 at the Tüyap Fair and Congress Center in Istanbul, and just like
previous years it is expected to attract more than 75,000 visitors and
1,500 exhibitors from over 40 countries. The six trade fairs at WIN
Eurasia include sectors like automation, motion and drives, industrial
energy systems, electro-tech, metal working, welding, surface
technology, material handling and logistics. Top areas of focus in
terms of technology will be Industry 4.0 festival area, digital factory
- IIoT special area, additive manufacturing, smart manufacturing
line special area, the WIN 4.0 application park etc.
Hannover Messe - Integrated industry -
industrial intelligence
After Istanbul, the world of industries will travel to Germany, where
the city of Hannover will once again open its arms to welcome more
8 WORLD OF INDUSTRIES 1/2019

than 200,000 visitors and 6 500 exhibitor companies for the Hannover
Messe. Without a doubt, this has been the most popular and
pioneering trade event in terms technological sophistication in the
world. With strategically thought out themes, every year Hannover
Messe is driving forward the digital transformation of the production
and energy industries. For 2019, the main theme is “Integrated
Industry – Industrial Intelligence”, which spotlights digital networking
between humans and machines in the age of artificial intelligence.
It underlines the growing importance of artificial intelligence
and machine learning in the production and energy
industries, including areas of energy efficiency and autonomous
production processes as well as challenges in terms of interfaces,
protocols and security. At this event, international think tanks from
the fields of AI and industry come together to jointly discuss and
develop solutions for tomorrow. Like every year Hannover Messe
will include trade fairs like integrated automation, motion &
drives, digital factory, integrated energy, industrial supply,
research & technology and ComVac - compressed air and vacuum
technology show. As a part of it’s tradition, Hannover Messe
shines spotlight on a chosen Partner Country. In 2019, the
partner country will be Sweden. Collaboration, innovation and
digital transformation will be at the center of Sweden’s
showcase. It’s main objective shall be to promote networking,
trade and investment with partners from around the globe.
After the home leg in Europe,
its now time to fly to China
The international trade fair, Integrated Automation, Motion &
Drives Beijing 2019 (IAMD Beijing) will kick off in Beijing
Exhibition Centre from the 8 th to 10 th of May, 2019. As compared
to a few years earlier, the trade show has tremendously improved
in terms of exhibiting technology quality and number of foreign
visitors and exhibitors. More than half of exhibitors are
multinational companies like Phoenix, Beckhoff, Cognex,
Weidmueller, Pilz, IFM, Nord, Rollon, and Rittal. Following the
trends
of
Industry 4.0 to integrate power transmission exhibits to
automation trade fair, IAMD Beijing focuses on overall
solutions of automation, electrical power transmission,
fluid power transmission, control technology,
mechanical transmission, parts and equipment, sensor
technology, industrial automation software, interface
technology and power supply solution on a total display
area of nearly 20,000 m 2 .
After Beijing, the IAMD brand moves to the south of
China, to the city of Shenzhen. Shenzhen being an
industrial and technology driven city, the IAMD trade fairs find a
perfectly suitable audience here. As one of the leading
manufacturing regions in China, the absorption and penetration of
IAMD technologies is higher in Shenzhen. With more than 500
exhibitor companies from 15 countries like Germany, South Korea,
USA, Japan, Singapore, China and Italy covering a total display area
of 35,000 m 2 , the fair covers sectors such as integrated intelligent
manufacturing solutions for control system, PLC, SCADA, sensor
and actuator, servo motor, connectors, man-machine interface,
industrial communication, IoT, cloud computing, industrial Ethernet,
industrial personal computer, communication, hydraulic,
pneumatic, fluid transmission and components, mechanical
transmission components and parts etc.
Pack your bags, Shanghai is waiting for you
Over the last two decades, industrial trade fairs such as PTC Asia
and IAS Shanghai have been witnessing and contributing to
China’s rise as an industrial and manufacturing power. Like every
year, Shanghai will host the two fairs, bringing in a wave of
experts, industry professionals and academicians from all over
Asia. With a total display area of around 100,000 m 2 , PTC Asia
leaves no stone unturned to showcase the latest
developments in the industrial and manufacturing sector.
In last few years, this fair has brought in close to 100,000
visitors and 1 500 exhibitors from all over the world. Like
every year the event is to held in Shanghai New International
Expo Centre. The event kick starts in last quarter of the year
mostly in November, with intelligent manufacturing and
“Made in China 2025” being the focal point. As China catches
up with Industry 4.0 technologies, sectors such as hydraulics,
pneumatics, mechanical and electrical power transmission
are getting integrated more and more with IT. At events like
these, one can witness the latest innovations either in terms
of technology or the business model itself. Another event to
look out for in Shanghai is the Industrial Automation Show
- Shanghai, which hosts 700 well known enterprises from
China and abroad with a display area of more than 70,000
m 2 . At this event, the exhibitors showcase products such
as assembling and handling systems, linear positioning
system, control system, industrial image processing
system, sensor and actuator, embedded system,
measurement and test systems, industrial automation
data acquisition and identification system and
factory’s integrated management software.
Photographs: fotolia
WORLD OF INDUSTRIES 1/2019 9

Turkey will bounce back,
as it’s industry’s fundamentals
are still alive and strong
Despite the recent currency crisis and macro-economic instability in the country, Turkey has a vibrant
manufacturing sector which holds immense potential for growth, and is on right track, as well.
NEWS AND MARKETS
A
s one of the largest countries in the Eurasian region in terms of
population, Turkey has a strong and a growing economy. With
more than 65 % of the population within the working age of 16 to 64
years, Turkey is blessed with a demographic advantage and an
expanding middle class, which results in consistent domestic
demand. It’s strategic geographic position as a bridge between
Europe and Asia has made the country an important manufacturing
and distribution hub. It is the 17 th largest economy in the world
and its industrial output accounts for more than a quarter of it’s
GDP. Turkey positions itself in the global value chain by leveraging
its logistical advantage, lower labor costs and flexible production
capabilities.
In terms of global competitiveness, Turkey ranks 61 st worldwide,
with relative strengths on market size, infrastructure, public health
and the innovation capabilities. As compared to other emerging
nations, Turkey’s performance on the innovation scale is fairly good
mainly due to strong research institutions and active participation
in global technology publications and forums. But the country faces
many bottlenecks when it comes to converting ideas into businesses,
Author: Sushen Doshi, International Correspondent for World of Industries
mainly due to barriers faced by entrepreneurs in ease of doing business
and embracing disruptive ideas. In terms of product and labor
market, Turkey lags behind other European countries mainly due to
rigidities in worker-employer relations, internal labor mobility,
ease of hiring foreign labor and lack of meritocracy.
Turkey’s manufacturing sector
As Turkey’s economy grew with an average growth rate of nearly 5 %
from 2002 to 2016, the GDP levels increased from $ 300 billion in
2003 to $ 850 billion in 2018. Export, which was $ 75 billion in 2005,
rose to more than $ 155 billion by at the end of 2018. For Turkey,
mechanical engineering and machinery sector in particular is one
of the most dynamic segment of the industry and with the collective
wisdom possessed by the country’s machine manufacturers, this
sector shall remain one of the driving force for Turkey’s economic
growth. Over the last decade, the machinery sector has more than
doubled its production capacities and has now risen as one of the
top exports of the country. Today, this sector accounts for nearly
10 % of the country’s total export. Turkey’s machinery export, which
was $ 5 billion in 2005, has reached more than $ 13.5 billion in 2017.
Turkey exports its machinery to more than 200 countries, with EU
10 WORLD OF INDUSTRIES 1/2019

and USA being the top export destinations, accounting for more
than 60 % of the total. By the year 2023, Turkish machinery aims to
double their share within Turkey’s total export. The top three industry
sectors driving the Turkish machinery ahead are as follows
1. Automotive and Vehicles segment: $ 24 billion
2. Machinery including computers: $ 14 billion
3. Electrical machinery, equipment: $ 8 billion
Turkey’s leading industry sub-sectors
Additive manufacturing: The automotive, aerospace and defense,
household appliances, jewelry, and medical/dental industries
started to use additive manufacturing in Turkey in 2014. According
to 2017 statistics, Turkey accounts for roughly 1.5 % of the global
additive manufacturing market with more than 400 3D printers
being used across the country in manufacturing. There is growing
demand for advanced 3D printers and CAD and CAM programs;
advanced printing materials, including biomaterials; and largescale
additive production capabilities.
Industrial Automation: According to the Industrial Automation
Association of Turkey, the industrial automation market in Turkey
was valued at $ 1.5 billion in 2016, with an annual growth rate of
over 20 %. It is expected to reach $ 4 billion within the next 5 years.
Many international companies present in Turkey also serve the
Russian, the CIS, the Middle Eastern and North African markets,
with an annual regional business volume of around $ 5 billion.
Data Analytics: Big Data and Data analytics solutions are mainly
used in the supply chain and warehouse management systems, in
predictive maintenance for real time monitoring of industrial
devices. Analysts estimate that the Turkey’s IoT market size will reach
a cumulative amount of $ 90 billion by 2022, including sensors,
optronics, M2M software and hardware, artificial intelligence, modeling
and simulations, cloud services, and cybersecurity applications.
Robotics: There are more than 12,000 industrial robots in Turkey,
with about half in the automotive industry. According to 2017
statistics, countries with advanced robotics in manufacturing use
300 robots per 10,000 workers. This amounts to just 12 robots per
10,000 workers in Turkey, which shows the potential growth opportunities
for robotics in manufacturing industries.
Advances and opportunities in manufacturing sector
Turkish industry lies in between the 2 nd and 3 rd industrial revolution,
the most mature sectors include materials (rubbers & plastics),
computers, electronics and optical devices as well as the automotive
sector. Advanced manufacturing technologies are
increasingly being implemented across Turkey with European
automotive and aviation companies leading the way. These sectors
employ numerous local suppliers, and have taken swift and bold
steps to adapt to the latest technical and technological requirements.
In order to prepare the Turkish industry for the fourth industrial
revolution, Turkey’s industry bodies and associations are taking
strong actions in digitalization and automation of manufacturing.
With this the country aims to move up from cheap labor to high
productivity and innovation, and climb up the global value chain
and ensure its future global competitiveness and boost the economy.
Currently, approximately 30 % of Turkey’s manufacturing
output and 35 % of its exports consist of medium- and high-tech
products. With the help of advanced manufacturing technologies,
the Turkish government aims to bring medium- and high-tech
product manufacturing up to the EU average of more than 60 %. If
Turkey fully adapts the industry 4.0 concept, it could save more
than $ 15 billion every year in current manufacturing costs.
Depending on the GDP growth in the coming decade, Turkey is
expected to invest about $ 3-5 billion annually in the integration of
industry 4.0 technologies into the manufacturing process.
Tubitak (the Scientific and technological research council of
Turkey) has prepared a roadmap to prepare the Turkish industry
for adoption and development of Industry 4.0 concepts. It identifies
three technology groups, which are digitalization, connectivity and
future factories. In the digitalization segment, focus is given on
developing cloud service platforms, data analytics and cyber
security solutions. In terms of connectivity, attention is given on
establishing an industrial IoT platform, machine-machine and
machine-human software and hardware that will increase the
quality and productivity during the product life cycle; and
development of the innovative sensors, industrial wireless
networks, and machine vision and image processing software. In
the future factories segment, focus will be to develop intelligent
production robots, equipment, software and management systems
that can compete in the international markets in terms of technical
quality and cost. A report by the Turkish informatics foundation
indicates that 50 % of manufacturers in Turkey plan to invest in industry
4.0 within the next three to five years, 20 % still do not have
any knowledge/strategy, and the remaining 30 % plan investments
in five to ten years. In a survey conducted by Tubitak in 2018, the
technologies that Turkish SMEs consider most important for their
industry are automation and control systems, advanced robotics,
and additive manufacturing.
Despite the currency crisis and diplomatic tensions with US
President Donald Trump and German Chancellor Angela Merkel,
many European businesses remain committed to Turkey because
they see the country’s long-term growth potential. Making any
investment in Turkey seems to be a risky business at the moment.
Even thou international companies are holding off investing in
Turkey right now, in no-way has the willingness to invest died off. z
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WORLD OF INDUSTRIES 1/2019 11

Driving the innovation of electric motors
forward with highly efficient test bench
HBM and Schabmüller GmbH, producers of electric motors for mobile machinery, have developed
a new test-bench concept for a new type of drive. It offers precision and convenient equipment
for cycle-accurate testing and measurement. With sensors integrated into the measurement
system, they can control the tests based on acquired data. With its formula database, the motor
developer can make real-time DSP calculations foe customizable measuring and testing tasks.
MOTION AND DRIVES
With e-vehicles on the rise, the requirements for motor
performance and efficiency are continually rising. Hence,
electric motor manufacturers work continuously to develop new
drives. Simultaneously, new test-bench concepts are in demand to
test these new motors with the required accuracy. The challenge is
to obtain reliable results while precisely controlling test processes.
Schabmüller GmbH, one of the leading manufacturer of electric
motors for battery-powered vehicles, also applies these
requirements to its own test equipment. Together with HBM, the
motor manufacturer has developed a test-bench concept that
enables measured data to be acquired and evaluated in line with
these requirements.
Schabmüller designs electric drives for forklift trucks, hybrid
trucks and buses, as well as for construction and agricultural
machinery. The company relies on HBM’s extensive measurement
technology in their new synchronous motor test bench, specifically
the ‘Genesis HighSpeed’ data acquisition system and the
‘Perception’ software program. A software program developed
using National Instruments’ LabView development environment is
deployed for automating and controlling the test bench. “The
Genesis HighSpeed measurement system is exceptionally easy to
work with and all processes run in parallel and in real time. This
makes the development processes of our test bench software much
easier and less complex,” explains Dr. Martin Hafner, Manager of
Technology Development for Permanent Magnet Synchronous
Machines at Schabmüller.
A modern test bench concept for innovative
electric motors
As a driver of innovation, Schabmüller also offers its customers
permanent magnet synchronous electric motors. This new type of
drive, without any changes to the cooling concept, produces just as
much power as comparable asynchronous motors while requiring
considerably less space. Optimizing or revising the cooling concept
enables this effect to exponentially increased. To ensure precision
in testing of the new electric drives, Schabmüller worked with HBM
experts to optimize the test bench’s entire measurement chain.
Stefan Lauck, development engineer at Schabmüller explains,
“We chose the combination of Genesis HighSpeed and Perception
software, as well as the LabView development environment as they
are very easy to connect with an interface. “Thanks to the Percep-
12 WORLD OF INDUSTRIES 1/2019

01 The combination of HBM’s Genesis HighSpeed data acquisition
system and Perception software with the LabVIEW development
environment allows precise measurements and fast analysis
tion’s sensor database, we can also integrate a wide range of different
sensors for current, voltage and torque into the measuring
system quite easily, simply by plug-and-play, like inserting a USB
device in a computer. Integrating vibration sensors as part of electrical
measurement equipment is possible without any problems.
That saves us time and resources in setting up the test bench.”
The Schabmüller test bench is used for various measurement
tasks to reliably determine the short-term or continuous power and
energy conversion efficiency of synchronous machines, or to identify
their service life and component reliability. Schabmüller experts
measure rotational speed and torque, generate efficiency maps,
and based on this measured data, determine longitudinal and
transverse inductances. Additionally, Schabmüller implements
service life experiments under maximum mechanical stress. Longterm
thermal experiments also determine how various long-term
and interval loading patterns affect the motor function.
An optimum system for extremely fast real-time tests
To reliably determine all measured data, the test bench’s individual
components must work together perfectly. The sensors acquire
measurement signals such as current, voltage, temperature and
torque and send them to the data acquisition system. The Genesis
HighSpeed GEN7tA data acquisition system is used on the Schabmüller
test bench along with GN610B acquisition cards. The DSPs,
digital signal processors on the cards, process the measured data
and calculate the initial results in real-time. The calculated measurement
results are forwarded to LabView for analysis – at up to
1000 times per second thanks to the EtherCAT connection. In parallel,
HBM’s Perception software also saves all the acquired raw data.
“Measured data and real-time computing results are acquired and
forwarded simultaneously and with the same time stamp. That’s an
enormous advantage for analysis,” emphasizes Stefan Lauck.
“We can also create our own formula database for the calculations
in Perception and can be used in both, post-process as well as realtime
calculations in the DSPs, without any programming of the
respective computer architecture.” Perception communicates with
the LabView software via a freely programmable software interface.
The LabView software is responsible for controlling and automating
the test-bench processes. Based on real-time computing results, it
controls the load and test specimen machines’ inverters. “The
measured data can be processed for cycle-synchronous individual
values. Then only the relevant cycle-synchronous computing
results are used for control and automation of the test processes.
For example, the RMS values of current and voltage or the torque
values,” says Stefan Lauck. “Since, if need be, the raw data will still
02 In Schabmüller’s test bench, torque transducers measure the
torque and transmit the results to HBM’s GN610B and GN1610B data
acquisition cards that record the measured data with high-resolution
sample rates of up to 2 MS/s
03 HBM’s Perception software communicates with the LabView
development environment via a freely programmable software interface
be saved, we can also use it for more extensive post-process
analyses.” In addition to the cycle-synchronous individual values,
continuously measured data can also be linked in the Perception
formula database and processed in real time. No programming
knowledge is required for this either.
Easy sensor integration and channel synchronization
“The combination of LabView and HBM’s Perception software
offers us many advantages,” says Stefan Lauck. “Genesis HighSpeed
synchronously records measured data of sensors and allows for
sample rates of up to 2 ms/s on up to 51 power channels. It automatically
synchronizes the sample rates of the different channels
and input cards. This considerably reduces users’ overhead. We
were also able to make optimum use of LabView advantages, such
as the TDMS data format, to rapidly save large amounts of data. This
also facilitates the subsequent data analysis using a wide range of
available software products.”
Schabmüller’s developers received customized support from
HBM’s Perception experts as they integrated the data acquisition
system into the test bench. According to Stefan Lauck: “Perception
is an efficient software program that acquires data reliably. Thanks
to the introductory training from HBM, we quickly became proficient.
And because Perception is so easy to work with, we are able to
define measurement sequences for our specific purposes.”
www.hbm.com
WORLD OF INDUSTRIES 1/2019 13

Electric drive systems
for offshore cranes
The most common type of drive technology on
ships and offshore platforms has been the hydraulic
drives. With increase in safety requirements and
environmental regulations becoming more
stringent, the electric drive technology has
become a key area of focus. In co-operation
with the German gear manufacturer O&K
Antriebstechnik, offshore pedestalmounted
lattice boom cranes with
innovative electric drive concept
were recently commissioned by
Palfinger Marine.
01 The four drives of the
cable winch within the
lattice boom are arranged
face to face in the steel
lattice boom crane made
by Palfinger Marine
MOTION AND DRIVES
14 WORLD OF INDUSTRIES 1/2019

The overall mechanical requirements of the project have sparked
the ambition of the engineers. For steel lattice boom cranes with
a reach of up to 57 m and a safe working load of 60 t, the aim was to
develop the most compact electric drives possible for the main
winch and boom winch. The steel lattice structure of the crane
boom strictly dictated the respective installation spaces, for safety
reasons, nothing could protrude beyond the lattice structure. At the
same time, the size of the crane also dictated the cable thicknesses
and lengths, as well the dimensions of the drum. In conjunction
with the necessary torques and motor outputs, it quickly became
clear that the performance requirements could not be met within
the available space by a simple electrical drive. The constructional
task was thus to distribute the power to several motors on the one
hand, while transferring the total torque to the winch drum on the
other.
Tight installation space requires particular layout
The calculations within the given framework conditions resulted in
the drive of the rope winch that operates the hook being divided
into four electric motors of size IEC 280, each with a weight of
approximately 1.2 t. The boom winch has two motors of size IEC 315,
each with a weight of approximately 1.7 t. This determined the
entrance side, but there was still a constructional task left to tackle:
The effective layout and connection of the motors to the winch system.
It was not only the transmission of drive power that had to be
considered but also the size and weight of the motors themselves.
The special asynchronous motors, at about 2 m long and with the
above stated heavy weight per engine, are not insignificant. When it
comes to load distribution of the drive, which occurs via electronic
control, then the purely mechanical elements must also be safely
arranged in a purely constructional manner.
The mechanical solution from O&K Antriebstechnik consists of
two components each on both sides of the drum: a motor flange
and an angle system flowing into the actual winch system. For the
boom winch, the angle gear is designed in such a way that a fail-safe
brake is mounted opposite the engine’s power side for emergency
situations. This ensures that the crane boom remains in position
and cannot sag, even when there is an interruption in power, a
significant safety aspect. With a high degree of efficiency, a bevel
gear setup transfers the motor input torque to the winch’s planetary
gear, which is located in the winch drum. The winch itself can be
found at the crane tower and experiences only the rotational movements
of the tower. There should be no anomalies when lubricating
the angular gear. A control system ensures synchronous operation
of the drives on both sides of the winch.
The large cable winch drum, which has a width of around 2 m, is
mounted near the tower in the boom of the crane. The four drives of
the cable winch are also arranged on both sides of the winch drum,
with two drives apiece directly facing each other. These motors are
also mounted with a motor flange on an angular gear, which transfers
the combined power of the two motors, which are joined at
right angles, to the planetary gear that is integrated into the winch
drum. Of particular importance here is the sophisticated lubrication
system of the bevel gear setup, which ensures that the lubricant
is supplied to the best possible degree, irrespective of the position
of the boom. The four motors, which are also inverter-fed, work in
perfect synchronization with each other.
Complete electrification offers clear advantages
Together with the electric rotary drives, the boom crane is thus
completely electrically driven. The control system is at the cutting
edge of current technology, operates and reacts quickly and ensures
safety up to a significant wave height of up to 6 m, which can
only be reached during stormy winds. The electrical drives are also
advantageous in terms of flexibility in operation and even enable
remote access to the crane, which can be implemented for fault
detection and fast support, for example. In addition, standard components
are used to a large extent, which enables easy maintenance
and fast supply of spare parts. In all, the electric drives provide a
higher level of energy efficiency, thus ensuring lower energy consumption
and practically eliminating the risk of oil contamination
that could occur due to a breakdown or accident involving the
hydraulic system.
These electric drives have proven themselves completely effective
in other industries that operate in harsh environmental conditions.
In construction machinery, they can provide service in their
role as travel or slewing drives that is just as reliable as it is when
they are used in wind turbines around the globe and under extreme
weather conditions. Developed in accordance with strict EN13852-1
and Norsok R002 standards, they reliably fulfill all requirements,
even in offshore applications. The cranes that are equipped with
electric drive technology have less wear-prone components, which
therefore means they also have lower maintenance costs. Above all,
however, they work much more quietly and produce noticeably less
vibration. So there are many reasons for implementing this change.
Know-how and experience are fundamental
The specially designed drive components were implemented by
engineers from German drive technology experts O&K Antriebstechnik.
In close co-operation with colleagues from machinery
manufacturers, they have developed and designed machine-specific
solutions in a surprisingly short period of time. After a thorough
range of tests that are tailored towards the requirements of a specific
application, the product will go into serial production ensuring
reliable supply to customers.
Photographs: Palfinger Marine/Bonfiglioli
02 The steel lattice structure of the crane boom strictly dictated the
installation space of the winch drives in the crane of Palfinger Marine
www.bonfiglioli.com/en
WORLD OF INDUSTRIES 1/2019 15

Bearings with black
oxide finish
Bearing manufacturer NKE Austria
GmbH presents bearings with black
oxide finish. The protective layer
improves run-in and wear characteristics
and protects against environmental
effects. Especially in critical
applications such as wind turbine
gear boxes, black oxide finish is a
cost-effective and technically viable
means of prolonging the service life and performance of
rolling bearings. The black oxide finish forms a protective layer
for steel parts. In a multistage chemical process, the surface
layer of the treated parts is converted into a 1 to 2 micrometer
thin mixed ferrous oxide layer that causes the characteristic
black appearance. Black oxide finished bearing components
feature a set of special technical characteristics, especially in
the case of components that move relative to each other.
Multiple protective effects can be achieved if only one
functional element (typically the rolling elements) is treated.
For best effect, however, all functional surfaces of a rolling
element bearing, including the inner and outer ring as well as
the rolling elements, should be black oxide finished.
www.nke.at
Digital motor feedback for smart
servo drive systems
As a result of increasing
digitalization in
mechanical and plant
engineering, electric
drive systems are
increasingly faced by
the challenge of having
to be integrated as
smart components in future-oriented overall mechatronic
concepts. The Sick range of motor feedback systems with
digital Hiperface DSL interface offers the required remote
intelligence and communication capability for motors
and servo drive systems. The rotative sensors also meet all
requirements for application-based functionality,
maximum precision and dynamics as well as certified
safety. The new product families EDS35 and EDM35 are
the technological highlight in this range. Here, Sick
presents the second sensor generation with digital
Hiperface DSL one cable technology.
www.sick.com
Couplings for the big drive
background: fotolia
PRODUCTS
Axial piston variable pump: medium-to-highpressure
all-rounder
Construction machinery and its components must first and foremost be
reliable and robust, even when under extreme application conditions.
Hydraulic units are also expected to be space-saving and energyefficient.
Over-sized and hence expensive high-pressure units are often
used for applications with a pressure level somewhere between the
classic thresholds of medium pressure (280 bar) and high pressure
(350/380 bar). With its A10VOH
(series 60, size 145), Rexroth has
created a solution which perfectly
bridges the gap in order to enable
users to achieve efficient operation
in this “light heavy-duty” application
area.
The axial piston variable pump
A10VOH features a permissible
nominal pressure of 320 bar in
corner power operation at
maximum swivel angle and rotational speed. If the swivel angle is
reduced, the permissible nominal pressure increases to up to 350 bar. As
such, the A10VOH is ideal for use in various applications, including
steering drives, hydrostatic fan drives and working hydraulics. It is
lightweight and, despite its size of 145 cm³, so compact that it requires
the same installation space as the Rexroth A10VO (series 31, size 100).
www.boschrexroth.com
The metal bellows couplings of the KXL series
from Jakob Antriebstechnik were designed for
medium and large drives up to a maximum of
65,000 Nm. A special design feature is the
three-piece design with a flexible bellows package
as an intermediate piece. This removable intermediate
piece, consisting of an optimized, torsionally
stiff stainless steel bellows with 2two bellows
shafts per side and a variable length intermediate
pipe, is frictionally connected (screws ISO 4017 /
10.9) with the two hubs. This results in a considerable
ease of assembly, as e.g. can be omitted in
the maintenance or service case a costly disassembly
of the heavy drive or driven units. The
designer has several hub variants available for the
specific application. The extremely favorable
moment of inertia and the rotationally symmetric
design ensure good dynamic performance. The
KXL couplings are particularly suitable for precise
drives, such as for printing presses, cross cutters,
main spindle drives, transfer axes or transmission
connections.
www.jakobantriebstechnik.de
16 WORLD OF INDUSTRIES 1/2019

A filter, breaking all records
The smallest non-woven element ever produced at Argo-Hytos
in Kraichtal has a diameter of 25 mm and a height of 35 mm and
is used in the control block of a wheel loader. The smallest filter
from Argo-Hytos is just the size of a thumb, but does not
compromise on
functionality. A
multi-layer filter
fleece encloses the
perforated support
tube. The close
cooperation
between development
department
and prototype shop
guarantees the process-reliable manufacturing of the necessary
materials. Complex process steps must be mastered in a new
dimension: cut to width, four-layer pleating of the materials,
optimization of the pleat geometry, cutting the pleat pack to
length, bonding of the longitudinal seam, dosing of smallest
quantities of glue, secure fixation of all parts during curing,
assembly of support tube and end cap. The miniature filter
elements thus produced are then subjected to quality testing,
which they have passed without complaint. In sample production,
process reliability is also assessed and documented, which
is important for future series production.
www.argo-hytos.com
Optimized insulation of motor and
servo cables
The development of new motors known as variable
frequency drives (VFDs for short) is pointing in a clear
direction: ever more compact at the same or higher power
with extremely high switching accuracy of the frequency
inverters. As a
result, when
selecting a
cable in the
future, the user
will not only
have to pay
attention to the
correct number
of cores and cross-section combination, but also to the
electrical properties of the cable. For this reason, igus has
now developed a material for its latest generation of motor
and servo cables that is up to the new challenges. This
material withstood more than 45 million strokes in the test
with a bending radius of 7.2 x d.
www.igus.com
DER ANTRIEB
Reliable. Versatile. Global.
Hall 15
Stand H31
THE GEAR UNIT
Strong bearings
Quiet running
THE MOTOR
High efficiency
Global standards
THE DRIVE ELECTRONIC
Field distribution system
Easy implementation
Getriebebau NORD GmbH & Co. KG | Fon +49 4532 289-0 | info@nord.com
nord.com

Laser modules provide improved
efficiency for thin-film solar modules
Manz AG is one of the world’s pioneers in photovoltaic
engineering. In the realization of the largest order in
the company’s history so far, Z-Laser laser modules
play a decisive role in quality assurance and enable the
production of solar modules with very high efficiency.
With CIGSfab, Manz AG is the only supplier worldwide of a
turnkey, fully integrated production line for the production of
CIGS thin-film solar modules. “We are absolutely convinced that
the future belongs to CIGS thin-film solar technology in photovoltaics,”
emphasizes Bernd Sattler, Head of Vision & Metrology at
Manz AG in Reutlingen.
In January 2017, the company, which was founded in 1987, won
the largest order by far in the company’s history with a volume of
263 million euros for this product: A joint venture of the Chinese
Shanghai Electric Group Co., Ltd. and the Shenhua Group Co., Ltd.
ordered a CIGSfab with a capacity of 306 MW and a CIGSlab, a
research line with a capacity of 44 MW. Both factories are scheduled
to start production in the summer of 2019.
50 times thinner than a human hair
When checking
the lines that are
created in the first
two structuring
processes, laser
modules ensure
optimum
illumination
In a conventional crystalline solar module based on a high-purity
silicon wafer, a large number of individual solar cells are soldered
and mounted between a glass pane and a film. The individual
wafers are up to 100 times thicker than the semiconductor layer
CIGS (copper-indium-gallium-diselenide) on a thin-film module.
This is vapor-deposited in a vacuum system, in just one process
step, directly onto a glass pane. The use of expensive semiconductor
material is correspondingly higher in crystalline technology. In
addition, thin-film technology eliminates the labor-intensive and
expensive multilevel process of the raw silicon, the wafer, the cell,
and the module fabrication by direct application of the
semiconductor to the glass substrate.
The advantage according to Bernd Sattler: “The CIGS absorber
layer has a thickness of only approx. 2 μm and is thus 40 to 50 times
thinner than a human hair. The positive effects on the manufacturing
costs due to the material savings and fewer process steps are obvious.”
01 In the P2 structuring machine, two laser processing
heads are operated in parallel, which is why two Z-Laser
illumination lasers are used on one unit
AUTOMATION
18 WORLD OF INDUSTRIES 1/2019

02 The CIGS absorber layer has a thickness of only about 2 microns
and is thus about 40 to 50 times thinner than a human hair
The manufacturing process of the 600 x 1 200 mm solar modules at
Manz therefore requires the highest precision. Bernd Sattler
describes the essential steps as follows: “The carrier material is
coated and structured in several process steps. The entire area has to
be divided into smaller cells, as the whole area generates a high
current. By connecting these small cells in series, the voltage can be
increased from about 0.6 V per cell to, for example, about 80 V per
module. “This requires three separation steps, two of which are realized
with one processing laser and one with a special engraving stylus.
Exact measurement for higher efficiency
For the correct function of each module, it is essential that the
structures for interconnecting the solar cell diodes are applied
correctly. For economic reasons, it also makes sense to check these
structuring lines after each of the three separation steps in order to
recognize defect modules at an early stage, to take them out of the
process immediately and thus not to cause unnecessary costs.
The measurements that have to be made include the widths and
distances of the structuring lines, the so-called dead-area as well as
structuring distances. Precise measurement results have a direct
influence on the quality of the solar modules produced. The
so-called dead-areas are required for structuring, but do not
generate electricity. For that reason, the smaller these areas can be
manufactured, the higher the efficiency of the entire solar module
gets. With the measured results, the structuring systems are set and
the distances are kept constant to ultimately optimize the efficiency.
High demands
The structuring lines denoted P1 and P2 are generated by a solidstate
processing laser in the infrared wavelength spectrum.
Especially when applying the P2 line, the laser illumination is of
particular importance: To minimize the dead-area, the position of
the laser is actively controlled during the process of the second line
(P2 structure) to produce this as close as possible and in parallel to
the already existing P1 structure.
Sattler describes how his team solved this problem: “The
processing laser for the P2 process is positioned using a very fast
matrix camera. It measures the P1 line with a frequency of 1 000 Hz
and an accuracy of less than 5 μm ahead of the processing laser.
With this tracking data the position of the laser scanner, which
writes a second line parallel to the first line, is directly controlled.
In addition to accuracy and frequency, the main challenge,
according to Sattler, was to safely separate the laser used
for the illumination from the processing laser
so that the processing laser would not
damage either the camera or the
03 The laser modules ZQ1 are
developed to facilitate the most
demanding measuring methods
illumination laser. “The entire integration into the optical path of
the laser components could only be realized through a very close
cooperation with our laser process group and the mechanical
design,” says the department manager.
Sattler also recalled that choosing the optimal laser lighting was
not easy: “For this purpose the needed wavelength is above
1 000 nm because the transmission of CIGS layer starts at that point,
and the suitable CMOS camera is still sensitive enough in this
wavelength area to produce a usable image.”
Specialized laser modules
During the design phase of the systems, Sattler and his colleagues
used a proprietary prototype for lighting with a laser diode that
offered the required characteristics. “When it came to series design,
we looked for a partner who had more expertise in the field of laser
diodes,” says Sattler.
After reviewing various options, Sattler decided in favor of
Freiburg based manufacturer Z-Laser: “Z-Laser’s offer was the
safest and most interesting option for us. The hardware costs were a
bit higher than we calculated, but we were able to compensate for
this by the fact that the Z-Laser modules were very precisely
manufactured and pre-adjusted. As a result, the adjustment times
in the machines were significantly lower than originally planned.
“At the beginning, the size also gave the Manz developers team a
headache. “However, we were able to master this challenge with
some good ideas in mechanical design.”
Sattler mentions another important argument for working with
Z-Laser: “We had specified the laser diode required for this
measurement task very exactly. Our partner already had a laser
module available in which this laser diode could be used with little
effort. “According to Sattler, the further cooperation went very well:”
Even the first prototype and also the later series models that we
received from Z-Laser worked very well right away. The learning
curve typically associated with new suppliers and components was
much shorter than usual. Z-Laser quickly provided us with a
solution to our demanding challenge. “
Even when inspecting the quality of the modules after each of the
three process steps, backlight laser modules ensure optimum
illumination to enable perfect camera images. In a second measuring
system at the final quality inspection stage, the entire substrate is
scanned with a contact image sensor in order to ensure the
completeness of the lines of the third structuring process and to
detect any damage. “Laser modules from Z-Laser thus play a
decisive role in all three surveying steps and help to optimize
the production process of the thin-film solar modules,”
explains Bernd Sattler. “Every CIGSfab uses several of the
described systems. This is the only way we can ensure that
the planned throughput is 100 % controlled and that only
defect-free substrates leave the plant. “
www.z-laser.com
Photographs: teaser, 01-02 Manz, 03 Z-Laser
WORLD OF INDUSTRIES 1/2019 19

Taking a look into outer space
AUTOMATION
Specialist glass manufacturer Schott supplies huge
mirrors for the European Extremely Large Telescope
(EELT), currently the largest telescope in the world,
which is under construction on the mountain of Cerro
Armazones in Chile.
C
erro Armazones, Chile. The European Extremely Large
Telescope (EELT), currently the world’s largest telescope, is at
present under construction on top of the Chilean mountain of
Cerro Armazones. The glass specialist Schott is one of the companies
manufacturing the enormous mirrors for the telescope. The manufacturing
process is based on a special ceramic glass so that the mirror
can withstand the extreme local conditions. This is why Schott
has chosen Siemens technology for the manufacturing process. The
process control system Simatic PCS 7 ensures the temperature is
measured and controlled extremely accurately during production.
In addition to the main mirror with a diameter of almost
40 meters, the European Extremely Large Telescope also has four
other mirrors which act as reflectors. Three of these large mirrors,
which measure up to four meters, are produced by Schott. The
Mainz-based company uses a special ceramic glass (Zerodur) in
The most being opend in
the Schott cooling hall
the manufacturing process as the mirror substrate. The benefit of
this ceramic glass is that it has a very low coefficient of thermal
expansion. This means that the material does not expand even if
temperatures vary considerably. This is an important property if the
EELT is to supply sharp images.
Perfect temperature control for perfect mirrors
In order to avoid stress cracks, the special glass is repeatedly heated
and cooled over long periods of time during production. Temperature
control at this point must be accurate to three decimal places
which is why Schott has chosen the Simatic PCS 7 process control
system and the Simatic ET 200SP distributed I/O system from its
long-term partner Siemens for this project. Initially Schott
“Schott chooses Siemens automation
technology to produce mirrors for the
world’s largest telescope.”
employees and experts from Siemens tested the fundamental
feasibility in the laboratory and, after successful tests, Siemens then
programmed a new module specifically for this application. The
solution includes many types of measurement such as stress,
voltage and resistance, as well as resistance thermometers and
thermal elements.
Undiscovered worlds
This extremely accurate measurement of temperature allows Schott
to produce mirrors which can not only withstand the adverse
conditions on top of this Chilean mountain, but can also contribute
to taking a look at hitherto undiscovered worlds.
Photographs: Schott
www.siemens.com
20 WORLD OF INDUSTRIES 1/2019

How to check presence and
position simultaneously
SmartRunner technology is a unique combination of light section technology and a 2-D vision
sensor with integrated LEDs. This innovative combination offers completely new applications
for demanding detection tasks and allows you to design efficient, future-proof processes.
Robotic handling systems are often used to feed workpieces or
raw materials into production and processing systems. Workpiece
carriers are used to transport the materials to the plant, where
the materials are then automatically removed. In conventional
solutions, standard vision sensors are used to control the position
of the materials being fed. This process is costly and complex since
these sensors quickly reach the limits of their detection performance
when working with low- contrast objects. In such cases,
standard vision sensors require additional external lighting and
complex configuration.
Efficient operation without plant downtime
An uninterrupted supply of raw materials is crucial for maintaining
cost-effective operations in production plants. The materials, which
can vary in color, are transported to the machine in workpiece
carriers. Before the materials are picked up by the robotic system, it
is necessary to check whether the materials are present (presence
check) and whether the materials are in the correct position (position
control). Efficient operation without plant downtime or
production waste is always the top priority.
Two detection tasks in a single step
With the SmartRunner Matcher light section sensor from
Pepperl+Fuchs, both detection tasks can be performed in a single
step. The sensor is mounted above the conveyor system and checks
two items simultaneously by detecting the height profiles. When
these height profiles match the reference profile stored in the sensor,
the switching output sends a “good” signal. Differing height
profiles indicate either missing or incorrectly positioned raw material,
and the sensor sends a “bad” signal. The SmartRunner Matcher
thus prevents waste and plant downtime, enabling more efficient
production.
The benefits
SmartRunner Matchers are optimized in the factory to compare
height profiles, meaning they can be integrated directly into the
application without any specialized expertise required. The solution
is easy to configure, and there is no need to evaluate raw data.
Instead, the detection result is delivered as a switching signal that
can be understood by any control panel.
Light section technology delivers highly precise, reliable results,
regardless of the surface quality, contrast, and color of the objects
being detected. Unlike conventional vision-based solutions, expensive
and difficult-to-install external lighting is not required. The
wide detection range of 160 mm allows multiple objects to be
detected and verified. An extended version of the SmartRunner
Matcher is also available, allowing up to 32 height profiles to be
stored in the sensor for quick reparameterization after plant
changeovers.
Photographs: Pepperl+Fuchs
www.pepperl-fuchs.com
IOT
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Joining, cutting &
Engineering of tomorrow
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revolutionise your business.
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www.kjellberg.de
Kjell.indd 1 11.02.2019 07:44:49
WORLD OF INDUSTRIES 1/2019 21

Safety light grids for hygiene-sensitive
sectors
The Schmersal Group has developed a new product line for
safety light grids and curtains eminently suitable for use in
hygiene-sensitive sectors, such as the food industry,
pharmaceuticals and meat and milk
processing. The new product line SLC/
SLG 440 IP69K is resistant to all daily
cleaning processes prevalent in such
industries. Thanks to a sophisticated,
detailed design, this product line
achieves the protection rating IP69K and
is thus protected against ingress of water
during close-range high-pressure and
high-temperature spray downs. The
locking caps are manufactured in
stainless steel (V4A) as are the cable inlet
and the fastening parts. The material
guarantees greater availability and a
long service life for safety light curtains
and grids, also allowing a compact
design for encapsulated safety sensors.
Other characteristics include additional functions such as
double confirmation, contactor control and integrated beam
blanking, which allows moving parts to be conveyed through
the protection field without triggering the stop signal.
www.schmersal.com
Modular field bus system for
on-machine installation
New clamp concept for energy chains
Safety plays a key role when humans and robots work hand in
hand in the industry. That is why users of cobots and
industrial robots are already using igus’ multi-axis round
triflex R e-chains for energy and data supply. To easily attach
these energy chains and increase work safety in industry, igus
has now developed new plastic mounting clamps. With quick
installation, these minimise the risk of injury with their
rounded edge design. The triflex R range has been specifically
developed for sophisticated 6-axis robots in industrial
environments. By combining the flexibility of a hose with the
stability of an energy chain, the round triflex R ensures
reliable cable guidance in multi-axis movements. A ball/
socket principle ensures high tensile strength and easy
installation of the e-chain. The interior separation is freely
selectable. The circular bend radius stop and the high
twistability of the e-chain prevent the over-stressing of cables
- this system increases the service life and operational
reliability of the application. The triflex e-chains are available
as a complete package with cobot designed clamps, cables
and connectors immediately ready for connection.
www.igus.com
background: fotolia
PRODUCTS
The Cube system from Murrelektronik is a modular field bus
system for on-machine installation concepts. It’s engineered
flexibly to be the optimal solution for any application – meeting
protection class IP20 through IP69K. Cube67 features
great functionality, easy connections, a robust and compact
design, fully molded
modules, and
multi-functional
inputs and outputs.
The modules can be
installed right next to
the sensors and
actuators. The
one-cable-technology
connects the modules
to the bus node, transferring both data and power. Extensive
diagnostics enable maximum transparency. The number of
terminals in the control cabinet is reduced by moving field
bus modules into the field, freeing up space. The Cube67 field
bus system makes it possible to change bus without changing
system: installation concepts can be implemented
independent of existing control concepts. Simply select the
bus module with the desired field bus protocol; Murrelektronik
can provide bus nodes for the most common field bus
systems.
www.murrelektronik.com
New camera series for embedded
vision
The all-new Alvium camera
series is a new camera
platform developed by
Allied Vision that opens the
gates of industrial machine
vision to embedded system
designers. Alvium offers a full range of digital cameras
designed on an innovative platform which offers three
configurations (board level, open-housing and closed
housing) utilizing MIPI CSI-2 and USB3 Vision interfaces. At
the core of Alvium is the unique Alvium technology, a
proprietary System-on-chip (SoC) designed by Allied Vision
which completes on-board image processing through a
comprehensive image processing library (IPL). Integration
into systems from the software prospective is made easier as
one driver is needed for each platform to operate all Alvium
camera models. Furthermore, designers/integrators can
control the camera via Video4Linux, GStreamer, Direct
Register Access, and GenICam. Models from the 1 500 Series
and the 1 800 Series will be the first to be made available.
www.alliedvision.com
22 WORLD OF INDUSTRIES 1/2019

Safe handling of motion and dynamics
Machine areas that continue running after switching off are often
part of automated production processes. If one thinks, for example,
of a large flywheel mass or slowly running down saw blades, it is
absolutely essential that the machine operator is prevented from
accessing them with the help of a safety guard until the dangerous
movement has come to a complete standstill. Safety interlocking
devices with guard locking such as the new SLC (Safety Lock),
ensure, that protective guards, safety doors and other covers stay
closed as long as a dangerous condition exists.
www.bernstein.com
Optical sensors with an impressive function
variety
The O200 sensors from Baumer considerably raise the performance bar for optical
miniature sensors. The sensors ignore ambient light by machine reflections or
other sensors, even bright LEDs emitting a similar spectrum of light and operating
on similar switching frequencies. With
conventional sensors, such disturbances
result in the object not being detected
or sensor operation being slowed
down. O200 sensors feature high-power
mode to reliably detect ultra-black,
light-absorbing objects even at long
distance. Product variants with V-optics
specialize in glossy or transparent
objects. O200 sensors with IO-Link are
ready for Industry 4.0 and IIoT. The
latest IO-Link standard allows the sensors to be configured automatically.
The series comprises around 130 variants with different properties and
combinations.
www.baumer.com
Piezo sensor module also with digital I²C signal
Integrative pressure measurement in the smallest of spaces: Wika has expanded
its portfolio for OEM applications with the very compact MPR-1 piezo sensor
module with standardised output signal. With a diameter of 19 mm and a height
starting from 17 mm (depending on the process connection), the sensor module
can be integrated into a wide variety of products and systems. The custom-fit
specification is supported by the
selection of analogue and digital output
signals. The version with digital I²C
signal features very low power
consumption and a fast response time
(3 ms). It is therefore ideal for
applications with battery operation. In
addition, a temperature value can be
output via the I²C signal. The model
MPR-1 is available, as standard, with gauge and absolute pressure measuring
ranges (from 0 ... 0.4 bar to 0 ... 25 bar) as well as vacuum measuring ranges. It
measures with an accuracy of ≤ ±0.5 % of the span. On request, a higher accuracy
and other pressure ranges can be realised.
Some industries operate like
clockwork in the constant battle to
staycompetitive. In over200
countries,thoseare the industries
working with us.
With over
11.000
members, we represent the
Turkish engineering
industry.
5TOP
The main export products of
Turkish machinery:
air conditioners and cooling machines;
engines;
washing and drying machines;
contruction machines;
pumps andcompressors
www.turkishmachinery.com
Main Foyer/F10
www.wika.com
WORLD OF INDUSTRIES 1/2019 23
Turkish-Machinery.indd 1 11.02.2019 10:33:06

Fully serviced
in Europe
LOGISTICS
Beumer Group installed the entire conveying, picking
and sortation technology for car parts dealer Inter Cars
S. A. at its new European Logistics Centre (ELC) near
Warsaw. This includes a warehouse control system
(WCS) that manages the entire material flow.
Optimizing throughput and minimizing costs, Inter
Cars gets its spare parts now even faster to workshops
and customers all across Europe. For this project, the
system supplier has permanently stationed employees
on site as part of its residential service.
“Inter Cars was one of the most important projects for us to
successfully complete in Poland,” Sandra Lückmann sums up. She
is business development manager at Beumer Group in Beckum,
Germany, and was responsible for the successful handling of this
order. What was remarkable: “As system integrator, we designed
and installed the entire conveying, picking and sortation technology
for the spare parts dealer at its European logistics centre, including
our WCS, that controls the inbound area, quality assurance, picking
and shipping.”
Spare parts distributor with potential
Inter Cars is one of the leading spare parts distributors for passenger
cars, transport vehicles and trucks. The company, headquartered in
Poland, has more than one hundred subsidiaries and branches
spread all across the Baltic states and the Balkans. In addition, there
is a nationwide network of approximately a thousand workshops.
The previous logistics centre in Czosnów, Poland, supplied smaller
24 WORLD OF INDUSTRIES 1/2019

distribution centres all over Europe who then supplied the
workshops and customers. The increasing number of stored and
delivered parts however started to exceed its capacities. The managers
decided to build a new automated European logistics centre
in Zakroczym, approx. 30 km from Warsaw. The in-house logistics
provider ILS was commissioned as general contractor – “and this is
how we got involved as system supplier of intralogistics solutions”,
says Sandra Lückmann. “At the end of 2013, ILS called our Polish
subsidiary. At the time, the project was still in its design phase. We
only knew how many parts needed to be sorted in a given period of
time.”
Up to seven million products
In January of 2015, Beumer Group got awarded the contract,
installation started in September of 2015, and the start-up process
began the following September, with completion in December.
Inter Cars closed the previous logistics centre at the end of 2016, the
new European logistics centre started fully operating in May 2017.
“There are currently stores around 7 million pieces like spark plugs,
brake disks, V-belts, batteries, but also more bulky parts, like exhausts
and hoods, basically everything needed for cars,” explains
Lückmann. The complex is comprised of four buildings, the largest
one with 40,000 m², ten metres in height. It is equipped with a fourstory
shelving rack. The other buildings are 5,000 m². Here they
store tyres and hazardous material, such as oils and varnishes, that
must be kept separate due to fire protection measures.
The products are divided into different clusters, similar to clothing
sizes into S, M and XL and XXL, depending on dimension and
weight. “Items are picked in two stages,” describes Lückmann. With
a set number of totes placed on a trolley, the employee drives along
the aisles of the shelves, collecting all the components displayed on
the hand-held scanner. The small and medium parts are taken out
of the shelves in batches, consolidating multiple orders into one
picking wave. The totes are then placed on the roller conveyor and
transported automatically to the packing sorter. “Depending on the
WORLD OF INDUSTRIES 1/2019 25

LOGISTICS
content, the WCS distributes the incoming totes to one of three
induction areas,” explains Lückmann. The conveying technology
transports them to the workplaces where the items are taken out of
the totes. Each item is identified with a matrix camera and placed
on the sorter. Empty totes are returned to the conveying system and
follow the track back to the receiving area. “We provided our
Beumer BS7 Belt Tray Sorter for this sorting process,” explains
Lückmann. This system manages a throughput of around 14,000
without presorting, and up to 27,500 items per hour when using the
described presorting process.
Destinations ensure gentle sortation
Power and data transmission on the Beumer BS7 is contactless.
This prevents mechanical friction losses and wear and tear.
Compared to conventional cross-belt sorters, this sorter has 50
percent less components, which reduces maintenance costs by 80
percent. Energy requirements are also reduced during production
and operation. The distance between the individual conveying
elements on the Beumer Group systems is reduced to a minimum.
The use of belt trays makes it possible to have narrower, more
closely arranged destinations. Therefore, the sorter requires less
square footage. “The special feature of our BS7 are the 361 specially
developed destinations, that ensure careful handling of the very
different spare parts,” so Lückmann. Everything must be sorted and
discharged while keeping the packaging intact. To this end the
destinations are divided in two parts. If the spare part weighs up to
1.4 kg, the WCS classifies it as “light”, up to six kilogram as “heavy”.
This way the heavier parts are placed in the tote or cardboard
box before the lighter parts when the order is picked.
“The XL items from the main storage are handled differently,”
explains Lückmann. “Their size means that only one spare part fits
in one tote or box.” They are picked separately and conveyed
directly to the consolidation area. The same happens with items
from other buildings like tyres and hazardous material. Together
with the items from the packing sorter, the orders are consolidated
in totes and boxes and put together into shipping units. The units
are then weighed, compared with the target weight, closed,
labelled and then strapped. They are conveyed to the connected
shipping sorter that distributes the consolidated orders to up to 50
different dispatch destinations, at a capacity of 2,500 totes per
hour.
And what if the spare parts are not working or are no longer
needed by the customer? “They go back to the logistics centre in
Zakroczym,” explains Lückmann. Employees examine the
returns: is the part damaged, was it just not needed or was it the
wrong choice? If it is still in its original condition, it goes back to
the warehouse. The material flow for all these processes
throughout the entire distribution centre is controlled by the
WCS, from inbound to outbound. The orders are sent from the
operator’s warehouse management system.

02 The totes are placed on the roller conveyor and transported
automatically to the packing sorter
03 The Beumer BS7 Belt Tray Sorter manages a throughput of around
14,000 without presorting, and up to 27,500 items per hour when using
the described presorting process
01 Beumer Group installed the entire
conveying, picking and sortation
technology for car parts dealer Inter
Cars S. A. at its new European
Logistics Centre
Residential service: Beumer Group takes
responsibility
Beumer Group continues supporting the project even after this
point. ILS opted for the residential service, a special component of
the Beumer’s comprehensive customer support, to focus more on
the their own core business. “With this 24/7 service, the Beumer
employees ensure availability of the machines and systems,” reports
Jaroslaw Gorczynski, General Technical Director, Poland. “It must
be perfectly coordinated during the entire operating time, so that all
processes run smoothly.” The team has its own control room, and
the workplaces were designed in a way so that potentially critical
areas can be reached as quickly as possible.
The Beumer Group employees also perform preventive maintenance
work. Gorczynski explains: “This way, we can avoid
unplanned machine breakdowns that can get very expensive for the
customer.” The team carries out maintenance and inspection work
on the systems at defined intervals. They also check the safety
devices, electrical components and automation technology. And
they can perform repairs that might be necessary in case of an
unscheduled failure of components. The team checks the technical
installations and maintains them regularly, at agreed intervals. The
contract with Beumer Group runs over five years until 2022.
Guaranteed system flexibility
“Our systems and machines fully met the customer’s targets.
The system offers high level of availability, high and precise
throughput and can be easily adjusted to changing customer requirements.
The same holds true for our modular WCS,” describes
Lückmann. The owner is very happy with the cooperation: “We
were able to accommodate all requirements. Delivery, installation
and commissioning went all according to plan.” The companies are
currently in talks about an extension of the system.
Photographs: Beumer Group
www.beumergroup.com
WORLD OF INDUSTRIES 1/2019 27

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