WORLD OF INDUSTRIES 02/2019 (EN)
WORLD OF INDUSTRIES 02/2019 (EN)
WORLD OF INDUSTRIES 02/2019 (EN)
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www.world-of-industries.com<br />
20<br />
Gear units for<br />
Sugarloaf Mountain<br />
in cooperation with
HANNOVER MESSE<br />
PIONEERS GET NEW<br />
TECHNOLOGY FIRST.<br />
1 – 5 April <strong>2019</strong><br />
Hannover ▪ Germany<br />
hannovermesse.com<br />
#HM19<br />
Home of industrial pioneers<br />
1
EDITORIAL<br />
10 years of innovation<br />
Dear readers,<br />
ten years ago, the idea for this magazine came into the world. We had the<br />
idea to publish a journal that follows the industry all around the globe.<br />
Today, we can proudly announce, that this dream became reality. We<br />
were (and still are) successful. <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> offers you all the<br />
latest from the different worlds of motion and drives, industrial<br />
automation as well as intralogistics and supply chain management.<br />
Thanks to our collaboration with the Deutsche Messe AG, we are always<br />
right at the heartbeat of the industry. We report live from the fairgrounds<br />
all around the world and offer you comprehensive insights into the<br />
different markets and innovations all around the globe.<br />
In this special issue of <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong>, we celebrate our 10 year<br />
anniversary by looking back and retelling the history of this magazine but<br />
also by recollecting different highlights of our publishing history. Thus,<br />
you will find an extensive interview with the masterminds behind<br />
<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong>, Dr. Michael Werner, the publishing director<br />
behind this magazine, and Christian Kluge, Director International<br />
Relations of Deutsche Messe AG, on pages 6-7. Additionally, we put<br />
together our favorite job reports and the most spectacular success stories<br />
from the last ten years (pages 8-9). But in the end, it is not enough to<br />
solely reminisce. Of course, we dare to look into the future, too. Therefore,<br />
we will ask business leaders in this issue as well as in the upcoming ones<br />
what their expectations for the next ten years look like (page 35).<br />
And now, please raise your glasses and let us drink a toast to <strong>WORLD</strong> <strong>OF</strong><br />
<strong>INDUSTRIES</strong>: Cheers! Prost! Skål! Santé! Gom bui! Serefe! Wáshe<br />
zdarówje! ...<br />
The editorial team<br />
of World of Industries<br />
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ELEKTRISCHE V<strong>EN</strong>TIL- UND<br />
PUMP<strong>EN</strong>ANSTEUERUNG<br />
16 I 25 Jahre mechatronische<br />
Antriebslösungen für die Hydraulik<br />
oup-fluidtechnik.de<br />
5445<br />
09 September 2018<br />
ORGAN DES FORSCHUNGSFONDS<br />
FLUIDTECHNIK IM VDMA<br />
08 I LOUNGE<br />
„Hydraulik bietet unzählige<br />
Möglichkeiten technischer<br />
Innovation“<br />
Christine Grotz<br />
TITELSTORY<br />
und warten per App<br />
86 I S<strong>OF</strong>TWARE<br />
So effizient lassen sich<br />
Stirnräder auslegen<br />
92 I HANNOVER MESSE<br />
Diese Neuheiten sollten<br />
Sie nicht verpassen<br />
www.engineering-news.net<br />
14 I GIPFELTREFF<strong>EN</strong><br />
„Wir sind gut aufgestellt“<br />
Mit Hartmut Rauen auf dem Main Tower<br />
www.antriebstechnik.de<br />
Organ des Forschungsvereinigung Antriebtechnik e.V.<br />
19174<br />
04 APRIL <strong>2019</strong><br />
Mit System: All-in-One-Lösung<br />
30 zur industriellen Markierung<br />
in cooperation with<br />
www.industrielle-automation.net<br />
„Wir bringen digitale<br />
Kurze Taktzeiten im<br />
Special – Trends in<br />
22 Intelligenz in Kabellösungen“ 32 Automatisierungsverband 46 Robotik und Automation<br />
19239<br />
www.foerdern-und-heben.de<br />
FÖRDERTECHNIK<br />
MATERIALFLUSS<br />
LOGISTIK 4.0<br />
2884<br />
06 Juni 2018<br />
22 I NEUES KLEINTEILE-<br />
REGALBEDI<strong>EN</strong>GERÄT<br />
VEREINT VIELFÄLTIGES<br />
ANFORDERUNGSPR<strong>OF</strong>IL<br />
16 I PRODUKTE UND SYSTEME<br />
Roboterpalettierung ermöglicht 100<br />
Prozent mehr Output<br />
34 I M<strong>EN</strong>SCH<strong>EN</strong> UND MÄRKTE<br />
Recht Logistik verdankt Logcoop<br />
Großauftrag in der Display-Logistik<br />
38 I PERSPEKTIV<strong>EN</strong><br />
Beendet die Blockchain<br />
die Zettelwirtschaft?<br />
TABLE <strong>OF</strong> CONT<strong>EN</strong>T<br />
06<br />
16<br />
FLUIDTECHNIK<br />
4<br />
September 2018<br />
22 I GETRIEBE<br />
Bequem parametrieren<br />
Making the supply chain<br />
future oriented<br />
24<br />
26 32<br />
NEWS AND MARKETS<br />
03 EDITORIAL<br />
10 NEWS AND MARKETS<br />
12 TECHNOLOGY AND TAX CUTS CAN<br />
BAIL GERMANY OUT, IN CASE <strong>OF</strong> AN<br />
ECONOMIC DOWNTURN<br />
14 SMART LOGISTICS EQUIPM<strong>EN</strong>T AND<br />
MACHINERY TO DRIVE GROWTH IN<br />
LOGISTICS SECTOR IN THE COMING<br />
DECADES<br />
16 HANNOVER MESSE <strong>2019</strong>: TAKING YOU<br />
TO THE FOREFRONT <strong>OF</strong> THE FOURTH<br />
INDUSTRIAL REVOLUTION<br />
10 TH ANNIVERSARY<br />
06 2009-<strong>2019</strong>: 10 YEARS<br />
<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> HOW<br />
AN IDEA CAME TO LIFE ...<br />
08 10 YEARS <strong>OF</strong> <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong><br />
– 8 GREAT PROJECTS<br />
35 GLOBAL INDUSTRY: PAST AND FUTURE<br />
MOTION AND DRIVES<br />
19 PRODUCT NEWS<br />
20 GEAR UNITS FOR SUGARLOAF<br />
MOUNTAIN<br />
22 CABLE CARRIERS WITH CHEMICAL-<br />
RESISTANT PLASTIC DEAL WITH HIGH<br />
ACID EXPOSURE<br />
24 DRIVE TECHNOLOGY COMPLIANT<br />
WITH FOOD AND PHARMACEUTICAL<br />
PACKAGING INDUSTRY STANDARDS<br />
AUTOMATION<br />
26 FOCUSSING ON ROBOTICS<br />
AND AUTOMATION<br />
28 POWERFUL AND SOLID: SAFETY OVER<br />
IO-LINK IN A MACHINING C<strong>EN</strong>TER<br />
30 LABEL INSPECTION AT THE<br />
HIGHEST LEVEL<br />
LOGISTICS<br />
32 A HEALTHY BATCH <strong>OF</strong> SAFETY<br />
4 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong>
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<strong>02</strong>/<strong>2019</strong><br />
www.world-of-industries.com<br />
Christian Kluge<br />
20 Gear units for<br />
Sugarloaf Mountain<br />
Dr. Michael Werner<br />
in cooperation with<br />
Christian Kluge and Dr. Werner<br />
brought the idea of<br />
<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> to life<br />
WIN_WIN_<strong>2019</strong>_<strong>02</strong>_<strong>EN</strong>_E-Paper_001 1 08.03.<strong>2019</strong> 09:59:11<br />
2009-<strong>2019</strong>: 10 years World of Industries<br />
How an idea came to life ...<br />
It was a turbulent time for the global economy,<br />
triggered by the property bubble in the USA. At this<br />
exact time, a German publisher and Deutsche Messe<br />
AG dared to launch an international cross-media<br />
project on the market. The objective was to report on<br />
the latest exciting technological achievements. We<br />
spoke to Christian Kluge, Deutsche Messe, and Dr.<br />
Michael Werner, the Publishing Manager, about the<br />
beginnings and developments of World of Industries.<br />
Always on the lookout for exciting technologies: Our editorial<br />
teams are attending trade fairs around the world<br />
Ideas are often developed at the strangest times, including the<br />
idea to develop an international, cross-media project – <strong>WORLD</strong><br />
<strong>OF</strong> <strong>INDUSTRIES</strong> – ten years ago.<br />
Werner: It must have been 2011 when I met Christian for the first<br />
time at a trade fair stand. At the time, we had already been working<br />
on special publications in China for two years. Back then, it<br />
was mostly printed editions that we sent by post to readers in<br />
companies. The idea that we developed at that trade fair stand was<br />
incredibly simple: The publisher produces editorial content all<br />
about international trade fairs conducted by Deutsche Messe AG,<br />
and Deutsche Messe in turn supports international sales with its<br />
international subsidiaries.<br />
Kluge: A crucial question was posed by Michael: How would we<br />
get our publications to the right readers in China at the PTC and<br />
CeMAT Asia trade fairs? It was my idea to send all visitors an electronic<br />
copy of the publication. In addition to the printed publications,<br />
this gave us the opportunity to considerably increase our<br />
reach by including channels in the USA, Turkey, Russia, India, etc<br />
– so that’s how everything started.<br />
How does a German publisher suddenly start operating at an<br />
international level?<br />
10 TH ANNIVERSARY<br />
Werner: We looked at it from a customer’s point of view. If the innovations<br />
of a German company are being presented at a trade fair<br />
in China, the USA, Turkey, Russia, India or anywhere else in the<br />
world, we as a publisher must be in a position to be able to report<br />
on it. Over the last ten years, the focus has increasingly shifted from<br />
printed publications towards the Internet and social media.<br />
At the start, you wanted to spread the idea of “Made in<br />
Germany” around the world. Nowadays “World of Industries” is a<br />
lot more?<br />
Werner: Definitely! We started off with exported English publications.<br />
Nowadays we are increasingly communicating with com-<br />
6 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/<strong>2019</strong>
oup-fluidtechnik.de<br />
5445<br />
ORGAN DES FORSCHUNGSFONDS<br />
FLUIDTECHNIK IM VDMA<br />
Christine Grotz<br />
TITELSTORY<br />
Mit Hartmut Rauen auf dem Main Tower<br />
19174<br />
www.industrielle-automation.net<br />
September 2018<br />
www.foerdern-und-heben.de<br />
2884<br />
pany subsidiaries around the world and are cooperating directly<br />
with these locations.<br />
Kluge: I personally do not know of a comparable format that offers<br />
exhibitors, the publisher and us as a trade fair organizer such a<br />
global platform all year round.<br />
At the time Deutsche Messe was already internationally active<br />
and very successful. Why did it also need such a communication<br />
tool?<br />
Kluge: Firstly, exhibitors and visitors operate on a global scale and<br />
secondly, World of Industries already informs its readers before<br />
and during the trade fair about the next events and their topics,<br />
markets, and participants. I believe the combination of thematic<br />
content and markets is excellent.<br />
Communication across borders can often entail hidden<br />
challenges. Was that the case? And if so, how did you overcome<br />
them?<br />
Kluge: Deutsche Messe has the opportunity to collaborate with<br />
many excellent partners. Our colleagues in China, the USA, Turkey,<br />
etc. do the same job on the ground. The greatest challenge<br />
was to clearly illustrate the priorities and opportunities this project<br />
had to offer. We have had to be very hands on with this project.<br />
Nowadays World of Industries is more than a project, it is a<br />
complete platform. How can the readers benefit from this and<br />
what can they expect to read?<br />
Werner: From an editorial perspective, we always want to strike a<br />
balance between specialist information and reporting on trade<br />
fairs. Communication usually starts about four weeks before the<br />
trade fair via the websites for the publisher and trade fair, via<br />
newsletters from both partners and of course by means of activities<br />
on the social networks, which have become increasingly important<br />
in recent years. The trade fair book is available digitally as<br />
an e-paper but a printed version is also available at the exhibition<br />
site – provided in English around the world and in Mandarin in<br />
China.<br />
Which of these particular channels should individuals interested<br />
in technology take a look at?<br />
Werner: The website www.world-of-industries.com is the starting<br />
point for all publishing activities. Although social media is becoming<br />
increasingly important. From our perspective, LinkedIn in<br />
particular is developing very quickly. As a reader, it is of course<br />
best to subscribe to one of the newsletters from the trade fair or<br />
publisher. That will ensure you definitely do not miss a thing.<br />
Readers will especially benefit from the live posts and numerous<br />
videos posted by the team at trade fairs around the world.<br />
Werner: Definitely. From an editorial perspective we operate in<br />
three different stages. Before the trade fair – at the trade fair – after<br />
the trade fair. The live feed from the exhibition site is particularly<br />
important to us. Although that does not have the same level of<br />
success at every location, as it is dependent on the infrastructure.<br />
We are relying on moving images, our editors capture exciting<br />
topics on site in video interviews, which are then published on the<br />
website as well as in the e-paper and in the next printed edition.<br />
Kluge: In brief, moving images are more authentic, work better,<br />
and provided a clearer overview of the relevant message. Rough<br />
edges and corners are even an advantage when it comes to social<br />
media and their performance.<br />
Over the last ten years, World of Industries has grown into a<br />
strong brand that covers topics from automation, motion &<br />
drives, and intralogistics. Are these topics that will be suitable for<br />
future trade fair concepts?<br />
Kluge: Good question, our trade fairs always represent the markets.<br />
It is quite possible that topics will disappear and new ones<br />
will be added. That applies to us and the editorial staff alike. But<br />
that is exactly what makes it exciting.<br />
What are your future plans, what can the reader expect?<br />
Werner: We are going to develop with the market. From an editorial<br />
perspective, World of Industries is currently one of our most<br />
interesting projects and the one where we learn the most along<br />
the way. That keeps us on our toes and ensures we increase our<br />
skills, which turn helps to strengthen our core business in German-speaking<br />
Europe. In this regard, I hope we face many new<br />
challenges over the coming years.<br />
Kluge: If you just take a look at the main topics at the Hanover<br />
trade fair, such as artificial intelligence or platform economics and<br />
the opportunities and innovations that they have to offer. Add a<br />
touch of international cooperation and we can expect to see some<br />
exciting projects. One example is the “Industrial Transformation<br />
Asia Pacific” event. This is a new format for us and a new platform<br />
for exhibitors. This in turn will provide World of Industries with<br />
some exciting topics.<br />
www.world-of-industries.com<br />
09 September 2018<br />
FLUIDTECHNIK<br />
www.engineering-news.net<br />
FÖRDERTECHNIK<br />
MATERIALFLUSS<br />
LOGISTIK 4.0<br />
06 Juni 2018<br />
22 I NEUES KLEINTEILE-<br />
REGALBEDI<strong>EN</strong>GERÄT<br />
VEREINT VIELFÄLTIGES<br />
ANFORDERUNGSPR<strong>OF</strong>IL<br />
ELEKTRISCHE V<strong>EN</strong>TIL- UND<br />
PUMP<strong>EN</strong>ANSTEUERUNG<br />
16 I 25 Jahre mechatronische<br />
Antriebslösungen für die Hydraulik<br />
World of Industries<br />
is the best<br />
of four “worlds”:<br />
fluid power,drive<br />
technology, industrial<br />
automation and<br />
intralogistics<br />
08 I LOUNGE<br />
„Hydraulik bietet unzählige<br />
Möglichkeiten technischer<br />
Innovation“<br />
22 I GETRIEBE<br />
Bequem parametrieren<br />
und warten per App<br />
86 I S<strong>OF</strong>TWARE<br />
So effizient lassen sich<br />
Stirnräder auslegen<br />
92 I HANNOVER MESSE<br />
Diese Neuheiten sollten<br />
Sie nicht verpassen<br />
14 I GIPFELTREFF<strong>EN</strong><br />
„Wir sind gut aufgestellt“<br />
04 APRIL <strong>2019</strong><br />
Making the supply chain<br />
future oriented<br />
www.antriebstechnik.de<br />
Organ des Forschungsvereinigung Antriebtechnik e.V.<br />
Mit System: All-in-One-Lösung<br />
30 zur industriellen Markierung<br />
in cooperation with<br />
„Wir bringen digitale<br />
Kurze Taktzeiten im<br />
Special<br />
22 Intelligenz in Kabellösungen“ 32 Automatisierungsverband<br />
19239<br />
4<br />
– Trends in<br />
46 Robotik und Automation<br />
16 I PRODUKTE UND SYSTEME<br />
Roboterpalettierung ermöglicht 100<br />
Prozent mehr Output<br />
34 I M<strong>EN</strong>SCH<strong>EN</strong> UND MÄRKTE<br />
Recht Logistik verdankt Logcoop<br />
Großauftrag in der Display-Logistik<br />
38 I PERSPEKTIV<strong>EN</strong><br />
Beendet die Blockchain<br />
die Zettelwirtschaft?<br />
The latest, exciting topics are<br />
available on the website at<br />
www.world-of-industries.com<br />
<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong> 7
10 years of World of Industries –<br />
8 great projects<br />
This year, we celebrate 10 years of World of Industries. Since 2009, we follow the<br />
latest trends in engineering, automation and logistics. During this decade we<br />
were able to present you some of the most spectacular projects and solutions<br />
from all around the world. These are our favorite articles from tens years of<br />
reporting from the industry. Please click or enter the links into your browser to<br />
read the job reports.<br />
It was only meant to stay there for five<br />
years. Now it has already been there<br />
more than 15 years. I travelled to London,<br />
England to learn more about the<br />
condition of the Schaeffler bearings<br />
installed in it. Even at corporate headquarters<br />
in Germany I was able to gain<br />
interesting insights into the history of<br />
the Ferris wheel which was once the<br />
largest in the world.<br />
Long-Ma, the dragon-scaled winged<br />
horse of Chinese mythology, had to<br />
come to life during the official<br />
ceremony in the Beijing<br />
Olympic Stadium in<br />
October 2014. France<br />
and China planned<br />
to celebrate the<br />
50th anniversary<br />
of their diplomatic<br />
relations.<br />
With only 12<br />
months lead time<br />
Dintec, a wellknown<br />
system<br />
integrator for electric<br />
drives and hybrid<br />
applications, accepted<br />
the challenge to power the<br />
dragon-horse.<br />
http://bit.ly/WINDintec<br />
http://bit.ly/WINSchaeffler<br />
10 TH ANNIVERSARY<br />
When ICR, the Italian perfume manufacturer from Milan set out to bring<br />
its intralogistics up to the state of the art, it was also a decision with<br />
ramifications for the future. ICR found a partner for the job of jointly<br />
developing a suitable concept with intralogistics specialist Jungheinrich.<br />
In this manner a special system solution was developed<br />
featuring industrial trucks equipped with RFID technology and<br />
oriented towards the strategic market goals of ICR.<br />
http://bit.ly/WINJungheinrich<br />
8 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/<strong>2019</strong>
At the port of Callao in Peru,<br />
Beumer installed pipe conveyors<br />
with a length of around three<br />
kilometers for transporting<br />
copper, lead and zinc concentrates<br />
for completion<br />
in 2014.<br />
http://bit.ly/WINBeumer<br />
Dassault Aviation has performed test flights with a<br />
Falcon 7X using a Flir Systems thermal imaging camera<br />
that can differentiate between laminar flows and<br />
turbulent flows, allowing developing technologies for<br />
cleaner and quieter next-generation aircraft.<br />
http://bit.ly/WINFlir<br />
The annual Robo Cup is played to<br />
determine the best football-playing<br />
robots. Several US universities<br />
developed the Darwin-OP robot in<br />
co-operation with South Korean<br />
robotic specialist Robotis and won<br />
both, the RoboCup 2012 and 2013.<br />
http://bit.ly/WINMaxon<br />
Europe‘s largest<br />
plant for<br />
protective gas<br />
hardening<br />
is located<br />
in Bochum-<br />
Riemke. Machine<br />
parts<br />
up to 5.2 m in<br />
diameter and<br />
5.0 m height<br />
are engulfed in<br />
one furnace. Gears<br />
can even be treated<br />
vertically therein and thereby<br />
remain highly customized and dimensionally<br />
stable. Reason enough to send for an<br />
American gear manufacturer to send their<br />
21 -ton gear on the long journey from the<br />
USA to Germany.<br />
http://bit.ly/WINReese<br />
Four<br />
rotary<br />
impellers,<br />
mounted<br />
one above<br />
the other on<br />
the left and<br />
right, propel the<br />
snow as far as 40 m.<br />
Up to 8,500 t of this white<br />
“cargo” can be moved efficiently<br />
each and every hour. In the Alps,<br />
four railway snow blowers, manufactured<br />
by the Swiss company<br />
Zaugg AG Eggiwil, keep the lines<br />
operated by the Rhaetian Railway<br />
clear all year round.<br />
http://bit.ly/WINRexroth<br />
<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/<strong>2019</strong> 9
W RLDWIDE NEWS<br />
Weidmüller wins German Design Award <strong>2019</strong><br />
The electrical engineering company Weidmüller received the German Design Award<br />
<strong>2019</strong> for its innovative range of terminal blocks “Klippon Connect” in the Excellent<br />
Product Design Industry category. The terminal block convinced the international<br />
jury, primarily because it is easy and convenient to use. The clear and straightforward<br />
product structure of the terminal block won over the 46 design specialists from<br />
11 countries during the evaluation. The German Design Award presented by the<br />
German Design Council recognises pioneering products and projects within the<br />
German and international design landscape. This year, the German Design Award<br />
received more than 5,400 entries from 63 countries in the area of product and communication<br />
design. Image caption: Andreas Rutz (l.) and Arnd Schepmann (r.) were delighted<br />
to receive the award in the Excellent Product Design Industry category.<br />
www.weidmueller.com<br />
Asmet automates with TGW<br />
Asmet Sp. z.o.o Sp.k., one of Poland’s leading wholesalers<br />
and manufacturers of special fasteners, has<br />
awarded TGW with logistics consultation and the<br />
erection of a new automated logistics center at<br />
Moszna-Parcela, near Warsaw. With the installation of<br />
the new automated distribution center,<br />
the Polish hidden champion<br />
particularly intends to increase<br />
the level of customer service<br />
and storage capacity for<br />
further global growth.<br />
The order includes the<br />
construction of a new<br />
automated DC based on a<br />
shuttle system, the<br />
integration of multi-functional<br />
workstations for order<br />
picking and packing as well as<br />
the creation of spacious zones for<br />
in- and outbound and an empty tote buffer. The core<br />
of the new logistics solution is a partially equipped,<br />
3-aisle shuttle system with a total of 60,000 storage<br />
locations for totes.<br />
www.tgw-group.com<br />
R+W: Construction of<br />
new headquarters<br />
started<br />
R+W, the specialist for industrial<br />
and precision couplings, is<br />
building a new headquarters in<br />
Wörth am Main in Lower<br />
Franconia, Germany. Work<br />
started at the new Weidenhecken<br />
industrial park in February, where<br />
the new headquarters will be constructed<br />
on a roughly 7,000 m 2 plot. Around<br />
2,500 m 2 will be used for the production facilities<br />
and another approx. 1,000 m 2 will be for office space. “This development<br />
will enable us to significantly increase our capacities in a short amount of<br />
time,” explains the Managing Director, Steffen Herter. This work is necessary<br />
because of the increasing demand in the booming machine manufacturing<br />
market. More than EUR 8 million is being invested in the development that<br />
comprises office and production facilities, production equipment, the expansion<br />
of the German and international teams, as well as product developments. The<br />
move to the new facilities is planned for the end of the summer later this year.<br />
The location was selected in close collaboration with the parent company<br />
Poppe+Potthoff based in Werther, Westfalen, Germany.<br />
www.rw-couplings.com<br />
NEWS AND MARKETS<br />
www.mayr.com<br />
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Mayr.indd 1 12.<strong>02</strong>.<strong>2019</strong> 14:23:32<br />
10 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong>
Jungheinrich: Strategic investment in<br />
lithium-ion technology<br />
Wittenstein SE: Dr. Bertram Hoffmann takes<br />
over as Chairman of the Board and CEO<br />
Change at the helm of the South-West German<br />
mechatronics corporation: Dr. Bertram<br />
Hoffmann (55) will soon be taking over as new<br />
Chairman of the Board and CEO of Wittenstein<br />
SE. A Doctor of Engineering, he is<br />
currently a member of the Executive Board of<br />
Bosch Rexroth AG. Hoffmann will succeed<br />
Wittenstein SE Board Spokesman Dr. Bernd<br />
Schimpf, who will be leaving the company on<br />
March 31, <strong>2019</strong>, at the start of the new fiscal year<br />
<strong>2019</strong>/20. Hoffmann studied Engineering at Karlsruhe<br />
University of Applied Sciences. In 2012, Hoffmann moved to Bosch<br />
Rexroth AG and became Member of the Executive Board responsible for<br />
the Business Unit Renewable Energies. In 2015, he accepted additional<br />
responsibility as Member of the Executive Board for the Business Unit<br />
Mobile Applications and was also made Executive Vice President of the<br />
Business Unit Mobile Applications, responsible for engineering.<br />
www.wittenstein.de/en-en<br />
Jungheinrich AG and Triathlon Holding GmbH have come<br />
together to found JT Energy Systems GmbH, a joint venture<br />
focused on the production and recycling of lithium-ion<br />
battery systems. The company will be based in Glauchau,<br />
Saxony. The founding is subject to approval of the project<br />
by the relevant competition authorities. Jungheinrich holds<br />
a 70 per cent share in the joint venture with Triathlon<br />
taking the remaining 30 per cent. The company is due to<br />
begin operations in August <strong>2019</strong>. JT Energy<br />
Systems intends to create around 100<br />
new jobs at the plant in the next few<br />
years. The aim of the joint venture<br />
between Jungheinrich and<br />
Triathlon is for the two<br />
companies to expand their<br />
production capacities to<br />
cover the ever-increasing<br />
demand for lithium-ion<br />
battery systems and to<br />
further develop their<br />
technological leadership in<br />
this field. JT Energy will<br />
supply products to both<br />
companies.<br />
www.jungheinrich.com<br />
INFO:<br />
VDW – Generalkommissariat EMO Hannover <strong>2019</strong><br />
Verein Deutscher Werkzeugmaschinenfabriken e.V.<br />
Corneliusstraße 4 · 60325 Frankfurt am Main · GERMANY<br />
Tel.: +49 69 756081-0 · Fax: +49 69 756081-74<br />
emo@vdw.de · www.emo-hannover.de<br />
VDW.indd 19xxx_World 1 of industries_185x130_gb.indd 1 26.<strong>02</strong>.<strong>2019</strong> 25.<strong>02</strong>.19 12:11:03 14:06<br />
<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong> 11
Technology and tax cuts<br />
can bail Germany out,<br />
in case of an economic downturn<br />
NEWS AND MARKETS<br />
Last quarter of 2018 and the first quarter of <strong>2019</strong><br />
has not been a very positive one for Germany, but<br />
nevertheless, <strong>2019</strong> still looks to be a positive year as<br />
Industry 4.0 and similar advanced technologies<br />
start to penetrate deeper into German<br />
manufacturing set-up. Going forward, these<br />
technologies will become the new growth drivers of<br />
German manufacturing industry.<br />
Traditionally seen as the powerhouse of Europe, Germany’s<br />
economy is starting to cause concern with uncertainties over<br />
global trade and the manufacturing industry. In January <strong>2019</strong>, the<br />
European Commission revised the growth forecasts for the country<br />
and is now expected to grow by 1.1 % this year, from a previous forecast<br />
of 1.8 %. Germany is Euro zone’s largest economy, this means<br />
that any deceleration will likely be bad news for the rest of the<br />
Europe as well. The Commission also lowered its prospects for the<br />
Euro area as a whole. The region is now set to grow by 1.3 % this year,<br />
from a previous forecast of 1.9 %. The slowdown was caused mainly<br />
by factors, like global trade tensions and weakening exports growth<br />
due to slowdown in emerging economies including China. Recent<br />
data from the German statistical office shows that the country posted<br />
a growth of 1.5 % in 2018, as compared to 2.2 % in the previous<br />
year. German industrial production also declined by 0.4 % monthon-month<br />
in December — following a fall of 1.3 % in November,<br />
making this the fourth consecutive month of decline. This has been<br />
the weakest growth rate in five years. Also, factory orders data<br />
showed a 1.6 % decline in December.<br />
While we have to brace ourselves for another weak quarter in the<br />
first quarter of <strong>2019</strong>, there could be some positive momentum in<br />
the spring. With serious trade negotiations between the U.S. and<br />
China under way, and UK’s Brexit on-going negotiations, chances<br />
Author: Sushen Doshi, International Correspondent for World of Industries<br />
are that progress on these issues will be the game changer that<br />
could turn the sentiment around. This would bring around a<br />
humble return in growth momentum in Germany and the euro<br />
zone. In case of an economic downturn, the German government is<br />
working on bringing in tax cuts and increasing government<br />
spending. Though many experts have discouraged general tax cuts<br />
for Germany in recent years, due to high state debts, the finance<br />
ministry believes that such measures would be justified as a means<br />
against a possible recession. Speaking to a German newspaper, the<br />
Finance Minister Olaf Scholz said, “The good times in which the<br />
state kept taking in more taxes than expected are coming to an end,”.<br />
From rags to riches<br />
After German re-unification, the economic performance of western<br />
Germany was initially strong. In fact, GDP grew at a solid rate of 5 %<br />
until 1991. However, it deteriorated by 1992 and remained dismal<br />
for the remainder of the 1990s. During this time, the unemployment<br />
rate nearly doubled, as GDP growth averaged a meager 1.5 % per<br />
year. In 1994, the Germans feared that the unification of the two<br />
Germanys had failed. By 1999 and 2000 Germany was tagged as<br />
“the sick man of Europe” and in 2003 the German economy was in<br />
deep recession. Since 2004, Germany has emerged from its economic<br />
sluggishness with an exceptional performance. In recent<br />
years, people commonly interpret the rebirth of the German economy<br />
as a new Wirtschaftswunder, an economic miracle which has<br />
brought back the prestige and diplomatic assertiveness that can<br />
determine the fate of the rest of Europe.<br />
Over the past few years, other European countries like Sweden<br />
and France have also had comparable growth rates. But the German<br />
exception lies in having permanently transformed its economic<br />
model in line with the global challenges. The transformation has<br />
also allowed the achievement of the traditional shared goals of the<br />
German society – full employment and low income inequality –<br />
which have always characterized the social market economy. German<br />
governments, both state and federal, have also accompanied<br />
the economy’s internationalization process which was initiated by<br />
large companies and major financial institutions. The common<br />
political analysis behind this is that a population of around<br />
80 million, which produces more than 5 % of global GDP, can<br />
12 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong>
maintain its standard of living only by tying its growth to that of<br />
countries and bringing 6 billion people out of relative poverty. For<br />
this reason, the entire German production system had to and was<br />
able to strengthen its export orientation, while facing the major<br />
geopolitical changes that have directly involved the country: the<br />
German reunification, the European monetary unification, Eastern<br />
Europe opening to international trade. The reality is that, the<br />
process of transformation of German economy was born long<br />
before becoming a political project. It was born under the impulse<br />
of a group of industrial and financial players who were subject to<br />
intense pressure of global competition. Only later, an intensive set<br />
of government-led economic reform programs accompanied the<br />
transformation of production, allowing the entire economy to<br />
benefit from their acquired competitive success.<br />
Export scenario for Germany<br />
In 2017 alone, Germany shipped nearly $ 1.5 trillion worth of goods<br />
around the globe. In dollar terms it reflects a gain of more than<br />
7.5 % from the previous year. In the first nine months of 2018,<br />
Germany exported goods worth $ 1.2 trillion. This 9-month metric<br />
puts German exports on track for an annualized $ 1.5 trillion<br />
estimated for all of 2018. From a continental perspective, around<br />
two thirds of German exports by value were delivered to other<br />
European countries, approximately 18 % were sold to Asian<br />
countries and 10 % to North America. With Germany’s population<br />
of nearly 80 million people, its total $ 1.5 trillion in 2017 exports<br />
translates to roughly $ 18,000 for every resident in the country. The<br />
top industry sectors driving the exports were as follows:<br />
n Automobiles and components: $ 250 billion<br />
n Machinery including computers: $ 245 billion<br />
n Electrical machinery, equipment: $ 150 billion<br />
n Optical, technical, medical apparatus: $72 billion<br />
n Aircraft and aviation products: $ 40 billion<br />
Germany’s focus on advanced manufacturing<br />
technologies<br />
For the next 5-10 years, advanced manufacturing technologies are<br />
set to provide the best export potential for industry sectors such as<br />
machine tools, industrial machinery, robotics, information and<br />
communication technology, process control instrumentation and<br />
electronics equipment, additive manufacturing and advanced<br />
materials. On the domestic front as well, till 2<strong>02</strong>5, more than 80 % of<br />
German manufacturers plan to invest more than $ 100 billion every<br />
year into smart manufacturing technologies.<br />
Germany is the fifth largest robot market in the world with about<br />
20,000 industrial robots being used in industries such as automotive,<br />
electrical and electronics, metal working, chemical, plastics,<br />
and the food industry. Overall the robotics and automation sector<br />
in Germany saw a successful period with sales figures reaching<br />
nearly € 15 billion in 2017, posting a growth of 13 %. All three sectors<br />
of German robotics and automation were on a strong growth<br />
course. The machine vision sector experienced a growth of around<br />
17 % taking its annual turnover to € 2.6 billion. The German robotics<br />
sector also experienced a dynamic period of growth with sales<br />
rising by 17 % to € 4.2 billion. The largest sub-sector of German<br />
robotics and automation, the integrated assembly solutions saw a<br />
sales growth of 9 %, reaching a new record of € 7.6 billion. After the<br />
enormous investments of the electronics and automotive industries<br />
in 2016-17, order intake in the first half of 2018 was no longer as<br />
dynamic as the previous years, due to a normal cyclical effect. In<br />
addition, political developments with protectionist tendencies in<br />
North America and Asia had a dampening effect on the willingness<br />
to invest. This has given the robotics and automation companies a<br />
breathing space and to reduce the order backlog. A high order backlog<br />
and the extended delivery times for systems are reasons for a<br />
partial shift in sales to <strong>2019</strong>. The transformation of the powertrain in<br />
particular requires new technological competencies and manufacturing<br />
solutions. New components such as the battery or the hybrid<br />
drive require new automation solutions with diverse measuring<br />
and testing tasks. With Asia’s electronics sector undergoing heavy<br />
automation, the demand for German products will be on the rise in<br />
the coming years. Further growth opportunities are also seen in the<br />
metal, plastic, medical technology and the food and packaging industry.<br />
A growth rate of at least 5 % is expected again in <strong>2019</strong>,<br />
provided that the political and economic situation does not hinder<br />
investments in automation.<br />
Photo: fotolia z<br />
<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong> 13
Smart logistics equipment and<br />
machinery to drive growth in logistics<br />
sector in the coming decades<br />
NEWS AND MARKETS<br />
With conventional growth slowing down in China,<br />
all industry sectors are adjusting to this ‘new<br />
normal’, to ensure their readiness for the coming<br />
decades enterprises even in logistics sector are<br />
swiftly moving towards latest technologies like<br />
logistics 4.0 and smart logistics equipment. At the<br />
LET event in Guangzhou, one can witness the<br />
direction in which logistics sector in China headed.<br />
D<br />
ecades of double digit growth has made China not just a manufacturing<br />
powerhouse, but also one of the biggest logistics<br />
market in the world. The logistics industry has played an extremely<br />
essential role in China’s rise to top. However, in comparison to<br />
developed industrial nations China’s logistics industry faces high<br />
operational costs and relatively low efficiency. The ratio of China’s<br />
logistics cost to GDP is roughly around 14 %, as compared to USA’s<br />
nearly 8 %. Taking automobile sector for example, the logistics cost<br />
ratio in China is somewhere around 8-9 %, whereas in Europe and<br />
America is around 3 % and 5 % in Japan. According to World Bank’s<br />
international Logistics Performance Index, which covers six key<br />
aspects: customs, infrastructure, international shipments, logistics<br />
competence, tracking &tracing, and timeliness, China is ranked<br />
26th in world. Showcasing big gaps over its competitors like<br />
Germany, Japan etc. Realizing this fact, China’s government has<br />
already taken strategic measures to reduce logistics costs and<br />
improve logistics efficiency to spur the real economy.<br />
Author: Sushen Doshi, International Correspondent for World of Industries<br />
But, over the last two years, the growth rate of China’s logistics services<br />
revenues has been facing pressure from a slowdown in the<br />
country’s GDP. According to data from China National Bureau of<br />
Statistics, the transportation and warehousing revenues have been<br />
growing much less than the average growth rate of the country. In<br />
terms of profitability as well, a continuous rise in warehousing costs<br />
and labor costs have been deteriorating the profitability for the<br />
entire sector. In the long-term, with an aging population, labor<br />
shortages will arise and due to rising urbanization the shortage of<br />
warehousing space will be inevitable, thus leading to rise and rise of<br />
operational costs.<br />
Currently, industry’s structure is also a lot more traditional in<br />
nature, which gives immense scope for modernization and<br />
incorporation of latest technologies. Now, China looks towards<br />
high-end manufacturing industry and the domestic consumption<br />
boom to drive up the demand for logistics services. From 2018,<br />
public sector as well as private companies are looking to prioritize<br />
on upgradation of logistics facilities and equipment to enhance the<br />
efficiency of the industry. Under such circumstances, smart logistics<br />
is gaining ground and becoming a key area to focus on for the whole<br />
industry to improve. Smart logistics has significant potential, for<br />
example, with modern warehousing concepts, companies can save<br />
nearly 50 % on land costs and labor costs. By fully monitoring the<br />
whole process of material transfer and storage, the efficiency and<br />
accuracy can be improved. Furthermore, with data collected by<br />
smart logistics systems, enterprises can more provide value-added<br />
services and derive new business models for customers.<br />
Future market opportunities<br />
China’s ambitious belt and road initiative is one of the driving engines<br />
for future development. It contributes largely to exports, and<br />
is expected to continue boosting logistics demand in the future. At<br />
present, most provinces and cities en route the ‘belt and road’ are<br />
14 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong>
accelerating the development of logistics industry, especially the<br />
mid-western area represented by Zhengzhou, Xi’an, Lanzhou, and<br />
Urumqi, in a vision to build themselves as logistics hubs. After the<br />
establishment of transportation logistics hubs, certain export processing<br />
enterprises targeting Europe and other regions may choose<br />
to produce, process, disassemble and package locally; it would also<br />
form clusters of populations in the mid-western area, accelerating<br />
its process of development.<br />
China’s intelligent logistics market reached Yuan 200 billion in<br />
2016, experts predict it will exceed 1 trillion Yuan by 2<strong>02</strong>5. Some<br />
emerging technologies including drone, robotics and automation,<br />
and data analytics are in high demand in logistics industry, as well<br />
as wearable devices, 3D printers, driverless trucks and artificial intelligence<br />
are being used in storage, transportation, delivery and<br />
other end parts of logistics. As China’s manufacturing sector undergoes<br />
transformation, factories will also focus on reforming their logistics<br />
operations, thus leading to an enormous demand for intelligent<br />
factory logistics systems. In China’s smart logistics segment,<br />
vendors are generally classified into three types; hardware suppliers,<br />
software suppliers and comprehensive suppliers. Amongst<br />
them, the comprehensive suppliers are the ones with a better competitive<br />
advantage thanks to their integrated services. Most of the<br />
foreign companies operating in this space are comprehensive suppliers,<br />
and enjoy a competitive edge in terms of technologies and<br />
project experience with strengths in high-end logistics hardware<br />
and software. Whereas domestic companies, with advantages in<br />
price and local reach have a competitive edge in mid-range and<br />
low-end projects. Domestic manufacturers mainly serve as equipment<br />
suppliers or system sub-contractors with each of them operating<br />
on a small scale. With the improvement in R&D as well as<br />
availability of intelligent logistics equipment, the systems provided<br />
by domestic manufacturers are able to meet the needs of most general-purpose<br />
applications, significantly impacting the market share<br />
of foreign manufacturers who are engaged in complete intelligent<br />
logistics equipment production. Moving forward, domestic manufacturers<br />
need to further increase their input in R&D to improve the<br />
level of hardware, lean production and software performance.<br />
Rising demand in the future for intelligent equipment in pricesensitive<br />
industries will provide more space for the development of<br />
domestic manufacturers which offer competitive prices. Based on<br />
integration experience and knowledge gained over time, domestic<br />
manufacturers will have the opportunity to expand their scales and<br />
become stronger in some application fields.<br />
Logistics equipment and technology exhibition<br />
While in the midst of multi-level transition of China’s economy as<br />
well as manufacturing and logistics industry sectors, events such as<br />
LET (Logistics equipment and technology exhibition), become the<br />
guiding light for large and small enterprises. LET, is a CeMAT Asia<br />
event, and is the biggest smart logistic equipment and technology<br />
trade fair in South China. Since the first edition in 2010, LET has<br />
grown to become a successful brand in itself over the last nine years.<br />
With the exhibition expanding its floor space display area, increasing<br />
number of visitors and exhibitor companies, and improving level<br />
of its exhibits, LET is becoming one of the strongest events in the<br />
South China region. Now in its 10th edition, the logistic equipment<br />
and technology show aims to cater the market with latest trends in<br />
technology, innovation and services in the sector. With a floor space<br />
of 20,000 square meters and around 32,000 visitors in 3 days, the LET<br />
show was a big success in 2018. The 10th edition of the LET show will<br />
be hosted at the China Import & Export Complex in Guangzhou<br />
from 29th - 31st May. <strong>2019</strong>.In <strong>2019</strong>, the LET event will be stronger, as<br />
it will be hosted by Hannover Milano Best Exhibitions (Guangzhou)<br />
Co.,Ltd, a joint venture between Guangzhou Best Exhibition Co.,<br />
Ltd. and Hannover Milano Fairs Shanghai Ltd. The show will combine<br />
the strengths of both the partners, and become one of the most<br />
influential shows for the Chinese logistics market.<br />
Like previous years, the show promises to provide a high-quality<br />
trade fair platform for exhibitors to display, communicate and find<br />
partners for co-operation in Chinese logistics market. In 2018, nearly<br />
300 top logistics equipment and technology companies from all<br />
over the world participated and brought their advanced exhibits<br />
like, intelligent forklift trucks, smart logistics systems, logistics robots,<br />
AGV, green material handling technology, lithium battery fast<br />
charging technology, laser slam unmanned guiding technology,<br />
smart factory solutions, etc. Furthermore, nearly 100 industry experts<br />
and scholars shall be present onsite to discuss on current<br />
trends of intelligent logistics, automation, information technology,<br />
advanced manufacturing, Industry 4.0 and Logistics 4.0. Visitors<br />
can interact with exhibitor companies and work together to develop<br />
tailor made solutions for the South China market.<br />
Over the last few years, China’s e-commerce industry has seen<br />
explosive growth, and so has the demand for logistics products and<br />
services like AGV, robots, logistics IT, sorting and delivery systems<br />
etc. At LET too, visitors have expressed their interests in these areas.<br />
The product category at LET includes mechanical handling equipment<br />
like cranes, elevators, cable cars, lifting equipment and platforms,<br />
hoisting platforms, bulk goods and monorail conveyors, trolleys,<br />
industrial trucks, forklifts, robotic handling systems, driverless<br />
transport systems, storage and retrieval equipment for shelves and<br />
racks, components of drive technology, hydraulics and pneumatics.<br />
The display area also has products for warehousing and shelving systems,<br />
industrial doors and gates, pallets, bins and containers, cleaning<br />
systems for warehouses and storage facilities etc. Exhibitors will<br />
also showcase various packaging and order picking systems, weighing<br />
and metering devices, labelling and identification systems etc. In<br />
terms of logistics software, visitors can see software for material flow<br />
and movement, various types of sensors and auto-identification systems,<br />
branch specific software for transportation logistics etc.<br />
Photograph: Fotolia<br />
www.chinalet.cn<br />
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Internet: www.world-of-industries.com
Hannover Messe <strong>2019</strong>: taking you to the<br />
forefront of the fourth industrial revolution<br />
Over the last few years, Industry 4.0 has been the buzz word for the entire<br />
industrialized world, and Hannover Messe has been it’s the global hotspot. It has<br />
been revolutionizing the industrial sector just like the steam engine, mass<br />
production and automation did. And the best part is, we are just getting started.<br />
NEWS AND MARKETS<br />
The foundation for this modern industrial revolution is the<br />
continuous exchange of data between production, logistics and all<br />
operations, making our factories more intelligent, efficient and<br />
sustainable. Few years ago, when the talk of fourth industrial revolution<br />
began, the mood around was ecstatic. This led to a rapid but haphazard<br />
development of products and solutions. Without completely<br />
understanding the opportunities and challenges that Industry 4.0<br />
brings, companies were working on random solutions and missing<br />
out on the bigger picture. This is where Hannover Messe comes in.<br />
Events like Hannover Messe, provide a broader view of the risks<br />
involved and the solutions needed to be developed. Regular visitors at<br />
Hannover Messe can surely feel the difference in standard and quality<br />
of Industry 4.0 products and technologies from six years ago and today.<br />
The level of sophistication and ability to find solutions on more and<br />
more complex problems of the industry has also increased. In the<br />
beginning, companies were focusing on the low hanging fruits and<br />
benefits of Industry 4.0, now with more and more organizations<br />
joining hands and sharing knowledge, the industry has started to<br />
unravel the real potential of Industry 4.0 technologies. Today, along<br />
with large corporations even smaller companies are investing their<br />
capital, human and technological resources to move closer to the<br />
vision of total digitalization.<br />
Just like every year, this year too, industry experts, professionals,<br />
manufacturers and end-users from all over the world shall gather on<br />
the fair grounds of Hannover Messe from 1 st - 5 th April, <strong>2019</strong>. This five<br />
day mega-event will see more than 220,000 visitors and 6500 exhibitor<br />
companies. With it’s lead theme as ‘Integrated Industry - Industrial Intelligence’,<br />
this year the focus will be on integrating artificial intelli-<br />
gence and industry 4.0 technologies. Along with digitalization, another<br />
important technology that has been picking up speed is artificial<br />
intelligence. In a smart factory, where machines, interfaces, and<br />
components communicate with one another, large amounts of data is<br />
accumulated. This data when analyzed, can optimize processes, find<br />
new solutions and make predictions. At Hannover Messe, visitors can<br />
understand what artificial intelligence and machine learning can<br />
make possible in industrial applications – both now and in the future.<br />
Meet your new colleague, ‘the Cobot’<br />
One of the biggest attractions at Hannover Messe has been the rise of<br />
Cobots or collaborative robots. Unlike traditional industrial robots, that<br />
perform their work in physically isolated units, cobots react to people<br />
and not just follow pre-programmed commands. Equipped with sensors,<br />
they observe the movements and positions of humans and assist<br />
workers directly without exposing the humans to any risk of injury.<br />
They are flexible, easy to program and easy to move, weighing just ten<br />
kilograms. With “direct guidance,” method, the robot only moves upon<br />
receiving direct input from a human, such as by touching the robot<br />
arm. This ensures the employee has complete control over the cobot at<br />
all times. With the rise of this technology, it has now become possible<br />
even for SME’s to invest in robotics and boost their competitiveness, as<br />
Cobots are cheaper than actual robots. With Germany being one of the<br />
leaders in robotics, it isn’t surprising that here Cobots are in demand as<br />
well. At Hannover Messe <strong>2019</strong>, visitors can meet and interact with the<br />
leading developers of cobots to understand their advantages and limitations,<br />
in order to make an informed decision.<br />
16 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong>
Predictive maintenance: repair before breakdowns<br />
In Germany, the topic of predictive maintenance has become increasingly<br />
important in recent years, and is inseparable from the themes of<br />
Industry 4.0. Today, machine manufacturers are working to equip their<br />
machines and industrial systems with sensors that enable remote<br />
monitoring, that can measure vibration, temperature or humidity, for<br />
example. Specialized maintenance software collects this sensor data,<br />
evaluates it and recognizes in advance when a component might be in<br />
danger of failing. Defective components that could soon lead to a system<br />
shutdown are identified and can be replaced before damage actually<br />
occurs. The key advantages of predictive maintenance are cost effectiveness,<br />
controlled breakdowns, reduced maintenance and energy<br />
costs. Right from the inception stage of this technology, Hannover<br />
Messe has been backing it up. At Hannover Messe <strong>2019</strong> as well, you can<br />
discover the innovations first hand that are headed towards the market.<br />
Digital twin: a clone for your machine<br />
Another technology that has been trending in Europe and America is<br />
the digital twins, i.e. digital representations of physical machines. Right<br />
from the initial design phase through to production even after the sale<br />
of the product, the virtual twin stays connected with physical product<br />
with sensors that send status data on a constant basis. The incoming<br />
data is gathered and compared against the original design and specifications.<br />
If a discrepancy is detected, then engineers can work on potential<br />
solutions directly on the digital twin - after which the real machine<br />
can then be updated to resolve the problem as quickly as possible. In<br />
the future, all stakeholders will be networked: suppliers, producers and<br />
customers. At Hanover Messe <strong>2019</strong>, visitors can look towards building a<br />
strong network between machine builders, electrical engineers and IT<br />
service providers who can work together on the twin technology.<br />
Hannover Messe <strong>2019</strong>: Trade Fair line up<br />
As the world’s largest and most influential industrial trade fair, Hannover<br />
Messe covers the most fundamental industry sectors. With 6<br />
international leading trade fairs at the same time under one roof, it<br />
offers an extensive collection of products and technologies. The trade<br />
show line up at Hannover Messe includes - Integrated Automation<br />
Motion and Drives (IAMD), Digital Factory, Integrated Energy, Industrial<br />
Supply, Research Technology and ComVac. The IAMD show<br />
is Hannover Messe’s flagship brand and one of the world’s leading<br />
show that attracts more than 2000 exhibitors and 100,000 visitors<br />
from around the globe. As the global hotspot for Industry 4.0. that<br />
covers everything to do with industrial automation, industrial IT,<br />
power transmission, and fluid power technology – from mechanical<br />
engineering and robotics to process automation. Product category at<br />
IAMD includes mechanical power transmission systems and equipment<br />
like belt and chain drives, couplings and clutch units, various<br />
types of braking systems and accessories for brakes, entire gears<br />
units, geared motors and bearings. Electrical equipment that<br />
includes, electric switch gears, contactors and relays, electric motors,<br />
frequency drives, cables and cabling accessories, electronic and<br />
opto-electronic components. The robotics display includes industrial<br />
as well as mobile robots including cobots, driverless transport systems,<br />
programming and engineering services for robotics. IAMD<br />
also has on display products and systems from the fluid power technology<br />
like hydraulic pumps, hydraulic and pneumatic cylinders,<br />
gear pumps, hydraulic variable speed drive units, control valves,<br />
pipes, hoses and connectors, filters for hydraulic and oil lubrication<br />
systems, pneumatic actuator drives, hydraulic and pneumatic sealing<br />
devices, products and systems for condition monitoring and<br />
predictive maintenance. In industrial automation segment, IAMD<br />
focuses on control systems like HMI, PLC, Scada, embedded systems<br />
and industrial PCs, sensors and actuators, communication network<br />
and field bus systems, measuring and test equipment.<br />
The Digital Factory is a trade show dedicated for industrial IT solutions<br />
and integrated processes. Here visitors can find a full array<br />
of solutions for tomorrow’s smart factories – for example, additive<br />
manufacturing systems for non-metals, artificial intelligence and<br />
machine learning systems, advanced simulation systems, image<br />
processing software, industrial cloud services for condition monitoring<br />
and predictive maintenance, data management software,<br />
and the required IT hardware, operating systems for industrial IT,<br />
virtual reality systems for industrial applications, software solutions<br />
for PLM, ERP, MES, raw materials and production planning etc.<br />
Integrated Energy: With increasing industrialization, the global<br />
energy consumption is bound increase. Also, the energy generation is<br />
set to increase especially in the renewable energy sector. Even today,<br />
we can experience the imbalance between energy production, storage<br />
and consumption. More than anything else, today the energy sector<br />
requires efficient utilization of the energy resources, but also sensibly<br />
connecting the energy production and storage system to form an<br />
integrated energy system. Smart grids ensure the efficient coordination<br />
of production, storage, grid management and consumption so<br />
that suppliers can maintain a smooth system. Hannover Messe <strong>2019</strong>,<br />
features the Energy show, a trade show for integrated energy systems<br />
and e-mobility. This show has on display latest technologies in energy<br />
generation and distribution systems, heat management for office and<br />
production buildings, virtual power plants, load management and<br />
energy intelligence software, energy data management and optimization<br />
systems, electrical energy conversion and storage systems like<br />
transformers, accumulators, chargers, UPS, hydrogen and fuel cells<br />
etc. The e-mobility sector is also featured prominently at Hannover<br />
Messe with spotlight on electric transport vehicles for goods and passengers,<br />
infrastructure solutions for e-mobility like charging stations,<br />
cables and replaceable battery systems etc.<br />
Photographs: Deutsche Messe AG<br />
www.hannovermesse.de<br />
<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong> 17
Hannover Messe:<br />
Home of industrial pioneers<br />
Christian H. Kienzle , CEO, Argo-Hytos<br />
Kirsten Billhardt, Marketing Strategist - Internet of<br />
Things, Dell<br />
THE SLOGAN <strong>OF</strong> HANNOVER MESSE IS A<br />
VERY GOOD APPROACH, BECAUSE IT WILL<br />
DEMONSTRATE THE COMPET<strong>EN</strong>CE <strong>OF</strong> OUR<br />
INDUSTRY <strong>WORLD</strong>WIDE. ALSO IT SHOWS THE<br />
EMOTIONS TO BE ON THE SHOW.”<br />
DELL’S WAR IS TO HELP TO <strong>EN</strong>ABLE A<br />
MANUFACTURING CUSTOMER TO ACHIEVE<br />
THEIR PIONEERING DREAMS.”<br />
www.world-of-industries.com/hm_usa_2<br />
www.world-of-industries.com/hm_usa_1<br />
Richard Huss, CEO, Festo USA<br />
Dr Jochen Köckler, CEO, DMAG<br />
PEOPLE ARE COMING TOGETHER FOR A<br />
TRADE SHOW. ALL <strong>OF</strong> OUR EXHIBITORS ARE<br />
PERSONS WHO <strong>OF</strong>FER SOMETHING TO MAKE<br />
LIFE MORE COMPETITIVE IN THE INDUSTRIAL<br />
<strong>WORLD</strong>.”<br />
AS HANNOVER MESSE GOES TO BE THE HOME<br />
<strong>OF</strong> INDUSTRIAL PIONEERS, FESTO <strong>OF</strong> COURSE<br />
WILL HAVE A NEW BIONIC PRODUCT, TO SHOW<br />
HOW NATURE HAS THE MOST <strong>EN</strong>ERGY EFFICI<strong>EN</strong>T<br />
AND MOTION EFFICI<strong>EN</strong>T WAY <strong>OF</strong> DOING THINGS.”<br />
www.world-of-industries.com/hm_usa_7<br />
www.world-of-industries.com/hm_usa_8<br />
Chris Dennen, Marketing Manager, Igus<br />
Christina Chatfield, Vice President of Digital<br />
Strategy, Harting<br />
HOME <strong>OF</strong> INDUSTRIAL PIONEERS, THAT<br />
REALLY EQUALS HARTING FOR ME. THE<br />
FOUNDER WILHELM HARTING WAS ACTUALLY<br />
THE INV<strong>EN</strong>TOR <strong>OF</strong> THE RECTANGULAR<br />
CONNECTOR. THESE DAYS, EVERYBODY IS TALKING ABOUT THE<br />
“HARTING CONNECTOR”.<br />
www.world-of-industries.com/hm_usa_3<br />
WE ARE VERY EXCITED ABOUT THE NEW<br />
THEME, BECAUSE WE BRING A LOT <strong>OF</strong> OUR<br />
INNOVATIONS FOR OUR CUSTOMERS WHICH<br />
THEY REALLY NEED TO BE AN INDUSTRIAL PIONEER.”<br />
www.world-of-industries.com/hm_usa_4<br />
Michael Koch, CEO, Michael Koch GmbH<br />
NEWS AND MARKETS<br />
Industry experts, professionals, manufacturers<br />
and end-users from all over the world shall gather<br />
on the fair grounds of Hannover Messe from 1 st<br />
- 5 th April, <strong>2019</strong>. World of Industries was present<br />
at the Hannover Messe USA and visited<br />
well-known companies. They were asked: “One of<br />
the themes of the Hannover Messe <strong>2019</strong> is “Home<br />
of Industrial Pioneers”. Does your company also<br />
see itself as a pioneer – and if so, in what sense?”<br />
WE BELONG TO THE HANNOVER MESSE AND<br />
WE ARE SUPPORTING INDUSTRIAL PIONIEERS<br />
E.G. BY THE HERMES AWARD.”<br />
www.world-of-industries.com/hm_usa_5<br />
Hala Zeine, President Digital Supply Chain and<br />
Manufacturing, SAP<br />
A PIONEER IS SOMEONE WHO IS ALWAYS<br />
PUSHING THE EDGE. [..] WE SEE OUR ROLE AS<br />
SUPPORTING OUR CUSTOMERS USING THAT<br />
INNOVATION AND THAT’S PIONEERING SPIRIT.”<br />
www.world-of-industries.com/hm_usa_6<br />
18 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/<strong>2019</strong><br />
Images: Dr. Michael Werner, Deutsche Messe AG
Energy-efficient high hressure hydraulics<br />
High-pressure hydraulic pumps from the PZH series produced by<br />
Nachi are designed to ensure the economic operation of bending<br />
presses and injection molding machines. Hydraulic presses and<br />
injection molding machines usually use a lot of energy. These<br />
axial piston pumps can be used to design the drives more<br />
efficiently. They generate up to 350 bar of pressure at a volume<br />
flow rate of up to 72 cm³/revolution. Eleven pistons<br />
ensure an even and low pulsating flow of<br />
hydraulic oil and also guarantee that<br />
the pump operates quietly. Their<br />
sturdy, cast casings, generously<br />
dimensioned roller bearings, and<br />
the spherically hardened swash<br />
plate mean that the pumps can<br />
even be used in harsh ambient<br />
conditions for long periods. The<br />
pump shafts are equipped with feather<br />
keys so that they can be driven with suitable<br />
electric motors and can transfer the required torques. Pressure,<br />
performance, and volume controllers are specially designed by<br />
the manufacturer for the pumps of the individually optimized<br />
hydraulic systems.<br />
EtherCAT with CiA4<strong>02</strong> drive profile<br />
JVL has launched the CiA4<strong>02</strong> drive profile<br />
and synchronization for EtherCAT. The<br />
EtherCAT module with this drive profile<br />
for JVL servo and step motors<br />
supports CSP and CSV, as well as<br />
older operating modes. The JVL<br />
EtherCAT module is equipped<br />
with two Ethernet connections<br />
and an integrated switch with<br />
which a line, star, tree, and ring topology can be implemented<br />
without additional hardware. Opto-insulated<br />
I/Os are integrated in the module thus enabling other<br />
sensors, etc. to be controlled without any external I/O<br />
modules. This keeps the number of devices in the<br />
network to a minimum and reduces cable costs. All of the<br />
indexes in the JVL MAC motor are also accessible via the<br />
EtherCAT connection thus providing complete control of<br />
the motor configuration and movements. JVL motors<br />
equipped with EtherCAT are plug and play compatible<br />
and can be used with PLCs from Beckhoff as well as other<br />
manufacturers of EtherCAT masters such as Omron,<br />
Lenze, or Trio.<br />
background: fotolia<br />
www.nachi.de<br />
www.jvl.dk<br />
DER ANTRIEB<br />
Reliable. Versatile. Global.<br />
Hall 15<br />
Stand H31<br />
THE GEAR UNIT<br />
Strong bearings<br />
Quiet running<br />
THE MOTOR<br />
High efficiency<br />
Global standards<br />
THE DRIVE ELECTRONIC<br />
Field distribution system<br />
Easy implementation<br />
Getriebebau NORD GmbH & Co. KG | Fon +49 4532 289-0 | info@nord.com<br />
nord.com
Gear units for<br />
Sugarloaf Mountain<br />
Sugarloaf Mountain in Rio de Janeiro is one of the most famous landmarks in the world. It is thus<br />
not surprising that every tourist wants to enjoy the view of the beautiful vista made up of the<br />
sea, city, and Christ the Redeemer statue. To ensure that operations continue to run smoothly in<br />
future, modern Flender gear units were installed in the cableway that runs to the<br />
peak of the mountain as part of a retrofit project. The individuals responsible for the<br />
prestigious project decided to choose a premium supplier from Germany.<br />
Author: Andreas Lüdiger is Vice<br />
President Service Sales at Flender<br />
GmbH in Bocholt, Germany<br />
MOTION AND DRIVES<br />
Thousands of tourists want to “scale” the world famous Sugarloaf<br />
Mountain in the Brazilian city of Rio de Janeiro. A column-free<br />
cableway takes tourists up the 395 m tall granite rock that protrudes<br />
out of the sea. Tourists start at sea level taking the first cableway to<br />
Morro da Urca from where they can catch a second cableway, often<br />
referred to as “O Bondinho”, to the top of Sugarloaf Mountain. At the<br />
summit you are rewarded with a panoramic view of the open sea,<br />
the city of Rio de Janeiro nestled between the cliffs, the famous<br />
beach at Copacabana, and the world famous, 38 m tall statue of<br />
Christ the Redeemer located at the peak of the Corcovado mountain<br />
about five kilometers away.<br />
The first cableway was placed into operation in 1912/13 and was<br />
renewed in 1972 to accommodate the rising number of visitors. A<br />
good forty years later, it was time to complete a comprehensive<br />
technical modernization to be able to guarantee the continuous<br />
fault-free operation for the around 1.5 million tourists from all<br />
around the world that visit Sugarloaf Mountain each year. “As the<br />
world’s leading manufacturer of gear transmissions, Flender was<br />
selected by the operating company to supply the new gear units for<br />
this prestigious retrofit project,” reports Andreas Lüdiger, Vice President<br />
Service Sales at Flender GmbH based in Voerde, Germany.<br />
Gear units for immediate installation<br />
A deciding factor was that the gear specialist was able to guarantee<br />
a plug & play solution. This meant that the new gear units were calculated<br />
based on the standard Flender gear unit system and then<br />
adapted to the existing connecting dimensions. In line with gear<br />
technology, that has continuously been improved over the decades,<br />
high-quality gear units with an even higher service factor than<br />
those previously used on Sugarloaf Mountain have now been<br />
installed. “For the operator, this basically means that they have<br />
invested in sustainability, which on the one hand is based on the<br />
“Made in Germany” quality seal and on the other relies on a significantly<br />
higher level of operational safety,” explains the Vice President<br />
Service Sales.<br />
With more than one million variants, Flender’s range of helical<br />
and bevel-helical gear units is the most comprehensive range of<br />
gear units in the world. “Our customers also realize that we by far<br />
offer the most comprehensive range of industrial gear units worldwide,”<br />
emphasizes Andreas Lüdiger. The associated flexibility this<br />
can offer in conjunction with decades of specialist knowledge, and<br />
the large production capacity are often the deciding factors when<br />
20 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong>
<strong>02</strong> Andreas Lüdiger (left) with<br />
Diego Scofano – Technical Director of<br />
the Sugarloaf Mountain cableway<br />
01 The Sugarloaf Mountain gear units were delivered<br />
ready-to-install so that no modifications had to be made to<br />
the existing structure<br />
03 With more than one million<br />
variants of the helical gear unit system<br />
from Flender, it is the world’s largest<br />
range of industrial gear units<br />
awarding contracts, such as the Sugarloaf Mountain project. The<br />
nominal transmission ratio of the gear units ranges from i=1.25 to a<br />
value of 450. The nominal torque ratio ranges from TKN=3 100 Nm<br />
to 1,400,000 Nm available in 28 sizes.<br />
Suitable solution for every retrofit<br />
“With our extensive range of gear units, everyone will find a suitable<br />
solution for their retrofit project,” guarantees Andreas Lüdiger. Two<br />
Flender bevel-helical manual gear units with a similar structure are<br />
being used at the intermediate station on both of the cableways on<br />
Sugarloaf Mountain. Two input shafts, that are offset at a right angle,<br />
are driven by two three-phase asynchronous motors. Activation<br />
will ensure that the transport performance can be adjusted accordingly<br />
if the number of passengers increases. The power at the output<br />
shaft can thus be increased to a maximum value of 250 kW. The<br />
bevel-helical gear unit weighs approx. 3.7 t and, just like the second<br />
gear unit, was able to be transported through the gate of the technical<br />
building. Andreas Lüdiger explains: “It is particularly important<br />
on retrofit projects that the optimum structural requirements are<br />
taken into consideration. As a premium gear unit manufacturer, we<br />
are able to build complete gear unit solutions that are as compact as<br />
possible and comprise high-quality geared parts and special sealing<br />
elements.”<br />
A „near-series”, ready-to-fit total solution of this kind was also<br />
delivered for this Brazilian prestige project. The axis heights and<br />
mounting dimensions on the base are designed in such a way that<br />
no minor alterations or adjustments were required on site. The new<br />
gear unit was installed within a few days thus ensuring that the<br />
tourists on Sugarloaf Mountain will continue to be transported<br />
safely in future. The motors have an initial speed of 1500 rpm, that is<br />
throttled to the speed (73.57) of the drive wheel on the cableways by<br />
the Flender gear units.<br />
Standard gear unit with cableway modifications<br />
Particular specifications must be met when equipping cableways.<br />
In addition to the engineering specifications and calculations based<br />
on cableway standards, the thermal application limits also play an<br />
important role. In this respect, Flender products cover a temperature<br />
range of -30°C to +40°C and the company also supplies additional<br />
heating units and various cooling system, if required. “The<br />
deciding factor is that the gear unit solutions are operationally safe,<br />
have a long service life, and are sustainable,” explains the Flender<br />
Service Sales manager. This means that standard gear units with<br />
cableway modifications are compact, have been optimized with<br />
regard to their noise levels and weight, and will operate for decades<br />
without any faults.<br />
Other advantages that the operators of the Sugarloaf Mountain<br />
cableway also greatly appreciate include the option to procure<br />
spare parts from the standard range of products, as well as the fast<br />
and professional reaction to service requests. The close proximity of<br />
the Brazilian Flender partner in Rio de Janeiro, just a few kilometers<br />
from Sugarloaf Mountain offers the operator of the prestigious<br />
cableway on Sugarloaf Mountain an additional level of security.<br />
“This enables us to strengthen our image as a premium supplier<br />
meeting the highest level of quality and service requirements,”<br />
explains industry expert Lüdiger.<br />
Gear units for a sustainable retrofit<br />
With just six months between the contract being awarded and<br />
delivery of both of the ready-to-install cableway gear units, the gear<br />
unit manufacturer demonstrated its ability to react quickly. At the<br />
same time, the customer also benefits from the intrinsic values<br />
developed during the retrofit project. These include the increased<br />
level of service – a direct result of the improved technology. In comparison<br />
to the original gear units from 1972, which were designed<br />
as tooth flanks and self-hardened as standard, the ones in use today<br />
are case-hardened and smoothed thus making them considerably<br />
more torque-resistant.<br />
Gearing technology as such has also become more powerful,<br />
which in turn affects the efficiency. The roller bearings have become<br />
significantly more powerful and have a longer service life compared<br />
to those of a similar caliber. “Over the decades, many of the gearing<br />
technology parameters have been gradually optimized, so that<br />
basically all retrofit projects benefit greatly,” summarizes Flender<br />
Service Sales Manager, Andreas Lüdiger. His conclusion: “When<br />
working with a premium gear unit manufacturer as a partner, modernizations<br />
such as the ones that were part of the prestigious Sugarloaf<br />
Mountain cableway project can be implemented quickly,<br />
con veniently, and sustainably.”<br />
www.flender.com<br />
<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong> 21
01 03<br />
<strong>02</strong>a<br />
<strong>02</strong>b<br />
Cable carriers with chemical-resistant<br />
plastic deal with high acid exposure<br />
MOTION AND DRIVES<br />
On the pre-treatment line of a hot dip galvanizing<br />
plant, working conditions are harsh, as the work-pieces<br />
have to be cleaned in diluted hydrochloric acid. As a<br />
result, the concentration of hydrogen chloride in the<br />
air around the pre-treatment line is around 2 percent.<br />
This means that the indoor crane and the components<br />
on it are subjected to exceptional acid exposure. Plastic<br />
energy chain systems from the motion plastics<br />
specialist igus along with plastic troughs made of a<br />
chemical-resistant material have been dealing with<br />
these aggressive conditions easily for years now.<br />
Since 1986, Meissner Krane GmbH has been offering customized<br />
solutions and services for crane systems and hoisting technology.<br />
One of the areas of supply for the company is the equipment used in<br />
hot dip galvanizing plants. In 2015, Meissner Krane equipped the<br />
first process crane in the pre-treatment line of a hot dip galvanizing<br />
plant of Wiegel Group, one of the largest and most important hot<br />
dip galvanizers in Europe.<br />
Bathing in acid<br />
Hot dip galvanizing is the most effective corrosion protection<br />
method that is used on an industrial scale to protect steel from<br />
corrosion. By immersing the work-pieces in metallic molten<br />
zinc, a zinc coating is applied. Iron-zinc alloys of different<br />
composition are formed on the steel surface. On the outside, the<br />
surface is closed by a coating of pure zinc. However, for a<br />
permanent and complete iron-zinc reaction, the work-pieces<br />
must be pre-treated. By immersing in a series of pre-treatment<br />
baths, the work-pieces are cleaned before the actual hot dip<br />
galvanizing, to remove production residues such as oils and<br />
other characteristic impurities such as rust and scale. This is<br />
followed by two rinses in order to minimise the carryover of acid<br />
22 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong>
01 The chains move in plastic troughs made of the chemically resistant<br />
material igumid EG+, as a result of which the system easily copes with<br />
the difficult conditions<br />
<strong>02</strong> In the pre-treatment lines of the galvanizing plants of the Wiegel<br />
group, energy chain systems from igus supply the process cranes with<br />
energy and data<br />
03 Before the actual galvanizing, the work-pieces must be pre-treated<br />
to rid the work-pieces of grease, rust and scale. In the enclosed pretreatment<br />
line there is an HCL condensate of about two percent in the air<br />
and salt residues with the galvanizing material as far as possible.<br />
In the penultimate step, the work-pieces are immersed in a flux<br />
bath, which is intended for the very fine cleaning of the steel<br />
surface. Thereafter, the parts are dried before being immersed in<br />
the molten zinc. The operating temperature of a galvanizing bath<br />
is between 440 - 460°C, where the steel surface enters into a solid<br />
bond with the zinc achieving excellent quality. Thereafter, workpieces<br />
are air-cooled.<br />
Harsh environment around the pre-treatment line<br />
Due to the open process baths, which are completely enclosed by<br />
the surrounding environment, an HCl condensate of about 2 %<br />
prevails in the air in the area of the pre-treatment line, which corresponds<br />
to a technical environment of 20 g/l hydrochloric acid.<br />
This means that it is important to use chemically-resistant components<br />
inside the pre-treatment line. In the past, a cable festoon was<br />
“The use of an acid-resistant energy chain<br />
was the right decision.“<br />
used at all Wiegel locations for the energy supply of the process<br />
cranes. Cables and hoses are suspended and moved with small trolleys.<br />
A disadvantage of this technology, is that at the end of the travel,<br />
a cable station takes up a lot of space and the rollers of the cable<br />
trolleys also quickly wear out, because the C-profiles in which they<br />
are guided become corroded and sharp-edged due to the acid<br />
exposure.<br />
Peter Zorn, Project Manager at Wiegel Verwaltung GmbH & Co<br />
KG, explains the development at that time: “Two things were very<br />
important to us: A tightly sealed area for material preparation,<br />
which was previously not the case with a festoon system, as well as<br />
high wear resistance. At that time Meissner Krane proposed to try<br />
out something different, and our answer was: ‘Yes, gladly!’ What<br />
ultimately convinced me of the igus energy chain systems were the<br />
pictures from composting plants or cement plants, where the chain<br />
could hardly be recognised due to the pollution, but the system was<br />
still running.”<br />
By the end of 2014, igus had presented the products to Meissner<br />
Krane, and the company was immediately ready to test this<br />
approach. In 2015, the first energy chain from igus was used in<br />
the Wiegel’s Lauchhammer plant. A year later, the next<br />
application followed at the location in Feuchtwangen, where<br />
igus supplied both the E4/4 series energy chain and the new<br />
plastic trough made of the chemical-resistant igumid EG+<br />
material. This ensures a high resistance to chemicals, so that the<br />
use of the guide trough is ideal for use in hot dip galvanizing or,<br />
for example, fertilizer production.<br />
Lightweight and chemically resistant: guidelite<br />
plus from igus<br />
The material igumid EG+ is characterised by a very low water<br />
absorption. This offers an increased resistance to aggressive<br />
chemicals. The material can be used in a temperature range of<br />
0 - 100 °C with its clearly optimised gliding properties for the guide<br />
trough and also for most series of e-chains. Since both the e-chain<br />
and the trough in the complete system consist of the chemically<br />
resistant material, they prove to be very good gliding partners. The<br />
complete system, consisting of chain and trough called ‘guidelite<br />
plus EG’, is now used in 4 Wiegel plants. “We are currently<br />
modernising about 2 Wiegel plants per year, using energy chain<br />
systems from igus,” explains Ronny Horn, Project Manager at<br />
Meissner Krane GmbH. “Another big advantage of the energy chain<br />
is that we have more options to safely guide the cables and hoses -<br />
even with larger cross-sections. Or to be able to add and change<br />
them later.”<br />
Wiegel, Meissner and igus: a successful tripartite<br />
co-operation<br />
The first systems have been in use at Wiegel for several years<br />
now. The relatively moderate crane speed of 40 m/min does not<br />
pose a big challenge to the igus energy chain system. The<br />
company has already successfully implemented applications<br />
with speeds of approx 10 m/s. Much more crucial here is the<br />
durability in the aggressive environment. Peter Zorn explains:<br />
“Of course we had to be bold to a certain extent and rely on the<br />
new solution from igus. Prior to this, we tested the chain made of<br />
the chemically resistant material by using it on the crane for just<br />
six to eight weeks to see if the material could cope with the<br />
environment. Now we expect a service life of at least 10 years, so<br />
that the higher initial cost pays off compared to a festooning<br />
system.”<br />
So far it has become clear that the energy chains from igus are<br />
doing reliably well at Wiegel. “The experience gained since 2015<br />
shows that the use of an acid-resistant energy chain in the area of<br />
the pre-treatment line for energy and signal transmission was<br />
the right decision,” concludes Ronny Horn from Meissner Krane.<br />
“In all factories, the systems have been running trouble-free<br />
since their commissioning.” And Peter Zorn from Wiegel adds:<br />
“The plastic trough was very important to us. Neither 304 nor 316<br />
stainless steel would have withstood these environmental<br />
conditions. Equally important to us was the fact that the wall<br />
around the pre-treatment line can now be completely closed and<br />
we also have much less maintenance with the new system.”<br />
These requirements have so far been fully met. Energy chain<br />
systems from igus will also be installed at the next Wiegel plants<br />
that will be retrofitting Meissner cranes.<br />
Photographs: igus GmbH<br />
www.igus.com<br />
<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong> 23
Drive technology compliant<br />
with food and pharmaceutical<br />
packaging industry standards<br />
Just within 5 years, the company Swiss Can Machinery has established<br />
itself as one of the leading manufacturer of fully automated packaging<br />
systems for powders and dry products. Complying with the stringent<br />
hygiene requirements of the food industry, the Swiss based company uses<br />
products with washdown-optimised drive technology from Nord<br />
Drivesystems.<br />
Founded in 2013, the company Swiss Can Machinery has since<br />
then been providing excellent products for packaging of coffee,<br />
powdered milk, snacks, toffees and pharmaceuticals. In a span of<br />
just 5 years, the company has made its mark in pouch filling, cans<br />
and glass jars with powders and dry products. Swiss can machinery<br />
has been designing its machines keeping in mind the specific<br />
requirements of food and pharmaceutical industry, which has<br />
made its products, right from individual machines up to entire<br />
filling plants world class. Its tailor-made packaging solutions are<br />
now gaining attention even from international buyers.<br />
Packaging sensitive products with innovative<br />
technology<br />
One of the mainstays is the baby food industry. The company’s<br />
international customer base includes many milk powder producers.<br />
“Powdered milk is a difficult product to fill” explains Michael<br />
Grabher, Managing Director of Swiss Can Machinery. “It can have<br />
very difficult filling characteristics, depending on the recipe, fat<br />
content, drying method, granulation and fineness. Even the<br />
characteristics of the same product vary from batch to batch and<br />
production conditions”. The company makes sure that its machines<br />
automatically adapt to the continuously changing filling conditions<br />
and package the powdered milk cleanly, precisely and efficiently. In<br />
this segment, the latest development is the SCM Line V-matic 127-3<br />
2018, a fully automatic can filling and sealing plant for powdered<br />
milk and baby food. The plant automatically performs all of the<br />
work stages from the empty to the full can. A special protective gas<br />
technology ensures that a residual oxygen value of less than 0.5 % is<br />
achieved in the can. This ensures a maximum shelf life for the<br />
packaged product.<br />
A swiss – german partnership<br />
A few yers ago, Michael Grabher and Marc, both brothers who<br />
manage the company were in the market looking for a new supplier<br />
of motor/gear unit combinations which meet their stringent<br />
hygiene requirements. Meeting with a company as experienced<br />
and reliable as Nord Drivesystems in this regard was the right<br />
decision by the Swiss brothers. Looking at Nord’s product portfolio<br />
and engineering expertise, this young company began its<br />
co-operation with Nord in 2016. Nord Drivesystems, is one of the<br />
global leaders in the industry and supplies completely matched<br />
drive systems consisting of gear units, motors and frequency<br />
inverters. The optimum solution is assembled individually on the<br />
basis of a comprehensive modular product range. This results in a<br />
MOTION AND DRIVES<br />
<strong>02</strong> Smooth motors with washdown-optimised cast aluminium housing<br />
03 Everything from a single source:<br />
NORD DRIVESYSTEMS supplies optimally<br />
matched drive systems consisting of the motor, the gear unit,<br />
motor and the drive electronics<br />
24 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong>
01 The laser marking station of QR codes<br />
and other specific product information,<br />
powered by Nord smooth motors<br />
solution which is fully tailored to the particular needs of the<br />
customer. For industries and applications with high standards of<br />
hygiene, the German drive specialist also supplies robust and<br />
durable drive technology in a washdown design.<br />
“With its modular system and extensive range of products, Nord<br />
convinced us from the very start. Essential advantages are the wide<br />
range, scalability and flexibility of the products” explains Marc<br />
Grabher. “With Nord we had the possibility of combining motors,<br />
gear units and electronics so that we could achieve a uniform,<br />
hygienic solution”. Swiss Can Machinery, deploys Nord drive units<br />
in two areas: one for transporting cans and other for feeding and<br />
mixing the products at the filling station.<br />
Smooth surfaces for easy cleaning<br />
For Swiss Can Machinery, hygiene of its plant is absolutely essential<br />
design parameter. Because of this, the conveyor belts are equipped<br />
with Nord IE4 geared motors with smooth surfaces, including<br />
motor-mounted Nord Base SK 180E frequency inverters to reliably<br />
transport the cans. Nord’s smooth motors (0.75 kW) are specially<br />
designed for easy cleaning. They consist of wash-down optimised<br />
aluminium housing and wherever possible, they have flowing<br />
transitions between surfaces. Thus, cleaning liquids and foam can<br />
be washed off easily. This protects the motors and shortens the<br />
cleaning times. They are also fan-less, so they do not contribute to<br />
the spreading of germs. Thanks to protection class<br />
IP66 they are optimally protected against the entry<br />
of dirt (dust-proof) as well as for strong water jets<br />
from all directions. Use of energy-saving 3-phase<br />
motors with efficiency class IE4 also enables high<br />
efficiency with low operating costs.<br />
“The conveyor belt is used in the high hygiene<br />
room. This is why the washdown design of the drives<br />
is so important”, explains Marcel Tobler, Automation<br />
Manager at Swiss Can Machinery. “Another<br />
advantage is communication via<br />
Profinet. Here, the motors are connected<br />
in series. This also reduces the amount<br />
of cables. Due to the modular construction<br />
of the conveyor belts we can use the<br />
same motor everywhere, which makes purchasing much easier.” The<br />
required continuous speed control of the conveyor belts is provided<br />
by the Nordac Base. The decentralised frequency inverter offers reliable<br />
technology with a robust design. Installation directly on the<br />
motor increases flexibility, simplifies maintenance and repair processes<br />
for end-users. Nord’s smooth motors are also used in the<br />
screw conveyor which feeds powdered milk into the mixer. A robust<br />
worm geared motor (0.25 kW) with cover drives the agitator. The<br />
compact drive units provide a high power density, excellent reliability<br />
and ensure trouble-free operation.<br />
World-wide support and assistance<br />
Swiss Can Machinery customers mainly come from Europe and<br />
Asia, but the company has also supplied to clients in New Zealand.<br />
Expressing satisfaction with Nord’s products, Marc Grabher says,<br />
“The modular range optimally meets our stringent requirements<br />
for hygiene and performance and allows us the flexibility which<br />
we need for our machines. We were also impressed by the flexible,<br />
support and on-site customer assistance throughout the world.<br />
Wherever we need spare parts, we can depend on rapid support<br />
from Nord.” This is possible mainly due to its closely meshed sales<br />
and service network of the drive experts with subsidiaries in 36<br />
countries as well as sales partners in 61 countries.<br />
Photographs: Lead Photo Swiss Can Machinery AG, Nord Drivesystems<br />
Group<br />
04 Michael Grabher, Managing Director<br />
and Proprietor of Swiss Can Machinery<br />
www.nord.com<br />
<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong> 25
Photos: lead fotolia, others<br />
Mayr power transmission<br />
Focussing on robotics and automation<br />
One of the most innovative German companies in the field of power transmission has its eyes firmly<br />
fixed on the sustained trend for automation and the high demands placed on robotic solutions. For<br />
this reason, the company has expanded its performance spectrum of clutches, couplings and brakes.<br />
Using new designs, new possibilities for brake monitoring are opened up – in particular also for<br />
applications in the fields of robotics and automation.<br />
AUTOMATION<br />
The degree of automation is increasing, humans and robots are cooperating<br />
more closely – in all the important industrial branches<br />
robots are on the advance. Machines and systems are increasing in<br />
performance density as well as operating speed and this also means<br />
higher demands on individual components. For this reason, Mayr<br />
power transmission, the specialist for safety brakes, torque limiters<br />
and shaft couplings from Mauerstetten in the Allgäu region of Germany,<br />
offers small, high-performance safety brakes, for example with<br />
the Roba-servostop construction series. These brakes are tailored to<br />
robotic requirements through their slim design and low weight.<br />
In addition, the company has a fluid-free linear brake in its portfolio<br />
with its Roba-linearstop in electromagnetic design, which has<br />
been designed to secure gravity-loaded vertical axes. These brakes<br />
are used in applications in which compressors or units for compressed<br />
air or oil hydraulics are not available or are unwanted, such<br />
as in medical technology or the food or pharmaceutical industry,<br />
where high hygiene standards are required. The Roba-brake-checker<br />
module now opens up new possibilities for brake monitoring also<br />
in these application fields. With a new module design and thanks to<br />
even more accurate evaluation, it is now possible to also supply and<br />
monitor small brake sizes from a braking torque of 0.7 Nm. This<br />
makes the Roba-linearstop not just the only electromagnetic rod<br />
brake on the market, but it also means it can be monitored even in<br />
small construction sizes with the aid of the module.<br />
26 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong>
01 <strong>02</strong><br />
03 04<br />
01 The Roba-brake-checker module is able to monitor and<br />
supply safety brakes without the use of sensors<br />
<strong>02</strong> The electromagnetic design of the linear brake construction<br />
series Roba-linearstop is the only electromagnetic rod brake on the<br />
market<br />
03 The new construction series of EAS-HT High-torque element<br />
clutches convinces through its improved performance density<br />
04 In the field of backlash-free, high-performance servo couplings,<br />
Mayr power transmission is permanently extending its standard<br />
modular system<br />
Sensorless brake monitoring – reliable even in<br />
adverse ambient conditions<br />
The intelligent Roba-brake-checker module works without the use<br />
of sensors. Instead, it detects the movements of the armature disk<br />
by analysing voltage and current, and knows what condition the<br />
brake is in at all times. In addition to switching condition,<br />
temperature and wear, it also monitors the tension path or tensile<br />
force reserve, i.e. whether the magnet is still able to attract the<br />
armature disk. With this module, Mayr power transmission is the<br />
only company to have an intelligent solution for the sensorless<br />
monitoring of electromagnetic brakes in its standard portfolio.<br />
The Roba-brake-checker can be integrated easily and quickly<br />
into machines and systems and even existing installations can be<br />
retrofitted without any difficulties. The module represents a costeffective<br />
solution, especially for small quantities. The fact that<br />
brakes in standard design are used for monitoring with the Robabrake-checker<br />
not only offers advantages in terms of costs and<br />
delivery time, but also for example with regard to corrosion protection<br />
as the brakes can be painted over easily, quickly and safely.<br />
Couplings for many kinds of applications<br />
In addition to safety brakes and the associated control and monitoring<br />
modules, Mayr power transmission has for decades developed<br />
and manufactured its tried and tested torque limiters and<br />
shaft couplings, and represents reliable complete solutions from a<br />
single source. To uphold this claim, the company has also substantially<br />
expanded the performance spectrum of its torque limiters.<br />
The new construction series of EAS-HT High-torque element<br />
clutches, for example, not only convinces through its improved performance<br />
density, but also stands for a substantially wider selection<br />
of possible bores. In addition, the company has launched a new<br />
construction series of EAS-Compact overload clutches, into which<br />
it has incorporated its years of experience and know-how obtained<br />
from numerous test series. The clutches thus cater for consistently<br />
increasing demands on speed and dynamics. Furthermore, the<br />
EAS-HSE Highspeed element clutches for high-speed applications<br />
have been extended by two small construction sizes. In the field of<br />
shaft couplings, Mayr power transmission has amongst other things<br />
enlarged the speed range of the large Roba-DS disk pack couplings,<br />
and is therefore able to offer reliable connections for measuring<br />
flanges for ranges larger than 100,000 Nm. And in the field of backlash-free,<br />
high-performance servo couplings, the company is permanently<br />
extending its standard modular system.<br />
High professional competence: Mayr power transmission is a<br />
leading manufacturer of safety brakes, torque limiters and shaft<br />
couplings. These products are primarily designed for application in<br />
electrically driven machines and systems. They can be found, for<br />
example, in filling plants, in machine tools, in packaging and printing<br />
machines as well as in elevators, in wind power plants and in<br />
stage technology.<br />
www.mayr.com<br />
<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong> 27
01<br />
Powerful and solid: safety over<br />
IO-Link in a machining center<br />
A manufacturer of high-precision machining centers and even more of their customers<br />
have already learned to appreciate the advantages of the bi-directional communication<br />
interface IO-Link. In their new MCC series the company has used Safety over IO-Link to<br />
integrate safety into the overall concept of IO-Link. This makes the processes simpler,<br />
more efficient, cost-effective and of course safer.<br />
Author: Wolfgang Zosel, freelance<br />
editor, Reutlingen, Germany<br />
AUTOMATION<br />
With its blue, gray and black painted cladding and ca.<br />
8 x 3 m, 3.5 m high MCC 630 simply radiates elegance and<br />
power. You get the feeling of solid performance, precision<br />
and reliability behind the compact dimensions. Not visible is the<br />
fact that this is a new model of series production machine with a<br />
complete set of possible uses. Nor is it obvious that behind the<br />
facade of this machining center is a modern control and safety<br />
concept from Balluff based on the digital IO-Link standard. With<br />
Safety over IO-Link from Balluff the system has the world’s first<br />
simple to install and easy to retrofit IO-Link safety system on-board.<br />
The advantage: Both Balluff safety components as well as safety<br />
devices from other manufacturers can be easily connected to the<br />
newly developed Balluff safe I/O module using M12 standard cable.<br />
Even standard components such as binary sensors can be bundled<br />
via the new safety I/O module. This also eliminates the need for a<br />
separate hub. Now the prerequisites for fully transparent<br />
configuration and diagnostics solutions, flexible and safe machine<br />
operation, as well as innovative Industry 4.0 concepts are provided.<br />
Flexible, fully digitized 5-axis machining centers<br />
Burkhardt+Weber (BW) has since 2012 been part of Indústrias Romi<br />
S.A., the largest machine tool builder in Brazil. With around 250<br />
employees BW is today an international manufacturer of machining<br />
centers for complex steel, cast and titanium parts of the highest<br />
quality. Notable among their customers in addition to those in the<br />
machine tool sector are many in the aerospace and diesel motor<br />
industry. Whether stand-alone or as part of an interlinked production<br />
system, the series MCC 630 and MCC 800 flexible, fully digitized<br />
5-axis machining centers process workpieces efficiently and<br />
ready-to-install with just a few setups. In general it is the large<br />
motor or transmission parts that demand a number of various<br />
milling, drilling, turning and measurement cycles.<br />
Beneficial partnership<br />
Balluff has been a technology provider and consultant to<br />
Burkhardt+Weber for over 20 years. “The cooperation over all the<br />
years has been outstanding, and we consider Balluff a reliable, creative<br />
and innovative partner,” says Benjamin Rother, Manager of<br />
Electronic Design. He remembers when six years ago Nico Schmid,<br />
Sales Engineer at Balluff, first presented the intelligent IO-Link<br />
interface. “At that time we wanted to wait and see how this new<br />
standard would develop. But since 2014 we have been consistently<br />
and committedly using IO-Link in our machining centers,” adds<br />
Benjamin Rother. Until then BW still used the traditional fieldbusbased<br />
wiring systems as the standard. Systematically separated<br />
from the standard signals, the safety-relevant signals were gathered<br />
in the field via ProfiNet. Cumbersome, complicated wiring was the<br />
order of the day, as were a variety of different cable types, sensors,<br />
28 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong>
01 Machining centre MCC 630 series from Burkhardt+Weber in interlinked configuration<br />
<strong>02</strong> Machining table and spindles of the fully digitized 5-axis machining centers process workpieces efficiently<br />
03 Balluff IO-Link safety hub (yellow) together with IO-Link master and sensor hubs provide essential services<br />
<strong>02</strong> 03<br />
actuators as well as tedious setup procedures. Beyond the actual<br />
switching signal there was only little usable and processable<br />
information available from the process or sensor level.<br />
When conceiving the new MCC series, the engineers at<br />
Burkhardt+Weber pursued a clear objective: in addition to characteristic<br />
BW features such as force, precision and availability, performance<br />
features were required which should benefit the manufacturer<br />
and operator equally: reducing the complexity in cabling,<br />
plug-in cables instead of discrete wiring, shortening the installation<br />
and commissioning phase, more transparency and information<br />
about what is happening in-place, and support through simple to<br />
use configuration, diagnostic and service concepts. Requirements<br />
that could be meet with amazing ease using the bi-directional communication<br />
interface IO-Link.<br />
IO-Link with conviction<br />
The new MCC machining centers are impressive power packs based<br />
on torsionally stiff cast components. With two independently operated<br />
plate changers, clamping a new workpiece is possible while<br />
the other one is being processed by a tilting spindle behind a safe<br />
chip protection door along five axes. The connected magazine<br />
holds more than 100 tools and can be easily expanded up to 320<br />
slots. The tools are automatically fed and are equipped with Balluff<br />
industrial RFID systems. Processing capacity up to 1.5 tons (or<br />
2.5 tons for the MCC 800), axis drives with 17.5 kN feed and motor<br />
spindles with speeds up to 12,000 rpm tell you that safety for man<br />
and machine is a central topic here. Each machining center comes<br />
with multiple interlocks, light curtains, and all drives, suspended<br />
loads such as the opened chip protection door as well as the<br />
obligatory E-Stop buttons are monitored.<br />
There was just no competition for “Safety over IO-Link! In interlinked<br />
production and assembly operations efficiency is especially<br />
important if high-performance systems are to have an optimal<br />
price-performance ratio. IO-Link offers us as the systems builder<br />
and even more so our customers a plethora of advantages,” says<br />
Benjamin Rother. Safety over IO-Link from Balluff is the logical<br />
extension of the IO-Link philosophy and uses the advantages of IO-<br />
Link and Profisafe for safety-relevant signals as well. Like IO-Link,<br />
Safety over IO-Link also features simple system construction, timeand<br />
cost-saving wiring, minimal control cabinet space requirements<br />
and lean system concepts. Safety always ends up on stop, as<br />
Safety over IO-Link applications can be adapted quickly and simply<br />
to changing requirements.<br />
Perfectly equipped<br />
Every machining center in the MCC series comes with a broad<br />
spectrum of Balluff products and systems: ten IO-Link sensor hubs<br />
with eight in- and outputs each collect the signals from the<br />
distributed sensors and actuators, including numerous inductive<br />
and optical sensors from Balluff. The sensor hubs are configured as<br />
needed for the requirement, i.e. 16 signals can be freely assigned,<br />
all of which can be connected as is typical for IO-Link using<br />
standardized 3-conductor cable with M12 connectors. The sensor<br />
hubs channel to six installed ProfiNet IO-Link masters. Three<br />
Balluff safety hubs serve as safety gates. In addition to the industrial<br />
RFID systems, optional inductive couples from Balluff can be used:<br />
these transmit power and signals without contact over an air gap of<br />
up to five mm. They are generally used where fixed wiring of<br />
sensors and actuators gets in the way, for example on rotary index<br />
tables and tool changers. As with the MCC series: as tools are<br />
placed in the machine, the controller does not release the gantry<br />
axes of the loading system until the clamping devices has reported<br />
perfect seating of the part to be processed via the opposite coupler<br />
modules.<br />
Best combination: automation and safety technology<br />
The safety-relevant data are handled both safety and simply, as<br />
Safety over IO-Link uses elements of Profisafe. The IO-Link master<br />
itself remains a non-safety standard device and is considered a<br />
“black channel”: the transported data are tunneled through the<br />
master to the control level safely and untouched and only there are<br />
they unpacked. The final programming is done using drag-anddrop<br />
from the programming interface of the controller.<br />
Automation and safety technology in one results in more economical<br />
and more productive system concepts. “The entire pallet of<br />
virtues that IO-Link brings with it, the simple integration of safety in<br />
the same system, provided the impetus for relying on the integrated<br />
Balluff Safety over IO-Link concept in the new MCC series. We give<br />
our customers high-performance machining centers at an outstanding<br />
price-performance ratio that sets new standards when it<br />
comes to configuration, flexibility and service and which are Industry<br />
4.0 ready in every respect,” summarizes Benjamin Rother.<br />
Photos: 01 Burckhardt + Weber, <strong>02</strong>-03 Balluff<br />
www.balluff.com<br />
<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong> 29
01<br />
<strong>02</strong><br />
03<br />
04<br />
01 The main task of the further processing<br />
systems from AB Graphic is to cut the incoming<br />
webs and to rewind them onto individual rolls<br />
<strong>02</strong> FleyeVision systems can also be adapted for<br />
the inspection of films and it can be equipped with<br />
UV lighting<br />
03 Among other things, the gaps between lines<br />
or dots as well as between web or label edges<br />
can be measured with fleyeVision gapControl<br />
04 The assistance given in the development of the<br />
fleyeVision systems by Stemmer Imaging and the<br />
sales contact there, Georg Schelle (l.), is considered<br />
very positive by Ralf Wirtz (r.)<br />
Label inspection at the highest level<br />
AUTOMATION<br />
Systems with an extremely high performance are<br />
required in order to inspect labels or other printed<br />
web goods and detect faults with 100 % reliability at<br />
speeds of up to 350 metres per minute. AB Graphic<br />
produces such machines and in doing so uses image<br />
processing from Stemmer Imaging.<br />
Five label webs run in parallel on the Omega SRI, a further processing<br />
machine for labels that Ralf Wirtz is currently preparing<br />
for delivery to a customer and on which he is performing the last<br />
tests. “The main task of our machine is to cut the incoming strands<br />
and to rewind them onto individual rolls, because the further processing<br />
companies generally require single-web labels”, says the<br />
sales manager of AB Graphic International GmbH.<br />
The machine that Wirtz is just finalising is designed for tape<br />
widths of 430 mm, but AB Graphic covers widths from 210 to<br />
1 200 mm as standard. The dimensioning of the label rolls is just one<br />
of many possible options, however: “Depending on customers<br />
requirements we can extend the basic functionality of rewinding<br />
the label rolls with the addition of various optional functions”, says<br />
Wirtz. A frequently used variant here is the integration of printers,<br />
which add sequential batch numbers or individual details to<br />
pre-printed labels, for example. AB Graphic also offers its customers<br />
Author: Peter Stiefenhöfer, owner for Stemmer Imaging, Germany<br />
options for the inspection of labels by adding image processing<br />
modules from the fleyeVision family to the systems.<br />
Image processing – a very special field<br />
These image processing modules are the speciality of the German<br />
branch of AB Graphic: within the British group they are also developed<br />
and manufactured at the Baesweiler location near Aachen<br />
under the designation fleyeVision. “An estimated 80 percent of the<br />
label machines manufactured by us here are equipped at the customer’s<br />
request with one or even two image processing modules.<br />
For machines produced in Great Britain that are ordered with a<br />
vision system, we prepare the image processing modules here and<br />
send them to our British colleagues for installation and for the<br />
finalisation of the machines.”<br />
In order to secure the quality of every single label, various features<br />
of the labels are checked with the fleyeVision modules in the processing<br />
chain. For instance, they detect missing labels, splice points,<br />
matrix residues, label damage, ink residues and dirt spots amongst<br />
other things. Such faults must be identified 100 % if possible, because<br />
in certain cases the label manufacturer may face extremely<br />
high demands for compensation if, for example, faulty labels have<br />
been affixed to end products and are therefore returned to the manufacturer.<br />
It can also be very expensive if production processes, for<br />
example in bottling plants, come to a standstill due to faulty labels.<br />
In the case of pharmaceutical products the consequences may be<br />
even graver, with danger to patients being conceivable.<br />
In order to rule out this kind of risk, AB Graphic offers its customers<br />
a large number of modular extension options for the fleyeVision<br />
system, which allow the inexpensive, tailor-made configuration of<br />
30 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong>
inspection systems in accordance with the customer’s requirements.<br />
“Regardless of whether the customer wishes to ensure the<br />
quality of graphics, texts, barcodes or colours, or to check the correctness<br />
of variable data: with fleyeVision we have the right solution<br />
for every task – and that means for every material, every language<br />
and every typeset font”, Ralf Wirtz stresses.<br />
Reliable detection without sensors<br />
Since 2004 AB Graphic has placed its trust in Stemmer Imaging as the<br />
supplier of the majority of the image processing hardware used in the<br />
systems manufactured in Baesweiler. “We have been procuring the<br />
majority of our cameras, image capture cards/frame grabbers, lenses,<br />
lighting and cables for our systems from this partner for many years<br />
and we’ve had nothing but good experiences”, Wirtz reports. “Over<br />
the years our requirements have continuously developed and Stemmer<br />
Imaging has always recommended suitable components to us.”<br />
He describes the cooperation that has now led to over 1000 implemented<br />
image processing systems as trusting, reliable and strong.<br />
The sensorless detection was developed in close cooperation<br />
between the image processing experts at AB Graphic and the<br />
Development Department at Stemmer Imaging on the basis of the<br />
Visual Applets FPGA development tool from Silicon Software. The<br />
solution thereby created processes the images from the line scan<br />
cameras that are employed in all systems from AB Graphic that<br />
feature image processing functionality. “The requirements for<br />
speed, resolution and thus data throughput are very high in label<br />
inspection. With line scan cameras we can cover all variants, which<br />
we offer our customers as options”, stresses Wirtz.<br />
The selection thereby ranges from line scan cameras with a 1k<br />
resolution through 2k variants up to models with an 8k resolution in<br />
monochrome or colour. Depending on the width of the tape to be<br />
inspected, speeds of up to 350 m per minute and the detection of<br />
faults down to a size of 0.<strong>02</strong> mm² are thus possible. The smallest<br />
detectable distance between two lines or the smallest resolvable<br />
line width is decisive for the reliable recognition of barcodes. The<br />
limit that can currently still be reliably recognised, for example with<br />
a web width of 210 mm with 8k line scan cameras, is 0.08 mm.<br />
The image processing system is completed by suitable line lighting,<br />
which can also be implemented as UV lighting for the inspection<br />
of films, as well as the matching lenses and cables, which Ralf Wirtz<br />
and his image processing colleagues also procure through Stemmer<br />
Imaging. The operating software, which enables the fast automatic<br />
or, if necessary, manual setup of new labels and displays the results<br />
of the image processing, was developed by AB Graphic itself.<br />
Mirror system and two-camera solutions<br />
The fleyeVision image processing systems are integrated into compact<br />
housings in the systems. Due to the tight installation space, the<br />
AB Graphic developers have cleverly extended the optical axis by<br />
means of a mirror system in order to achieve the required working<br />
distance for the cameras. One further special feature is important to<br />
Ralf Wirtz: “Two camera systems can optionally be used in the<br />
fleyeVision systems in order either to check the front and rear sides of<br />
label tapes or to increase the resolution with large tape widths. Even<br />
with such variants, the incoming data from both cameras is captured<br />
and processed by a single Silicon Software frame grabber. This illustrates<br />
the performance of our solution, which was only possible<br />
through the use of high-quality image processing components, the<br />
ideal configuration and the joint development by Silicon Software<br />
and Stemmer Imaging according to AB Graphic’s specifications.”<br />
Photos: 01 + <strong>02</strong> + 03 AB Graphic, 04 Stemmer Imaging<br />
www.stemmer-imaging.com<br />
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A healthy batch<br />
of safety<br />
LOGISTICS<br />
The finished, high quality organic products of Davert<br />
GmbH like rice, legumes and cereal products like sugar,<br />
dried fruit, nuts, oilseeds and sprouting seeds must be<br />
protected from dust and pests during storage and then<br />
transported without damage to drug and health food<br />
stores. The system supplier provided the Beumer<br />
stretch hood A for this task. It covers the mixed pallets<br />
of bags, cartons and buckets with a highly elastic<br />
stretch film, protecting them against external<br />
influences, keeping the merchandise secured during<br />
transport, even through sudden braking.<br />
Davert GmbH is a trading and manufacturing company for<br />
high-quality organic products. The company with its 150 employees<br />
is based in Ascheberg, in the southern Münster region,<br />
right next to the eponymous nature reserve Davert. “With our<br />
guarantee of origin, we are committed to fair trade and long-term<br />
business relationships world-wide,” says Erwin Tenbrink, Technical<br />
Director at Davert. The company acts as a consultant for its<br />
partners when it comes to product selection and cultivation and<br />
coordinates infrastructure projects. For its customers, Davert follows<br />
a multi-channel strategy: the merchandise is sold via their<br />
own online shop and in in selected drugstores and health food<br />
retailers.<br />
Cleanliness has the highest priority<br />
“We are ensuring the highest degree of cleanliness to meet our strict<br />
quality standards,” explains Tenbrink. Before being shipped out, the<br />
legumes, rice etc. have undergone special quality controls. The employees<br />
examine the incoming raw products and set up the required<br />
cleaning steps. “One of the preventive measure is the pressure treatment<br />
that we use to prevent any pest infestation from the start,”<br />
reports Tenbrink. “The sudden pressure release kills off any pests<br />
like bugs, moths or mites and their larvae and eggs, without compromising<br />
the quality of the product in any way.”<br />
In compliance with the quality assurance process, employees<br />
pack the merchandise in a variety of ways, depending on the product:<br />
rice, flour, linseed and grains are packed into bags, larger<br />
storage quantities into big bags. Packaged legumes, nuts, dried<br />
fruit and muesli is filled into boxes, honey into buckets. Depending<br />
on the store order, the team stacks the various unit loads onto<br />
mixed pallets. “Up to this point in the process, we assign the highest<br />
priority to cleanliness,” explains Tenbrink: “And now it is just as<br />
important to keep this level of cleanliness and protect the products<br />
from dust and pests during storage in our high-rack warehouse.”<br />
The units also have to be loaded safely onto the back of the trucks<br />
32 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong>
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<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong> 33
01 The machine is easy and safe to operate.<br />
No platform is required<br />
<strong>02</strong> The merchandise remains clearly visible through the<br />
smooth film surface. It protects against atmospheric influences<br />
and humidity, and ensures an aesthetic appearance on<br />
the shop floors<br />
03 The pallets are packaged in short cycle times. The machine<br />
covers the products with a highly elastic stretch hood<br />
01<br />
<strong>02</strong> 03<br />
LOGISTICS<br />
and reach the distributor without any damage. This is where the<br />
packaging comes into play.<br />
Reliable and powerful packaging system<br />
The managers were looking for a solution that could meet all these<br />
requirements, ensuring fast and reliable operation, high levels of<br />
availability, easy maintenance, and a small footprint. They found<br />
Beumer Group. The single-source provider for filling, palletizing<br />
and packaging technology delivered the Beumer stretch hood A<br />
high-capacity packaging system. “The machine is very easy and safe<br />
to operate,” describes Volker Feldmeyer, sales engineer at Beumer<br />
Group and responsible for the project at Davert. “In order to make<br />
work easier for the maintenance personnel, which also means<br />
higher levels of availability, the machine does not require any<br />
platform.” Maintenance work, such as changing the blades or the<br />
sealing bars, is handled at floor level. The operator simply opens a<br />
drawer, providing free access. Additional benefits include the<br />
compact design and the resulting low height and small footprint.<br />
A film transport system, which is particularly gentle on the material,<br />
introduces the previously cut and sealed film hood into the system.<br />
On its way to the crimping and stretching unit, the sealing<br />
seam on the film hood cools down so that it can be crimped without<br />
losing time. Energy-consuming cooling units and delayed cooling<br />
times become obsolete. This means that the pallets can be packed<br />
in a shorter cycle time. Economical engines and a lower demand in<br />
compressed air optimize the energy balance. In order to save resources<br />
and produce minimum waste, the company opted for this<br />
type of film wrapping. The palletized goods are also clearly visible<br />
through the smooth surface of the transparent, highly flexible film.<br />
The wrapping protects the merchandise against atmospheric influences<br />
and humidity, and ensures an aesthetic appearance on the<br />
shop floors. “The elastic film also increases the safety during transport<br />
considerably,” describes Feldmeyer. At Davert, the Beumer<br />
stretch hood A packages the pallets for high-bay storage systems:<br />
the pallet base remains unwrapped, so that the forks of the fork-lift<br />
truck won’t damage the film. This prevents any remaining film from<br />
interfering during the contour check before the pallet is stored in<br />
the high-rack system.<br />
Easily operated<br />
The system supplier has introduced the Beumer Group Human Machine<br />
Interface (HMI). This newly-developed operator panel with<br />
an optimized user interface and graphical navigation for operating<br />
the system offers an even more ergonomic workflow to the user.<br />
“The soft-touch panel uses pictograms to guide the user through<br />
the menu of the Siemens Simatic S7 machine control,” explains<br />
Feldmeyer. “The panel also gives the operator access to all required<br />
training programs and content.”<br />
“We implemented this project in close cooperation with Beumer<br />
Group,” Erwin Tenbrink is happy to report. He is entirely convinced<br />
of the great technical cooperation. One important aspect for him is<br />
reliable customer support, as even this high-quality machine needs<br />
maintenance and service. “If necessary, we send our service personnel<br />
to the plant to check the system and perform any required<br />
adjustments,” Feldmeyer promises. “This way we can ensure highlevels<br />
of availability at any time.”<br />
Photographs: Beumer Group<br />
www.beumergroup.com<br />
34 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong>
Global industry:<br />
past and future<br />
In this series, we will ask industry<br />
leaders what their thoughts are<br />
regarding the past ten years of the<br />
global industry and what their<br />
prognosis for the upcoming years<br />
looks like. We start the series with<br />
Jürgen Prochno, CEO of the<br />
German branch of The<br />
Lee Company,<br />
manufacturer of<br />
miniature fluid<br />
control products.<br />
Mr. Prochno, how do you evaluate the development of the global<br />
industry markets in the past ten years?<br />
The international markets have continued to grow together in recent years and<br />
progressed to merge technologically . The low-wage countries of the past are partly<br />
developing into the business partners in charge.<br />
Unfortunately, this leads to damaging reactions of major market participants, such as<br />
the US, who are now trying to foreclose their market more and more to strengthen the<br />
domestic economy and / or protect it from external influences. Given the prevailing<br />
global network of economic processes, I consider this to be the wrong way.<br />
After recovering from the financial crisis, markets are now unnecessarily<br />
discouraged from further merging and have to deal with issues such as punitive<br />
tariffs and countermeasures. Here, a few lose sight of the right measures and<br />
thus complicate the lives of many.<br />
What is your forecast for the next ten years?<br />
In which direction will the industry and your business move?<br />
At the moment, it is extremely difficult to make a serious prognosis for the<br />
next 10 or even just 5 years. There are just too many political, technological<br />
and environmental challenges and options. One of these challenges may<br />
come with the Brexit in a few weeks and no one can estimate the consequences<br />
for Europe and the world. You can try to prepare yourself for some scenarios, others<br />
you have to let them come to you to find a solution in a timely manner.<br />
As a global company, LEE will continue to strive to develop other markets in addition<br />
to its core aerospace industry. Even electrification opens up new applications for us.<br />
Certainly some classic hydraulic functions will be eliminated and replaced by purely<br />
electric ones. But if the hype of electrification has reduced to a reasonable level, it will<br />
strike a balance with the established markets.<br />
www.theleeco.com<br />
<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong> 35
FAULHABER BXT<br />
Power in new<br />
dimensions<br />
NEW<br />
FAULHABER Brushless Flat DC-Servomotors of the BXT family<br />
Today, you don‘t find visionary designs in Hollywood, but rather<br />
in the development departments of innovative companies. With<br />
the new BXT drive family, FAULHABER extends the limits of what is<br />
possible in the area of critical installation space. With diameters of<br />
22, 32 and 42 mm and lengths of 14, 16 and 21 mm, the motors are<br />
very compact and, thanks to their innovative winding technology,<br />
achieve continuous torques of up to 134 mNm and powers of up to<br />
100 W. FAULHABER BXT – prepared for the future.<br />
WE CREATE MOTION<br />
www.faulhaber.com/p/bxt/en<br />
Hannover, 01. – 05.04.<strong>2019</strong><br />
Hall 15, Booth H29