June-July 2017

VOLUME 4 | ISSUE 4 JUNE - JULY 2017

GH Media
Business

MANUFACTURING TECHNOLOGY | DEVELOPMENT | AUTOMATION

POWERING MANUFACTURING TECHNOLOGY BUSINESS WORLDWIDE

INDUSTRY FOCUS

 Machine Tools
 Electricals & Electronics
 Plastics & Polymers

FUTURE TECHNOLOGY

 Renewable Power Grid
 The Future of Product

Development
 3D Printing - Facts &

Forecast

POST SHOW

Hannover 2017

INTERVIEW

Hans Bangert

Managing Director
Bosch Rexroth India

PLUS

Research & Development |
News | Acquisition & Merger |
Articles | Case Study |
Product Spotlight | Events

www.GHMediaBusiness.com

Count on Global MDA Journal for Worldwide Expansion of Your Business







Editor’s GlobalD Journal
Desk
Motion Drive & Automation

Bi-Monthly Journal APRIL-MAY 2017

Fluid power technology is rapidly changing for its best. Truly, it is becoming compact Editorial & Marketing Office USA
ever and is a wing of electronic. There is hardly any application seen in either mobile Global Hydraulics Media, LLC,
or industrial hydraulic, where electronic is not a part. 1910, Buckthorn Court, Troy,
Michigan-48098, USA
This marriage between the Fluid power and electronic has improved overall www.GHMediaBusiness.com
performance of the machineries and equipment, precise and energy saver. Editorial & Marketing Office India
G H Media Business Pvt Ltd
Proportional technology with the help of computer science has vastly changed the Global Media House
A - 57, Sector 16, Noida-201301, INDIA
Fluid power world. There are hardly any CNC machineries seen with mass use of fluid [email protected]
T: +91 (120) 2512420 / 4117326
power. Lathe, Milling, Drilling, Shaping, Boring Managing Director/Editor
Ashok Kumar Gupta
“Hydraulic and many metal forming machineries have very [email protected]
limited Fluid power usage. These machineries Executive Director/Editor
applications have are abundantly productive with electronic P K Guha
become sleeker usage. Duty cycles are grossly improved with [email protected]
and precise in insurmountable energy saving Executive Member
Mobile applications. R. Ramani
Nevertheless, certain areas of industrial CEO, Fluid Tech Solutions Inc
hydraulic have very limited fluid power Mobile: +1-408 475 1946
[email protected]
Equipment in application, such Steel mill, Rolling Mills and Events/Response
Mining, Forestry Pipe testing machineries which continue to 9643446271
and Road building have limited use of hydraulics with the help +91 120 4117236, 2512420
continues to see of electronics.These machineries are by far Subscription & Circulation:
the great energy savers compared to the ones T: +91 (120) 2512420 / 4117326
[email protected]
the wide usage produced a decade back. Printed/Published/Owned by:
G H Media Business Pvt. Ltd.
of Hydraulic CNC machineries have very limited Fluid power Published at:
application.” application and are grossly dependent upon B-69, F.F.C., Okhla, New Delhi – 110020
solely electronic. Whereas, Mobile hydraulic Printed at:
U S Graphics Pvt Ltd
applications continues to have abundant usage B-186, Okhla Industrial Area,
Phase-I, New Delhi - 110020
of Pumps, Valves and Motors. This trend is likely to continue for a foreseeable future.
Journal in e-Book is available at:
All said and done, fluid power technology is here to stay for a long while and will Journal in e-Book is available at:
complement and supplement electronic world with computer science.

Let’s enjoy the best of both worlds.

Global MDA Journal.
Global MDA Journal.

Ashok Kumar Gupta P.K. Guha MDA
Managing Director/Editor Executive Director/Editor MDA

[email protected] [email protected]

June - July 2017 | Global MDA Journal 5

CONTENTS 15-17
08-11
Industrial Report
News
- Global Hydraulic Replacement Market
• RelWood by Reliance Industries Ltd - The Indian Machine tool Industry
• New development and demonstration
13-14
centre for Liebherr
• Chevron Phillips Chemical Increases Acquisition & Merger

Organosulfur Capacity at Tessenderlo • Timken Acquires PT Tech
Facility • INEOS to buy the entire Oil & Gas Business from
• Parker Strengthening Customer Services
• BASF presents ‘Material Selection 17/18 DONG Energy
• Intel Predicts Autonomous Driving Will
Spur New ‘Passenger Economy Worth $7
Trillion
• Wipro Launches Nine Solutions to
Accelerate Adoption of Blockchain across
Industry Sectors
• Volvo Penta Sees its First Engines
Produced in India come off the Production
Line

Regular

05. Editor’s Desk

12. Awards & Honours

46-52. Product Spotlight

57-68. Events & Exhibitions

54-56

Book In Series

• Hydraulics in Industrial and Mobile
Applications – by Assofluid

6 Global MDA Journal | June - July 2017

44-45 POST SHOW REPORT company’s index

Hannover Messe 2017 ABB...........................................................................................................48
ADVANCED SOLUTIONS, INC .................................................................... 12
32-33 Interview ASSOFLUID ..........................................................................................54-56
BASF .........................................................................................................09
Hans Bangert–Managing Director BASLER ..................................................................................................... 46
Bosch Rexroth India BOSCH REXROTH .................................................................................32-33
CHEVRON PHILLIPS ..................................................................................08
18-25 INDUSTRY FOCUS: CRANE BEL INTERNATIONAL PVT. LTD. ............................................2, 36-37
MACHINE TOOLS CUTWEL.....................................................................................................22
DEUTSCHE MESSE ...............................................................................44-45
• Shaping the future of Product DMG MORI ...............................................................................................50
Development – by Siemens DONG ENERGY .........................................................................................14
DÜRR ECOCLEAN ...................................................................................... 42
• Twice the cutting speed – by Trumpf EATON..................................................................................................38-40
• Form Knurling vs Cut Knurling ELESA+GANTER ........................................................................................51
FLARETITE INC. ........................................................................................ 12
– by Cutwel FRAUNHOFER ........................................................................................... 41
• Case Study: Retrofit tunes Ford HITACHI POWER TOOLS ............................................................................ 48
INEOS ....................................................................................................... 14
press to high performance INTEL CORPORATION ............................................................................... 10
– by Schuler Group KAWADA TECHNOLOGIES, INC ................................................................. 12
LANXESS ................................................................................................... 47
28-31 INDUSTRY FOCUS: LIEBHERR .................................................................................................. 08
Electricals And MAKINO ...................................................................................................49
Electronics panagon systems..................................................... INSIDE BACK COVER
PARKER HANNIFIN CORPORATION ........................................................... 09
• Charging as if by magic – By Bosch RELIANCE INDUSTRIES LTD ....................................................................... 08
• Consider this when planning high RENISHAW ................................................................................................52
RESYSTA INTERNATIONAL GMBH ............................................................. 08
voltage switchgear installation SCHULER ............................................................................................. 24-25
- by Edvard Csanyi, EEP SIEMENS ............................................................................................. 18-19
TAL MANUFACTURING SOLUTIONS .......................................................... 51
34-41 INDUSTRY FOCUS: TIMKEN .................................................................................................... 13
Plastics & Polymers TRUMPF .............................................................................................. 20-21
VOLVO PENTA ........................................................................................... 11
• New strategy produces stronger WIPRO LIMITED ....................................................................................... 10
polymers
advertiser’s index
• Not All O-rings are Equal
-By Aaron Clark, Eaton AMTEX 2018 .............................................................................................23
CRANE BEL INTERNATIONAL PVT. LTD. ............................................2, 36-37
• Wearable Technology: Smart ELECTROMA EXPO .................................................................................... 43
printed sensors monitor movement FLARETITE INC. ........................................................................................ 12
sequences G H Media business ............................................................................... 70
IME 2017...................................................................................................04
Additive Manufacturing panagon systems..................................................... INSIDE BACK COVER
PARAMOUNT cables................................................................................47
26-27 • 3D Printing: Facts & Forecasts PTC ASIA...................................................................................BACK COVER
SES 2017 ...................................................................................................53
-By Sandra Zistl, Siemens SHRI GURU NANAK ELECTRICALS PVT. LTD. ..............................................46
TECH INDIA ...............................................................................................03
article UNILINE Energy Systems Pvt. Ltd. ......................................................50

42 • Virtual Reality on an industrial level

-by Dürr Ecoclean

June - July 2017 | Global MDA Journal 7

news

RelWood by Reliance Industries Ltd (RIL)

RIL has entered into a licence agreement with Germany based Resysta International GmbH, which gives RIL the
exclusive rights of production and marketing of a natural fibre polymer composite (NFPC) in India.

Through this strategic partnership with and water-resistant material which has the
Resysta, RIL is looking forward to produce look and feel of wood, which is not affected
the RelWood compound exclusively in order by termites, does not splinter or rot over time,
to meet the fast-growing demand of real is obtained using a renewable resource and is
alternative to tropical wood. fully recyclable, a statement said.

This compound will be the raw material It (the composite) even weathers salt
for the production of sheets and various water, sun and wind. The material is a key
profiles used in a wide range of wood plywood innovation that was needed to address the
replacement applications. crisis of shrinking rainforests, as well as the
inferior quality of wood composite products.
The German company succeeded where
many others failed by developing a weather www.ril.com

Liebherr planning new development
and demonstration centre in Kirchdorf

Liebherr-Hydraulikbagger GmbH is The administration building will offer The planned development and
planning a testing hall with administration space for up to 100 modern workstations demonstration centre by Liebherr in
building, a large test site and a on four levels. The practical tests and
demonstration area on a total area of inspections to be implemented will be Kirchdorf
12.68 hectares. The key component is the prepared, evaluated and documented at
19.2m high testing hall. All prototypes will these workstations. The design of the test as well as existing customers, a better
be built, commissioned and optimised site also includes, in addition to various understanding of the operating principle
here in the future. Doors with a height digging facilities for earthmoving and of the machines within the framework
of 13m also make it possible to drive industrial machines, a noise measurement of practical tests, an area for customer
the fully-assembled machines, also large site for evaluating and optimising the demonstrations, training and sales and
port and harbour material handlers, out noise emissions, as well as an approx. marketing tests is planned.
of the hall. A test environment is also 900 m long testing track with slope and
being constructed in order to improve the various poor-quality roads for road tests. www.liebherr.com
components installed in the machines. In order to give potential new customers,

Chevron Phillips Chemical Increases Organosulfur
Capacity at Tessenderlo Facility

Chevron Phillips Chemical Company LLC (Chevron Phillips Chemical) has expanded
its Tessenderlo, Belgium plant by debottlenecking its production unit for
Ethyl Mercaptan (EM) and Tetrahydrothiophene (THT).

Construction began in November Chemical site to continue to be a premier mercaptans, sulfides, and polysulfides.
2016 and the expansion commenced manufacturing location for organosulfur Tessenderlo products are used in a
operations in May 2017. This expansion products, along with Borger, Texas plant. wide range of end-use applications
increased production capacity for these such as polymer modifiers, agricultural
products by 65 percent. This will enable us to ensure a long- chemicals, mining and ore processing,
term, dependable supply of EM and THT gas odorization, water purification,
Demand for EM and THT continues on a global scale. pharmaceuticals, lubricant additives, and
to grow around the world. This the reduction of coke formation.
debottleneck builds on already well- Chevron Phillips Chemical’s
established production platform at Tessenderlo facility produces sulfur www.cpchem.com
Tessenderlo, allowing this Chevron Phillips chemical intermediates, including

8 Global MDA Journal | June - July 2017

news

Parker Strengthening Customer Services

in Asia Pacific with Local Industrial Hose Manufacturing in India

The Fluid Connectors India Division of Parker Hannifin Corporation, the global leader New production capabilities to improve on-time
in motion and control technologies will now be manufacturing 12 industrial hose series in delivery throughout Asia Pacific region
Nagpur, India to improve. Coupled with Parker’s powerful industrial distribution network,
the addition of hose manufacturing capabilities in India will improve the company’s responsiveness and ability to provide a premier
customer experience and help its partners to improve their productivity and profitability.

The industrial hoses manufactured in India are designed for material handling, water and oil & gas applications. They feature
high tensile wire braid reinforcement, and offer unmatched durability, kink resistance and pressure capability.

www.parker.com

BASF presents ‘Material Selection 17/18’
• Food for thought and inspiration for future product developments
• Dynamically adapting, coated plastic films for geometries of the future
• Create an awareness of the traces left behind – with compostable foam

‘Material Selection 17/18’ is the second material trend book customers’ demands without leaving traces
by BASF that offers a global perspective on trends and materials. is growing. Here, BASF offers a biobased
It presents innovative plastics solutions that help customers particle foam which is very robust and also
face these trends. The trend book was developed jointly by the fully compostable. The material is attractive
designfabrik® experts in Tokyo, Shanghai and Ludwigshafen. where sensitive or heavy goods should be protected by biobased
and biodegradable transport packaging.
The trend researchers and designers of the plastics
division from both regions worked together to provide ideas “When ideas are ready to challenge the future, our material
and inspiration for future product developments for customers. solutions are ready to enable designs shaping the future,”
‘’We do not see trends as singular phenomena but as a chain of summarizes Johnny Zhang, designfabrik Shanghai, BASF, the two
developments. Two main trends emerge as a result of this chain trends.
reaction: ‘Morphology’ and ‘Mindfulness’. We believe that they
will be majorly influential”, says Alex Horisberger, designfabrik Material study supports global concept for
Ludwigshafen, BASF. “With this study, we offer customers a way innovations with and for customer
to materialise these trends.”
BASF is combining its competencies globally in design, trend
The trend study is exclusively available to designers and research and simulation in the plastics division even more. The
other creatives of customers and potential customers as part resulting centers in Europe, Asia and the US are enabling an even
of a scheduled personal presentation. It cannot be bought or faster launch of innovations across industries such as automotive,
requested separately. consumer goods and construction. The trend book supports the
creative ideas of customers and demonstrates where materials
‘Morphology’ – materials for a changing world in design concepts can produce the next innovation.

The end of certainty as we know it, is defining for our times. The designfabrik is renowned as the central hub for
The only certainty lies in seeing opportunity in uncertainty – and interdisciplinary exchanges between designers and BASF
not to perceive it as a threat. In times of accelerating changes, materials experts. Founded in 2006 in Ludwigshafen, it can look
the speed of technological innovations increases significantly, back on more than ten successful years of providing consultations
too. From traditional combustion engines to cars powered for designers, developers and engineers in Europe. In 2014, the
by electricity, from cars traditionally controlled by steering to first designfabrik in Asia was opened in Tokyo in order to meet
autonomous driving: Materials are needed that can keep up with the requirements of the local markets and trends.
these dynamic changes in a three-dimensional space. For these
applications in particular, BASF presents a new film made of TPU About BASF’s Performance Materials division
(thermoplastic polyurethane) with a flexible coating, which could
possibly be used in automotive interiors or furniture. BASF’s Performance Materials division encompasses
the entire materials know-how of BASF regarding innovative,
‘Mindfulness’ means more attention – for customized plastics under one roof. Globally active in four
oneself and the environment major industry sectors – transportation, construction, industrial
applications and consumer goods – the division has a strong
The second trend in the BASF study is based on an increased portfolio of products and services combined with a deep
awareness for traces of human behavior and action. Both understanding of application-oriented system solutions.
are traceable in the sediments of the earth; data, things and
residue remain on this planet. The desire for materials fulfilling www.basf.com

June - July 2017 | Global MDA Journal 9

news

Intel Predicts Autonomous Driving
Will Spur New ‘Passenger Economy’
Worth $7 Trillion

Study Estimates the Value of Goods and Services in the Early Years of the ‘Passenger Economy’ Will Be More Than
Twice the Size of the ‘Sharing Economy’

Intel Corporation revealed the economies. Autonomous driving will do green shoots of which will appear in
findings from a new study that explores the same. the business-to-business sector. The
the yet-to-be-realized economic potential emergence of pilotless vehicle options
when today’s drivers become idle Autonomous driving and smart city will first appear in developed markets
passengers. Coined “Passenger Economy” technologies will enable the new Passenger and will reinvent the package delivery
by Intel and prepared by analyst firm Economy, gradually reconfiguring entire and long-haul transportation sectors. This
Strategy Analytics, the study predicts an industries and inventing new ones thanks will relieve driver shortages around the
explosive economic trajectory growing to the time and cognitive surplus it will world and account for two-thirds of initial
from $800 billion in 2035 to $7 trillion by unlock. projected revenues.
2050.
The new report frames the value of The research firm further points
History has proven that technology the economic opportunity through both out that autonomously operated vehicle
is the catalyst for massive societal a consumer and business lens and begins commercialization will gain steam by
transformation and that businesses to build use cases designed to enable 2040 – generating an increasingly large
need to adapt or risk failure, or worse, decision-makers to develop actionable share of the projected value and heralding
extinction. New digital business models change strategies. the emergence of instantaneously
ushered in by personal computing, the personalized services.
internet, ubiquitous connectivity and Autonomous technology will drive
smartphones gave birth to whole new change across a range of industries www.intel.com
and define a new landscape, the first

Wipro Launches Nine Solutions to
Accelerate Adoption of Blockchain
across Industry Sectors

Wipro Limited (NYSE: WIT, BSE: sector. Wipro has developed solutions lab, clients have
507685, NSE: WIPRO), a leading global that address areas like Anti-counterfeit access to Wipro’s
information technology, consulting, and solutions and Air Worthiness certificate domain experts,
business process services company, tracking in the manufacturing industry and technology specialists, proprietary
announced that it has developed nine supply chain traceability across industries. tools and process assets to jump-start
blockchain-based solutions for the The benefits of these solutions include their blockchain journey. The lab hosts
Banking Financial Services and Insurance improved process efficiency, optimized technology platforms from Wipro’s partner
(BFSI), Manufacturing, Retail and costs and the ability to foster innovative ecosystem, which includes blockchain
Consumer Goods industries. Defined, business models. platform providers, blockchain application
designed and co-developed with clients in providers and technology providers who
Wipro’s Blockchain Innovation Lab, these Wipro’s Blockchain Innovation Lab specialize in specific blockchain use cases.
solutions demonstrate what block chain enables rapid provisioning of blockchain
can accomplish for global enterprises. environments to prototype and build use- In addition, Wipro’s consulting assets
case specific blockchain industry solutions for blockchain use case identification and
The industry solutions span across for clients. By leveraging the blockchain prioritization, business case creation and
areas such as Delivery v/s Payments environments in a cloud-based lab, clients blockchain platform selection are key
(DvP), Tri-party collateral management, are able to fast-track the development enablers for clients in their blockchain
Skip Trace Consortia, Trade finance, P2P of blockchain solutions by leveraging journey.
insurance for the sharing economy and pre-defined use-case blueprints and
Loyalty Rewards Management in the BFSI ready-to-use solutions. Along with the www.wipro.com

10 Global MDA Journal | June - July 2017

news

Volvo Penta Sees its First Engines Produced
in India come off the Production Line

Volvo Penta engines have been The VE Powertrain (VEPT) plant As a global company, Volvo Penta
manufactured in India for the was launched in 2013 by VE Commercial already has engines and products for the
first time, at a new dedicated production Vehicles, as a joint venture between most stringent emissions levels and will
line at the VE Powertrain (VEPT) plant. the Volvo Group and Eicher Motors. A be able to introduce technologies for the
The company is ready to serve Indian production line was created exclusively for Indian market whenever new standards
customers with off-road industrial engines the manufacture of Volvo Penta engines. are introduced.
that are made in India. Its 5- and 8-liter engines are certified
for Bharat Stage III emissions standards. Volvo Penta’s global strategy includes
Following the inauguration of an Both ranges can be used for a variety increasing production in different locations
exclusive Volvo Penta production line at of applications such as construction to be closer to customers in different
its manufacturing base in Pithampur in equipment, agricultural and forestry regions. And the roll-out of production in
the Madhya Pradesh region, customers machinery, crushers and screeners, the Asian country also ties in with Prime
are now taking delivery of 5- and 8-litre pumps and cranes. Minister Modi’s ‘Make in India’ – an
engines being produced in India. initiative which is aimed at encouraging
Volvo Penta provides global national and international companies to
The Volvo Penta engines, with their aftermarket support, so OEMs can be manufacture in the country, to utilize local
compact design, develop higher torque at assured that they can manufacture and skills and boost employment.
lower rpm, which enhances our machine’s trade in both the domestic and export
fuel efficiency. The engines are ready for markets. www.volvopenta.com
future emissions stage compliance.

June - July 2017 | Global MDA Journal 11

awards & honours

YPO Global Innovation Award – Asia
Top Innovator- Tadahiro Kawada,
President of Kawada Industriesadahiro Kawada is the President of Kawada Technologies, Inc, overseeing multiple businesses

Tincluding construction, ICT, aviation, environmental, and robotics. With a background in

mechanical and aerospace engineering, he led the research and development of humanoid robots at
Kawada, collaborating with the University of Tokyo and Japanese government agencies. Since 2000, the Kawada Group has developed
more than 10 variations of biped humanoid robots. Kawada’s newest robotics product, NEXTAGE, is an industrial-use collaborative
robot (cobot) that empowers manufacturing companies, facilitating factory innovation and labor efficiencies.

YPO Global Innovation Award-Michael Golway,
President and CEO of Advanced Solutions, Incichael Golway is the inventor of the BioAssemblyBot®, the world’s first 3D human tissue printer that

Muses a six-axis robot (www.bioassemblybot.com). BioAssemblyBot® is a disruptive technology that

allows researchers to complete their experiments faster, pharmaceutical companies to take cost and time out
of the drug development process and a new approach to solve for diseased or failing organs.

In addition to selling the innovation to customers around the world, Advanced Solutions Life Sciences
is using the BioAssemblyBot® technology platform in its own labs to help advance the science including
developments to support the goal of 3D printing human organs.

12 Global MDA Journal | June - July 2017

Acquisition & Merger

Global Industrial Manufacturing Deals
Insights: Q1 2017

Key trends/highlights of megadeals decreased from $14.4 value and volume, driven primarily by
billion to $12.3 billion, a 15% decrease, BWAY Corp’s acquisition of Mauser
• Deal value decreased 13% from $26.0 over the same period. Group for $2.3 billion.
billion in Q4 16 to $22.5 billion in Q1
17. Deal volume decreased from 68 • Industrial machinery continues to lead • The Asia and Oceania region remains
deals to 57 deals, a 16% decrease, over the M&A activity with a total deal as the top contributor to M&A activity,
the same period. value of $11.1 billion, representing and accounted for 42% and 60% of
49% and 35% of deal value and volume deal value and volume in Q1 17. UK
• Megadeal (deals greater than $1 for Q1 17, respectively. The rubber and & Eurozone was the only region with
billion) volume increased from six plastic products category registered growth in Q1 17 vs. Q4 16
to seven deals when comparing Q4 the highest growth over Q4 16 by both
16 to Q1 17, while disclosed value www.pwc.com

Timken Acquires PT Tech, Adding Industrial
Clutches and Brakes to Its Mechanical Power
Transmission Portfolio

The Timken Company (NYSE: to complement its strong position in The leading authority on tapered roller
TKR; www.timken.com), a global engineered bearings. In recent years, bearings, Timken today applies its deep
leader in bearings and mechanical power Timken has completed a number of knowledge of metallurgy, tribology and
transmission products announced that it acquisitions featuring products adjacent mechanical power transmission across a
has acquired the assets of PT Tech, Inc., to its core bearing lines. This includes belts, variety of bearings and related systems
a manufacturer of engineered clutches, gears and gear drives, chain, couplings and to improve reliability and efficiency of
brakes, hydraulic power take-off units and lubrication delivery systems, as well as a machinery and equipment all around
other torque management devices used variety of related services, all marketed the world. The company’s growing
in mining, aggregate, wood recycling and under strong industrial brands including product and services portfolio features
metals industries. Timken®, Philadelphia Gear®, Drives®, many strong industrial brands including
Lovejoy® and Interlube™. Timken®, Fafnir®, Philadelphia Gear®,
Based in Sharon Center, Ohio, PT Tech Drives®, Lovejoy® and Interlube™. Known
serves an established original equipment About The Timken Company for its quality products and collaborative
customer base primarily in North America. technical sales model, Timken posted
In 2016, sales were approximately $20 The Timken Company (NYSE: $2.7 billion in sales in 2016. With more
million. TKR; www.timken.com) engineers, than 14,000 employees operating from 28
manufactures and markets bearings, countries, Timken makes the world more
This acquisition advances the gear drives, belts, chain, couplings, and productive and keeps industry in motion.
company’s strategy to grow its portfolio of related products, and offers a spectrum
mechanical power transmission products of powertrain rebuild and repair services. www.timken.com

June - July 2017 | Global MDA Journal 13

Acquisition & Merger

INEOS to buy the entire Oil & Gas
business from DONG Energy A/S for a
headline price of $1.05 billion plus $250m
contingent

On completion, About DONG Energy

440 people will move to Daily production of oil and
gas in 2016 for the DONG Oil & Gas
INEOS, working across a Business averaged 100,000 barrels oil
equivalent. 70% of production comes
portfolio of production, from its Norwegian fields, about 15%
production from its Danish fields and
development, another 15% production from its
West of Shetland fields in the UK.
exploration and
The Business has shares in 10
appraisal assets in producing fields in Denmark, Norway,
and the UK. The vast majority of its
Denmark, Norway and production comes from the large
Norwegian gas field Ormen Lange,
UK (West of Shetland). in which Dong Oil & Gas holds a 14%
interest.
The business will form
About INEOS
part of INEOS Upstream,
INEOS is a leading manufacturer
a business division of of petrochemicals, specialty chemicals
and oil products. Comprising 18
the INEOS Group of businesses, with a production
network spanning 105 manufacturing
Companies. facilities in 22 countries, it produces
more than 60 million tonnes of
INEOS announced that it has agreed The strong petrochemicals, 20 million tons per
to acquire the Dong Oil & Gas portfolio of assets is annum of crude oil refined products
Business from DONG Energy A/S for an built around three world class fields; (fuels) and in 2016 it had sales of
unconditional payment of $1.05bn, plus Ormen Lange is the largest field in the around $40bn. Worldwide, INEOS
a contingent payment of USD 150 million DONG portfolio and the second largest employs 18,500 people. Today INEOS
related to the Fredericia stabilisation plant gas field in Norwegian waters, Laggan- is the 4th largest chemical company in
and a contingent payment of up to USD Tormore is a new gas field West of Shetland the world.
100 million subject to the development of which came on-stream early 2016 and Syd
the Rosebank field. Arne is a large oil field in Denmark. Along
with the existing production the portfolio
In acquiring the entire DONG Oil & also features several large scale oil & gas
Gas Business, the deal positions INEOS as developments in Denmark, Norway and
a top ten company in the North Sea and UK (West of Shetland).
the biggest privately owned exploration
and production business operating in this This transaction will enable INEOS
energy basin. to significantly expand its trading and
shipping activities making it a major
trader in the sector.

DONG Energy’s Oil & Gas business The acquisition and transfer of
brings with it a good mix of long life ownership is targeted to complete
and development fields, producing an within Q3 2017, subject to the receipt of
average of 100,000 boepd (in 2016) in the regulatory and other third party approvals.
North Sea, with around 570 million boe
of commercial and potential oil and gas The Business will be acquired by the
reserves in Denmark, Norway and the UK INEOS Industries business division.
(West of Shetland).
www.ineos.com

14 Global MDA Journal | June - July 2017

GLOBAL REPORT - HYDRAULIC REPLACEMENT market

GLOBAL HYDRAULIC REPLACEMENT MARKET

The replacement market for The Americas region is the world’s Needless to mention, UNITED STATES
hydraulic products remains largest hydraulic replacement market, OF AMERICA is by far the largest economy
at high potential as always. USA being the largest and lucrative. in this world. Therefore, Hydraulic
If at all, the global opportunities are Therefore, All hydraulic replacement applications in variety of industry in USA
underestimated always. PTC show at product manufacturers around the globe are the highest too. This culminates in
Shanghai every year gives us a signal, as look to USA, Mexico, central and South high and regular demand of hydraulic
to how this market thrives. America. replacement products.

North America still remains the THE AMERICAS Major hydraulic product
highest user market across the world.
The Middle Eastern countries market is manufacturers in USA in particular in USA
running neck to neck, with USA, Canada,
Mexico and South America. are too focused on OEMs. Consequently

The Global requirement for high their attention toward the replacement
pressure hydraulic hoses runs into Million
of dollars. Replacement market for the market is limited to none. This results
Seamless hydraulic tubing is somewhat
limited. In most cases in industrial into opportunity for other replacement
application the Power units eventually
die with the Machineries, and has long product manufacturers, particularly from
sustainable life. Hydraulic Joint and fitting
requirements are always a continuous China.
feature for the replacement market.
So is the case for accessories like Filter Hydraulic Cylinder replacement
elements. These items have a continuous market in the region is next to the hoses
replacement market across the globe. and fittings. Replacement Cylinder
manufacturing and repair in USA and
Mexico is very high and is a very lucrative
market.

Eaton Vickers V10/20 Vane Pumps
and PVB series Piston Pumps continues to
have very high demand in the replacement
market.

June - July 2017 | Global MDA Journal 15

GLOBAL REPORT - HYDRAULIC REPLACEMENT market

Eaton barely takes advantage of this a lot of Piston and Gear pumps. region’s economy.
market.
This has created a very healthy CHINA AND AUSTRALASIA
So is the case with Rexroth A10V replacement market for these products.
line of Products. Denison T6 line of Good for these manufactures is that they
replacement Pumps have field day in USA/ control and take full advantage of their
Mexico/South America replacement market, as there are no “look
alike “product manufacturers, as yet.
This region also has highest
population of pressure and flow control The European economy as a whole is
valves. Chinese replacement product struggling. Therefore replacement market
manufacturers have a great market share potential is very healthy.
in this region.
SOUTH EAST ASIA-MIDDLE
Interestingly, USA/Canada in the EAST
region do not have very many replacement
product manufacturer compared to China. India, Pakistan and Bangla Desh in
There is one known such manufacturers the region along with Middle Eastern
in USA, while there are too many Repair countries hold a very good replacement
Rebuild product houses. market promise.

EUROPE

The whole Europe’s economy is Users from these countries Australia and surrounding island
near equal to USA’s economy. Therefore, increasingly flock the Chinese PTC show country have healthy replacement
Hydraulic Replacement market potential in Shanghai for replacement hydraulic market. China off course is the biggest
too is proportionately similar. products. economy in the

The European Hydraulic replacement Eaton/Vickers V/VQ pump population region. Therefore, Hydraulic product
market has more Piston pump in this region is probably the highest, in replacement market in the region is very
applications than Vane Pumps. Therefore, addition Rexroth A10V line of products. healthy.
field population of Rexroth A10V series
and Eaton/Vickers PVB/PVH/PVM series Denison T6 line of Vane Pump has Australia’s replacement market is
pumps are abundantly found. very high field population in the region. flooded with Eaton/Vickers V/VQ and PVM
Pumps. Whereas, China who is nearing
Atos valve and Piston pump and Overall replacement market is very USA economy, continuously hold promise
valves also gaining ground. The gear pump healthy and in commensurate to the for all Vane and Piston Pumps and Motors.
application in the European replacement
market is also abundant. Permco has a Kazakhstan and Mongolia too draw
good market share in the region. resources from China for all their Vane
and Piston Pumps. Japan is self sufficient
Bondioli and Hawe Pumps are also in supporting their Hydraulic Replacement
sprouting up. Very many European market.
construction equipment manufacturers
such as JCB, Poclain, Volvo and others, use P.K. Guha
June 26. 2017

16 Global MDA Journal | June - July 2017

focus - Machine Tool Industry India stands 13th in production and 10th in the
consumption of machine tools in the world as per the 2016
THE Indian Gardner Business Media survey. The country is set to become
Machine a key player in the global machine tools industry and is likely
Tool to see substantial high-end machine tool manufacturing.
Industry With emphasis on Make in India and manufacturing growth,
for which the machine tools sector serves as the mother
industry.

The Indian Machine tool Industry has around 1000 units
in the production of machine tools, accessories/attachments,
subsystems and parts. Of these, around 25 in the large scale
sector account for about 70 percent of the turnover and the
rest are in the MSME sector of the industry. Approximately,
75 percent of the Indian machine tool producers are ISO
certified. While the large organized players cater to India’s
heavy and medium industries, the small-scale sector meets
the demand of ancillary and other units. Many machine tool
manufacturers have also obtained CE Marking certification,
in keeping with the requirements of the European markets.

The industry can be segmented in several ways:

CNC Conventional

Forming Rs. 126 Cr RS. 381 Cr

Cutting Rs. 3756 Cr Rs. 462 Cr

Indian Machine Tool Industry 2014-15 & 2015-16
(INR Crores)

2014-15 2015-16 Growth Rate

Production 4230 4727 12%

Exports 281 296 5%

Imports 5318 5945 12%

Consumption 9267 10376 12%

The Indian machine tools sector offers several
opportunities for investment. Given the current gap between
demand and supply, there is a clear need for adding capacities
in this sector. The industry is moving towards increasingly
sophisticated CNC machines, driven by demand from key
user segments, such as, automobiles and consumer durables,
Aerospace etc. Machine tool manufacturers need to develop
capabilities to cater to this demand and investments in this
area could yield long term benefits.

Source : IMTMA

June - July 2017 | Global MDA Journal 17

focus - Machine Tool Industry

Picture Courtesy : Siemens

Shaping the future of product
development

Robust enhancements for design, simulation and
collaboration

The Solid Edge ST10 portfolio of for 3D printing. More options for creating and efficiently manufacture parts
products from Siemens brings technical publications. Perfect control of designed using Solid Edge. These solutions
every aspect of product development to design data at any scale. And a brand new support a variety of traditional and new
the next level. way to collaborate on the cloud. manufacturing techniques including
machining, welding, sheet metal, molding
It gives the very latest in next A comprehensive set of and additive manufacturing.
generation design technologies. Fully manufacturing solutions are available for
integrated flow analysis. The newest tools Solid Edge users that enable to accurately Newly integrated topology

18 Global MDA Journal | June - July 2017

focus - Machine Tool Industry

optimization technology,combined the need to transfer data between companies of all sizes become digital
different applications, giving designers enterprises. Component classification
with Siemens’ exclusive Convergent the ability to achieve accurate and fast and off-line working are now supported
fluid flow and heat transfer analysis for Solid Edge using the embedded
Modeling™ technology, enables directly in Solid Edge. Teamcenter integration.

designers to dramatically improve Enhancements to integrated The Solid Edge portal will offer a
computer-aided manufacturing (CAM) cloud-based solution to collaborate with
product design efficiency andstreamlines enables efficient programming of CNC other users, suppliers and customers,
machine tools, and the ability to define simplifying communication in product
the ability to work with imported complex sheet metal components, development cycles. Offering a new way
optimized for manufacturing. New to work cooperatively, the portal allows
geometry. additive manufacturing tools enable users to upload and manage files in
users to 3D print parts in house or access cloud-based folders, with multi-platform
“We import many 3D models for a network of additive manufacturing browser-based viewing of Solid Edge and
components like lamps and cushions in services, optimizing material selection many other popular CAD applications.
a faceted format,” said Ricardo Espinosa, and delivery.
R&D Engineering Manager at Kimball “Digitalization is leveling the playing
International. “The new Convergent Solid Edge ST10 also includes field, providing unlimited opportunities
Modeling technology that underlies enriched publication features to quickly forsmall-to medium-sized businessesto
Solid Edge ST10 will enable us to work create detailed illustrations of designs. disrupt industry,” said John Miller, Senior
faster and more flexibly with this data.” Publishing interactive digital documents Vice President and General Manager at
can help communicate the correct Siemens PLM Software. “The release of
Expanding beyond traditional CAD manufacturing process and maintenance Solid Edge ST10 provides a portfolio of
capabilities, Solid Edge ST10 now offers procedures for products. These next generation product development
a complete portfolio of tools to improve documents are associative to the original tools that will enable our manufacturing
product development and design. New design information, enabling rapid customers to fully collaborate in the
topology optimization technology, a updates to the documentation when digital economy.”
subset of automated generative design, the design changes. New enhancements
quickly optimizes the strength to to built-in Solid Edge data management Solid Edge ST10 is scheduled to ship
weight ratio of individual part designs. and improved integration with Siemens’ insummer 2017.
Convergent Modeling greatly simplifies Teamcenter® software delivers scalable
the ability to work with geometry product data management to help www.siemens.com
consisting of a combination of facets,
surfaces, and solids – such as those
created by importing third-party CAD
files or through topology optimization.
New simulation capabilities such as fully-
integrated fluid flow analysis eliminate

Siemens Solid Edge ST10 offers

• Address design challenges including topology optimization and reverse
engineering using new Convergent Modeling technology

• Powerful and easy to use fluid flow and heat transfer simulation and
analysis

• Design parts that are perfect for 3D printing, and get direct access to
additive manufacturing services

• Teamcenter integration supports classification and working offline

• New Solid Edge Portal creates enhanced cloud-based collaboration

June - July 2017 | Global MDA Journal 19

focus - Machine Tool Industry

Twice Higher cutting speed = higher laser power. This
the formula has been more than just a rule of thumb.
cutting But TRUMPF engineers have now severed the
speed correlation between speed and kilowatts. The fruit
of their labor? The Highspeed and Highspeed Eco
New processes on TRUMPF 2D laser cutting cutting processes.
machines – 70 percent less cutting gas –
Doubling of sheet throughput A newly designed nozzle boosts the feed rate by up to
100 percent for solid-state laser machines that employ fusion
20 Global MDA Journal | June - July 2017 cutting with nitrogen. What’s more, laser power does not need
to be increased. Not only the feed rate is now faster, but also
the piercing process. These new cutting processes also allow
for a nearly twofold increase in sheet throughput compared to
standard cutting. What’s more, less cutting gas is used thanks to
the nozzle’s innovative design. The Highspeed process requires 40
percent less nitrogen on average; Highspeed Eco 70 percent less.
These new processes mean that TRUMPF has achieved another
milestone on the road to lower parts costs.

In fusion cutting, gas under relatively high pressure blows
molten material out of the kerf; this entails high operating costs.

focus - Machine Tool Industry

Flame cutting using oxygen has usually efficiently. The Highspeed Eco process “Highspeed Eco and
been used for mild steel, especially for relies on a patented nozzle fitted with
relatively thick sheets. The advantage a sleeve that forces the gas directly into Highspeed can now
of low gas costs is offset by oxidized cut the kerf, ensuring that little or no gas be used on machines
edges, which often need to be reworked. flows off to the side. While this moving in the TruLaser Series
The new Highspeed and Highspeed Eco sleeve glides across the material during 5000 equipped with an
processes, by contrast, are faster and fusion cutting, the nozzle remains 1.5 eight-kilowatt solid-
use less gas, which greatly increases millimeters from the sheet surface. state laser. Soon it will
the cost-efficiency of fusion cutting This ensures the nozzle can effortlessly be available for use with
mild steel with nitrogen. In addition, withstand any chips generated during six-kilowatt solid-state
the scope of application is now broader piercing – which accelerates piercing lasers. The Highspeed
for eight-kilowatt lasers used in fusion and minimizes the risk of damage. process is featured on
cutting. The laser can now cut sheets as machines in the TruLaser
thick as twelve millimeters – instead of Highspeed and Highspeed Eco can Series 3000 fitted with a
just ten millimeters as in the past. be used for fusion cutting of mild-steel six-kilowatt solid-state
and stainless-steel sheets at least four laser. Many relatively
The Highspeed process makes use millimeters thick. And just one nozzle is new machines can be
of a bi-flow nozzle. Some of the cutting needed in these cases, which makes mix- retrofitted with these
gas passes through the center of this ups less likely and shortens setup times. processes.
nozzle, as does the laser beam. The Cut edges exhibit low surface roughness
rest forms a secondary flow around the and a high-quality, homogeneous look.
principal flow to concentrate it onto the
kerf, expelling molten material more www.trumpf.com

Highspeed_Cutting_Process
The Highspeed cutting process can nearly double sheet throughput compared to standard cutting. A bi-flow nozzle reduces gas consumption by 40
percent on average.

June - July 2017 | Global MDA Journal 21

focus - Machine Tool Industry

Form Knurling vs Cut Knurling

Guide to Quick Cut knurling

Cut knurling machines the workpiece producing chips. It is the faster of
the 2 methods and the kindest on your lathe.
• Can be used for knurling thin materials without deformation
• Faster than form knurling
• Suitable for all materials, even plastic
• Powder metal wheels with ground teeth (many suppliers use HSS

wheels with milled teeth)
• Cutting process protects the expensive lathe
• Knurling to workpiece flange possible to a limited extent only
• More expensive than form knurling
• No or minimal changes to the external workpiece diameter

Guide to Quick Form knurling

Form knurling cold forms the workpiece using pressure. It is the
slower of the 2 methods and the cheapest, however it can be
damaging to the lathe if done often.
• Can be used for knurling up to a shoulder
• Knurling is possible at any position of the workpiece
• Lower cost than cut knurling
• Not recommended for thin materials
• It can effect the external workpiece diameter
• Powder metal wheels with ground teeth (many suppliers use HSS

wheels with milled teeth)
• Not ideal for visible knurls
Whilst form knurling is the much cheaper of the 2 methods, it is
most probably best used for short run or one off jobs.
For longer production runs or for people who do knurling regularly,
it is strongly advised to invest in CUT knurling tools to produce better
quality knurls and look after your lathe.

www.cutwel.co.uk

22 Global MDA Journal | June - July 2017

June - July 2017 | Global MDA Journal 23

focus - Machine Tool Industry

Case Study

Retrofit tunes Ford press

to high performance

The large panel the press already produced uncoupling takes place
press at Ford in over 1.2 million parts. This
Cologne was no longer up to is mainly due to the good automatically during die
date: Because the transfer cooperation between Schuler
was mechanically linked and Ford. Ford itself, with its change. This means that all
to the rest of the system, own qualified department,
Schuler installs the motion curves could brought the control of the necessary setup procedures
highly dynamic not be adjusted and the straight-sided press to the
Tri-axis transfer components had to be stored latest level and prepared can be carried out outside the
with overhauling between the press slides. it for the installation of
carriages and a Within just seven weeks, the new transfer. Thanks press and the diechangeover
blank loader with Schuler installed a highly to an innovative solution,
line scanner in dynamic Tri-axis Transfer with the interim storage has times can be significantly
seven weeks overhauling carriages as well become obsolete: With a
as a blank loader with a line servomotoric overhauling reduced. Schuler’s
scanner at the press – and slide, which is integrated
thus tuned the system to high in the transfer rails, step ProTransfeatures feed direct
performance. distances of more than 3.60
meters can be realized. drives with highly dynamic
In the first six months
after the modernization, The coupling and servomotors as well as

active vibration dampening.

An increase in output by up

to 30 percent and more is

therefore not uncommon.

Thanks to the free
programmability of the
transfer, which can be
controlled by its own
visualization, Ford can

24 Global MDA Journal | June - July 2017

focus - Machine Tool Industry

now design new dies more flexibly and is passing a line scanner; the blanks do shape and also protects the surface of the
optimize on output. The dies are also not have to stopanymore. On basis of blank. Last but not least, the maintenance
easier to set up and adjust. As the profile of this information, the following centering cost of the system is much smaller.The
the transfer rails reduces from 250 to 200 robot can align the blanks optimally for optical centering station is accurate up to
millimeters, the freedom of movement the subsequent forming process in a three millimeters, the location in and at
and visibility into the die improves. And, press.Because the line scanner is attached right angles to the transport directioncan
last but not least, energy supply as well right above the belt conveyor – and be corrected by up to 100 millimeters. The
as maintenance costs are reduced by the not at several meters in height as with maximum blank size is 4,100 millimeters.
elimination of the mechanical connection conventional optical centering stations The line scanner also captures double
to the press. – the system is largely insensitive to parts side by side as well as in a row.
ambient light passing through the ceiling
Continuous location detection window, for instance. This improves Thanks to a pre-commissioning of
increase cycle times process reliabilitysignificantly. Tri-axis transfer and blank loader with line
scanner at Schuler and a well-coordinated
The blank loader, too, improves Unlike a mechanical centering construction site, the downtime for Ford
the productivity of the press: The exact station, the system with line scanner is was less than two months.
location of a blankis detected while it also completely independent of the blank
www.schulergroup.com

14 1

Within just seven weeks,
Schuler modernized transfer
and blank loader of Ford’s
large panel press in Cologne.

25 2
3
Thanks to the blank loader
with line scanner, productivity
and process reliability
improve significantly.

3

For location detection, the
blank can pass below a line
scanner and does not have to
stop anymore.

4

Schuler’s new Tri-axis Transfer
takes the parts from one
die to the other, the interim
storage becomes obsolete.

5

The optical centering station
is accurate up to three
millimeters, the location can
be corrected by up to 100
millimeters.

Photo - Schuler

June - July 2017 | Global MDA Journal 25

article - additive manufacturing

Additive Manufacturing

3D Printing: Facts & Forecasts

-By Sandra Zistl

Although additive manufacturing won’t From Prototypes to Mass Industry? He thinks industry is already
replace conventional production Production close to the large-scale production stage in
methods, it is expected to revolutionize the use of AM to create metallic structures
many niche areas. Exponential growth is Until recently, additive manufacturing for selected products in medicine and
on the horizon. was mainly used for rapid prototyping. aviation.
Prototypes are produced layer by layer in
Market Researchers Predict the aerospace, automotive, and machine Additive manufacturing is already
300% Growth over the Next tool production industries, as well as a reality for making artificial hip joints
Decade in the medical and dental technology and crowns for teeth, for example. Using
sectors. According to studies conducted data obtained from scans, manufacturers
From the user’s point of view, the by the Fraunhofer Additive Manufacturing create custom-fitted implants as unique
additive manufacturing (AM) market can Alliance, approximately 150 companies items.
be basically divided into two sectors: the currently operate in this services market.
market for plastic printers that are now also In another sector, Siemens is now
affordable for private consumers, and the Even though analysts at Wohlers printing burner tips from powdered steel
market for professional devices that are Associates expect the rapid prototyping for use as replacement parts for gas
used in industry to “print” with materials market to grow from $1.5 billion in 2012 turbines
of all kinds, including ceramic and metal to more than $5 billion by 2020, they
powders. Although analysts still consider anticipate the most promising market Increasingly Efficient
the additive manufacturing market to be a to be in quite another area. “Money will Machinery
niche sector, they nonetheless state that it be made with manufacturing, not with
had a volume of up to €2 billion in 2012. It prototypes,” forecasts Tim Caffrey, a According to the Roland Berger study,
took the sector 20 years to reach a market consultant at Wohlers. This assessment faster machinery will play the biggest
value of €1 billion. The second billion was is shared by Bernhard Langefeld, a role in cutting costs. “Manufacturers are
attained only five years later, and analysts machine construction expert at Roland now greatly increasing the machinery’s
now believe that it could grow at least Berger Strategy Consultants and one of efficiency,” says Bernhard Langefeld.
fourfold over the next ten years. the authors of the study titled Additive “The latest generation of machines uses
Manufacturing – A Game Changer for the multiple lasers, larger build chambers,
automatic changing systems, and

26 Global MDA Journal | June - July 2017

article - additive manufacturing

improved online monitoring features. Performance can be substantially after that. This assumes, however, that the current
increased as a result.” average build rate will increase eightfold over the
next ten years.
Powders are also a major cost factor. “Some printing machine suppliers
have used the same business model as the manufacturers of inkjet printers,” Heading for Increased Product
explains Langefeld. “This means that the companies supply not only the Lifecycle Leverage.
3D printers but also the appropriate cartridges, which in this case contain
specialized powder. “However, the market analysis conducted for the Roland However, market researchers do not expect
Berger study showed that experienced operators of several machines had AM to replace conventional manufacturing
already created their own supply systems, and this led to considerable cost processes. It will instead establish itself in niche
savings. In the study, Langefeld therefore came to the conclusion that the sectors involving similar parts with minimal
manufacturing costs of printed metallic products will probably be cut in half differences. Examples include precisely tailored
over the next five years and decline by another 30 percent in the five years teeth and dental crowns, hip joints, and skull
implants., Additive manufacturing also allows
companies from all industries to design products in
such a way that the products can do things that
conventional ones can’t. That’s why there is also
great potential in the use of new materials. For
example, AM could conceivably be used for alloys,
for precious metals, and for products in which
different sections are “printed” with different
materials. Such products could include a material
that provides heat resistance and another for
ensuring stability. Moreover, metals that melt at
high temperatures could be used in completely
new ways.

As a result, it would be possible to quickly
produce exact and customized replacement
parts on site when they are needed for individual
machines or entire power plants. This would not
only eliminate storage and transportation costs but
also save money by preventing downtimes.

For example, the all-new method for making
Siemens burner tips for gas turbines reduces
the repair times for certain models by around 90
percent, because the replacement part no longer
has to be laboriously welded together. Instead, the
burner tip is simply printed onto the body of the
burner, reducing repair costs considerably.

Over the long term, this process will allow
product lifecycle leverage, as analysts call it, to
take effect. “This effect will set in sooner in the
aviation industry than in the automotive sector,”
says Langefeld.

Put simply, a product made by means of
additive manufacturing can cost ten times as
much as a conventional item if, for example, it
consistently reduces fuel consumption by one
percent during its entire service life. According to
Langefeld, the challenge for the next three to five
years will be to identify the products for which this
equation is valid.

www.siemens.com

June - July 2017 | Global MDA Journal 27

focus - electrical & electronics Industry

Charging as if by magic

Bosch and partners develop charging system to create an innovative infrastructure for renewable power grids

• Led by Bosch, BiLawE project partners are investigating an inductive charging system that can also feed energy back into the grid
• The system would integrate e-vehicles into the power grid as intelligent power storage units
• The project is aimed at ensuring high availability of mobile storage for renewable energy

Battery storage systems in electric connected to the grid as West cluster. The partners in the project,
cars could soon be to renewable often as possible and for besides project coordinator Robert Bosch
power grids what power banks are to as long as possible. This, GmbH, are the Fraunhofer Institute for
mobile phones: an external battery pack. in turn, necessitates a Solar Energy Systems ISE, the Fraunhofer
Quite practical, really – were it not for stationary infrastructure Institute for Industrial Engineering IAO,
those pesky charger cables. Currently, – that is, special inductive and GreenIng GmbH & Co. KG. The project
drivers have to brave the elements to charging stations that kicked off at the start of the year and will
connect the cable from the charging we want to connect to run for three years.
station to their electric cars. This could public and local grids, or
be about to change: Bosch, acting as even isolated grids that The Electric Mobility South-West
project coordinator, is working with the supply only a limited cluster is one of the most important
Fraunhofer Society and GreenIng GmbH area,” explains Philipp regional associations in the field of
& Co. KG on research into an innovative Schumann, a physicist electromobility. The cluster aims to
concept for charging vehicles inductively – who heads up the project drive forward the industrialization of
that is, without physical contact – through at the Bosch research electromobility in Germany and to
a magnetic field while the car is parked at campus in Renningen. establish the German state of Baden-
a charging station. Württemberg as one of the major
Wireless charging providers of electromobility solutions.
But this new technology can do even while parking It brings together leading corporations
more: it also helps make electric cars much and SMEs and networks them with local
more eco-friendly to drive, and power The advantage research institutions in four fields of
grids more stable. One challenge to their of the inductive system is its wireless innovation: vehicle, energy, information
stability lies in the fact that the amount of charging. Because vehicles no longer have and communication technology, and
energy obtained from renewable sources to be connected manually by means of production.
such as wind, sun, and water is subject to charger cables, they can be connected
natural fluctuations. With this in mind, to the grid more often. The project thus Source : Bosch
the consortium, collaborating through the also aims to develop a concept for the
publicly funded BiLawE research project, economical manufacture of charging
is developing an inductive charging system system components, as well as a business
to establish an intelligent infrastructure model for various grid services associated
for the sustainable use of renewable with energy recovery. And because
energies. the bidirectional charging stations are
connected to the grid, they can also
Their solution is based on electric reduce the load on and stabilize the grid
car batteries that enable bidirectional even when the vehicles are on the road.
charging: the batteries use a powerful
and intelligent charging system to store Strong partners
energy, but they can also feed this energy
back into the grid as needed. When strong The BiLawE (from the German for
sun and wind result in generation peaks, bidirectional, inductive charging systems
the electricity will be temporarily stored in economical in the grid) research project
the car batteries. When skies are overcast received 2.4 million euros in funding from
and winds are calm, it will be fed back into the German Federal Ministry for Economic
the grid to meet demand. “To make this Affairs and Energy as part of the ELEKTRO
system work, electric vehicles must be POWER II program, and is supported by
the leading-edge Electric Mobility South-

28 Global MDA Journal | June - July 2017

focus - electrical & electronics Industry

Consider this when planning high
voltage switchgear installations

By Edvard Csanyi

Editor-In-Chief and electrical engineer at EEP
http://electrical-engineering-portal.com

Planning high voltage switchgear

The following three criteria must be considered when planning high voltage switchgear installations:
1. Voltage levels
2. Plant concept and configuration
3. Dimensioning
1. Voltage levels
High voltage installations are primarily for power transmission, but they are also used for distribution and for coupling power

supplies in three-phase and HVDC systems. Factors determining their use include: network configuration, voltage, power, distance,
environmental considerations and type of consumer

June - July 2017 | Global MDA Journal 29

focus - electrical & electronics Industry

HV Installations Voltage level

Distribution and urban networks > 52 – 245 kV

Industrial centres > 52 – 245 kV

Power plants and transformer stations > 52 – 800 kV

Transmission and grid networks 245 – 800 kV

HVDC transmission and system interties > 300 kV

Railway substations 123 – 245 kV

2. Plant concept and configuration

The circuitry of an installation is specified in the single-phase block diagram as the basis for all further planning stages. Table 1
shows the advantages and disadvantages of some major station concepts.

The availability of a switching station is determined mainly by:

1. Circuit configuration, i. e. the number of possibilities of linking the network nodes via circuit breakers and isolators, in other
words the amount of current path redundancy,

2. Reliability/failure rate of the principal components such as circuit breakers, isolators and busbars,

3. Maintenance intervals and repair times for the principal components.

Table 1 – Choice of plant concept and measures taken in relation to given boundary conditions

Concept configuration Advantages Disadvantages
Single busbar 1. least cost 1. BB fault causes complete station outage

Single busbar with 1. low cost 2. maintenance difficult
bypass
2. each breaker accessible for maintenance 3. no station extensions without disconnecting the installation
without disconnecting
4. for use only where loads can be disconnected or supplied
from elsewhere

1.extra breaker for bypass tie

2.BB fault or any breaker fault causes complete station outage

Double busbar with one 1. high changeover flexibility with two busbars 1. extra breaker for coupling
circuit breaker per branch of equal merit
2. BB protection disconnects all branches connected with the
2-breaker system 2. each busbar can be isolated for maintenance faulty bus

3. each branch can be connected to each bus 3. fault at branch breaker disconnects all branches on the af-
with tie breaker and BB isolator without inter- fected busbar
ruption
4. fault at tie breaker causes complete station outage
1. each branch has two circuit breakers 1. most expensive method

2. connection possible to either busbar 2. breaker defect causes half the branches to drop out if they
are not connected to both bus bars
3. each breaker can be serviced without discon-
necting the branch 3. branch circuits to be considered in protection system (ap-
plies also to other multiple-breaker concepts)
4. high availability

30 Global MDA Journal | June - July 2017

focus - electrical & electronics Industry

Ring bus 1. low cost 1. breaker maintenance and any faults interrupt the ring
1½-breaker system 2. potential draw-off necessary in all branches
2. each breaker can be maintained without 3. little scope for changeover switching
disconnecting load

3. only one breaker needed per branch

4. no main busbar required

5. each branch connected to network by two
breakers

6. all changeover switching done with circuit 1. three circuit breakers required for two branches
breakers

1. great operational flexibility

2. high availability 2. greater outlay for protection and auto-reclosure, as the
middle breaker must respond independently in the direction of
3. breaker fault on the busbar side disconnects both feeders
only one branch

4. each bus can be isolated at any time

5. all switching operations executed with circuit
breakers

6. changeover switching is easy, without using
isolators

7. BB fault does not lead to branch disconnec-
tions

3. Dimensioning Table 2 – The principal types of design for high voltage
switchgear installations and their location
On the basis of the selected voltage level and station
concept, the distribution of power and current is checked and Basic design Insulation Used mainly Location Indoor
the currents occurring in the various parts of the station under medium for voltage ×
normal and short-circuit conditions are determined. Conventional level (kV) Outdoor
Conventional Air × ×
The basis for dimensioning the station and its components is GIS Air >52 – 123 ×
defined in respect of: Hybrid (2) SF6 123 – 800 × (1)
Air/SF6 >52 – 800 ×
1. insulation coordination 245 – 500

2. clearances, safety measures

3. protection scheme 1. GIS used outdoors in special cases

4. thermal and mechanical stresses 2. Hybrid principle offers economical solutions for station
conversion, expansion or upgrading.
The basic designs available for switching stations and
equipment together with different forms of construction offer There are various layouts for optimizing the operation
a wide range of possibilities, see Table 2 below. The choice and space use of conventional outdoor switchgear installations
depends on environmental conditions and also constructional, (switchyards), with different arrangement schemes of busbars
operational and economic considerations. and disconnectors.

June - July 2017 | Global MDA Journal 31

Interview Precise, safe and energy efficient: drive and control technology from Bosch Rexroth
moves machines and systems of any size. The company bundles global application
Hans Bangert experience in the market segments of Mobile Applications, Industrial Applications

MD, Bosch Rexroth India to develop innovative components as well as tailored system solutions and services.
Bosch Rexroth offers its customers hydraulics, electric drives and controls and
linear motion and assembly technology all from a single source.

How do you describe over the years, thrived to become ISO 50001 EnMS. Our paint shop uses
your success in Drive, one of the leading companies in India environment friendly paint for all our
Transmission and Control specializing in the field of Drive and products which fulfil reach compliance
Technologies? Control technologies. Thus Bosch and restricted the use of paint which
Rexroth is a partner for industrial contains Lead. For associates working
Bosch Rexroth started its applications and mobile applications. in this plant, we are introducing
operations in India way back in We design, develop and distribute ergonomics thus creating healthy
1974. Since then it is growing and components and systems in the working conditions. Bosch Rexroth
has become one of the main Drive areas of hydraulics, electric drives has put in lot of efforts to make this
and ontrol solution provider. This and controls, linear motion and plant and its processes environmental
has mainly happened as company assembly technology The products friendly. Last but not least Bosch
is focused on its strategic priorities. find application in major industries like Rexroth offer components and
Among these are: technological plastics, steel, bulk materials handling, solutions that help customers to design
differentiation, synergies with internal railways, construction machinery, machines with significant advantages in
and external partners and development agricultural and farm machineries, lower energy consumption.
of local products suited for local cutting machine tools and presses,
market. We focus on products designed automotive, food and packaging, Rexroth has established
for local requirements in India at textiles, etc. ‘Safety on Board’ path
affordable costs, adapted to regional to ensure intelligent and
demands, developed and produced We appreciate your economical machine safety.
locally. consistent working for Please tell us more.
Environmental Protection.
What do you say about Would you like to throw As a part of functional safety,
prevailing market scenario light on your Social Rexroth has established “Safety
and muted impact of the Responsibilities towards on Board” path to intelligent and
general slump in the market? Environment. economical machine safety. Rexroth
offers standard compliant system
Previous couple of years witnessed For Bosch Rexroth India, solutions, safety relevant products and
many big stories from politics and environmental sustainability is one a broad spectrum of certified products
business. In such a fluidity, it was tough of the priority areas in its business. for explosion hazard environments
to do business. The market fluctuations We always see to it that our internal to machine manufacturers and users.
have shifted the expectations of processes are lean and environmentally For example - our drive based safety
customers. Customers are increasingly friendly. Even within Bosch Rexroth solutions will help to increase machine
looking for one single source that can world, Protection of Environment availability ensuring the highest
cater their needs by supplying all drive is one of the highest focused areas. level of functional safety. Also, our
and control technologies. Although We have a dedicated process named hydraulic valves certified according
cost plays an important role, quality, “Design for Environment” managed to ATEX, IECEx, and numerous further
machine safety and energy efficiency by our global HQ, which reviews and national regulations combine standard-
coupled with productivity is dominating assesses environment impact before compliant function with maximum
when a customer specifically goes development of any new product. Our reliability. Every component we
for a solution. It is also much more state-of –the art- manufacturing plant design is designed considering safety
convenient for a customer to ask for a located in Sanand, Ahmedabad uses aspect. Even the parts we source or
comprehensive solution from a single the hi-tech equipment and hi-tech use to make our systems they are of
source that can supply the whole range cutting tools thus ensuring speed highest safety standards. We follow
of Drive & Control technologies. and efficiency of our manufacturing 10 steps of safety standards to achieve
processes and helping to consume performance level and protecting
Bosch Rexroth also offers less energy. We have procured the man & machine, reduce total cost
industry-specific solutions. equipment as per ISO 50001 EnMS of ownership, adhering to laws &
Please elaborate. (Energy Management Systems) standards. Thus Rexroth is offering a
compliance and our manufactured comprehensive product portfolio as
The company commenced products meet the requirement of system partner for machine safety.
operations in India in 1974 and has
under the aegis of Bosch Rexroth AG,

32 Global MDA Journal | June - July 2017

What are your plans for
Growth, Expansion and
Green Technology?

We draw our growth plan
by keeping our customers in
focus, improving productivity
and increasing maturity level
of business processes in
order to comply with internal
and external regulations.
As mentioned earlier, the
world is rapidly becoming
a market for electrification,
connectivity automation. We
are taking strategic initiatives
by expanding, customizing
our product offerings in these
areas to stay in- line with our
growth plan. We will continue
to do this with our consistent
& focused approach towards
environment protection thus
ensuring our products comply
with the standards of a Green
technology.

Hans Bangert

Managing Director
Bosch Rexroth India

Prior to his Indian
assignment, Mr. Bangert
served as Managing
Director of Bosch Rexroth
Denmark.
A Mechanical Engineer
from Ruhr University, he
has been with Bosch for
more than 35 years and
held various top level
positions in Bosch and
Rexroth worldwide.

June - July 2017 | Global MDA Journal 33

focus - plastic & Polymers industry

New strategy produces
stronger polymers

Simple technique cuts down on loops that weaken materials such as
plastic and rubber

Researchers have found a new approach for reducing the number Plastic, rubber, and many other useful
of loops (red) in a polymer. The method could offer an easy way for materials are made of polymers — long
manufacturers of industrially useful materials such as plastics or gels to chains arranged in a cross-linked network. At the
molecular level, these polymer networks contain
strengthen their materials. structural flaws that weaken them.

“Just by changing how fast Several years ago, MIT researchers were the
first to measure certain types of these defects,
you add one component to called “loops,” which are caused when a chain
the other, you can improve the in the polymer network binds to itself instead of
another chain. Now, the same researchers have
mechanical properties,” found a simple way to reduce the number of
loops in a polymer network and thus strengthen
-Jeremiah A. Johnson materials made from polymers.

To achieve this, the researchers simply add
one of the components of the polymer network
very slowly to a large quantity of the second
component. Using this approach, they were able
to cut the number of loops in half, in a variety of
different polymer network structures. This could
offer an easy way for manufacturers of industrially
useful materials such as plastics or gels to
strengthen their materials.

“Just by changing how fast you add one
component to the other, you can improve the
mechanical properties,” says Jeremiah A. Johnson,
the Firmenich Career Development Associate
Professor of Chemistry at MIT and the senior
author of the paper.

Controlling loops

In 2012, Johnson’s group devised the
first way to measure the number of loops in a
polymer network and validated those results with

34 Global MDA Journal | June - July 2017

focus - plastic & Polymers industry

theoretical predictions from Olsen. The typical synthesis process, when everything polymeric networks,” says Krzysztof
researchers found that the loops can is mixed together at once, some of the A2 Matyjaszewski, a professor of chemistry
make up about 9 percent to nearly 100 chains end up binding to two of the B4 at Carnegie Mellon University who was
percent of the network, depending on the arms, forming a loop. not involved in the research.
concentration of polymer chains in the
starting material and other factors. The researchers found that if they Better products
added B4 very slowly to a solution of A2,
A few years later, Johnson and Olsen each of the B4arms would quickly react The researchers also tried this
developed a way to calculate how much with a single molecule of A2, so there was technique with four other types of polymer
these loops weaken a material. In their less opportunity for A2 to form loops. network synthesis reactions. They were
latest work, they set out to reduce loop not able to measure the number of loops
formation, and to achieve this without After a few hours of slowly adding for all of those types of polymers, but
changing the composition of the materials. half of the B4 solution, they added the they did find similar improvements in the
second half all at once, and the star- strength of the materials.
“The goal we set for ourselves was shaped subunits joined together to form
to take the same set of precursors for a a cross-linked network. This material, the This approach could potentially help
material that one would normally use, researchers found, had about half as many to improve the strength of any material
and, using the exact same precursors loops as the same material produced made from a gel or other cross-linked
under the same conditions and at the using the traditional synthesis process. polymer, including plastics, membranes
same concentration, make a material with for water purification, adhesives made of
fewer loops,” Johnson says. Depending on how many loops were epoxy, or hydrogels such as contact lenses.
in the original material, this “slow then
In this paper, the researchers first fast” strategy can improve the material’s Johnson’s lab is now working on
focused on a type of polymer structure strength by as much as 600 percent, applying this strategy to a variety of
known as a star polymer network. This Johnson says. materials, including gels used to grow
material has two different building blocks: cells for tissue engineering.
a star with four identical arms, known as “This very simple ingenious and
“B4,” and a chain known as “A2.” Each powerful approach, based on slow The research was funded by the
molecule of A2 attaches to the end of crosslinker addition, diminishes the National Science Foundation.
one of the B4 arms. However, during the intramolecular cyclization and significantly
increases mechanical properties of www.mit.edu

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June - July 2017 | Global MDA Journal 35

36 T h eGlobal MDA Journal | June - July 2017 u l t i m a t e p e r f e c t i o n i n fl u i d

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p o w e r t e c h n o l o g y w i t h a d i f f e r e n c e !June - July 2017 | Global MDA Journal 37

focus - plastic & Polymers industry

Not All O-rings are Equal :
How Choosing the Wrong O-Ring
Material Can Bring Down your
Machine

- By Aaron Clark,Senior Chemist, Eaton

O-rings are the unsung hero of any application. These donut-shaped engineered objects seal connections in
equipment by forcing a rubber seal into a channel and applying mechanical or hydraulic pressure to prevent
clearance of a less viscous material. These inexpensive and easy to replace and maintain components don’t
always get the credit they deserve. But, when they are not properly selected or cared for, O-rings can wreak havoc.

O-rings are the unsung hero of any application. These donut- Common Causes of O-ring Failure
shaped engineered objects seal connections in equipment by
forcing a rubber seal into a channel and applying mechanical or O-ring failure can be traced back to design, installation,
hydraulic pressure to prevent clearance of a less viscous material. production quality and material choice. Choosing the proper
These inexpensive and easy to replace and maintain components materials, size, compression and surface finish will make a big
don’t always get the credit they deserve. But, when they are not different in machine performance and longevity. Design related
properly selected or cared for, O-rings can wreak havoc. failures are particularly common, and can be avoided with
certain considerations:
Because of their role in sealing machinery, O-rings are a
small but critical element. In an air conditioning (AC) system, • Know the depth – O-rings sit in a channel known as a gland.
for example, the most common cause of refrigerant leak is Knowing the gland depth allows a machine designer to
O-ring failure. This leakage leads to loss of lubrication that can calculate compression and choose an O-ring that will avoid
affect system performance, ice the evaporator coil or cause the extrusion and tearing.
compressor to overheat and eventually burn out. Compressor
failure usually leads to entire system replacement, which can be • Leave space – O-rings should not fill the entire gland, but leave
extremely costly. space for O-ring swelling and possible thermal expansion of
the seal.
Item Cost
$500-$1000 • Avoid stretching – Stretching the O-ring past five percent of
A/c Repair $1000-$5000 the centerline diameter should be avoided, as it can flatten
the O-ring cross section. If the O-ring must be stretched past
New A/c $7.99-$57.99 the five percent mark, the gland depth should be reduced to
System $39-$260 retain the necessary compression.

O-Ring • Proper installation – As with any component, proper
installation is important to successful operation. In the
AC Recharge case of O-rings, installers should use the correct lubricant,
keep both the O-ring and gland clean, and install the O-ring
Figure 1. AC system repair varies by supplier and geography, but is always significantly more without stretching or pulling on the device with a screwdriver
expensive than O-ring replacement. or other tools. The surface finish should also be inspected
before installation, and an O-ring with scratches, nicks or
There are a number of factors to consider when selecting the imperfections should not be used.
proper O-ring for your application. Sizing, design and installation
are all important, but the basic element of choosing the proper
polymer material while designing the equipment is key. Choosing
the proper O-ring material when replacing in the aftermarket is
equally important.

38 Global MDA Journal | June - July 2017

focus - plastic & Polymers industry

• Choose a reputable supplier – Sourcing O-rings from a key to avoiding O-ring compression set. Also key to avoiding
reputable supplier or manufacturer can help avoid potential compression set is chemical compatibility of the O-ring and
production-related quality concerns. Poorly made O-rings the fluid in the system. Different fluids will interact with each
might fail sooner than expected due to low quality materials. polymer type differently, and chemical incompatibility leads
to degradation, which accelerates compression set and can
Material-related O-ring Failures lead to failure in as few as 70 hours.

Some O-ring issues can be solved by addressing the Figure 3. The O-ring (brown) seated in the gland (gray) will permanently deform after time,
production quality, installation and design, but no number of pressure and temperature are applied.
design changes will fix the baseline issue if the correct material
was not selected for your application. Choosing the wrong • Thermal Degeneration and Weathering: The chemical
material can lead to abrasion, compression set, chemical structure of the base polymer will dictate the thermal, ultra-
compatibility issues, extrusion, spiral failure and improper violet (UV) and ozone compatibility of the O-ring. If you choose
thermal capabilities and weathering. a polymer without the correct temperature compatibility, the
O-ring can form radial cracks on the highest temperature
• Extrusion: Extruded O-rings are a result of both improper surfaces.
design and material selection. An O-ring seal is meant to plug
the opening between the two connections without extruding
through the opening, as seen in Figure 2. An extruded O-ring
will hold the seal while a machine is running, but if the
machine is turned off for repair or inspection, the O-ring will
relax, causing it to crack or flatten out. When the machine is
turned back on, the flattened O-ring will allow the connection
to leak.

Machine designers can address this concern by decreasing
clearances, choosing an elastomer material with a higher
hardness, and/or modifying the gland design to allow 25 percent
void space and 75 percent gland fill.

Figure 2. This cross section depicts the gland (gray channel) and O-ring (brown). With Figure 4. Polymers are not all equal when it comes to withstanding heat and cold.
improper design and/or material selection, pressure applied to the connection may cause the
• Chemical Compatibility: In its role as connection seal, an
O-ring to extrude through the opening. O-ring will regularly come in contact with the material that

• Compression Set: Rubber compounds can permanently
deform under strain, and compression set refers to the
percentage of deflection that the elastomer fails to recover
after a fixed period of time under specific squeeze and
temperature, as seen in Figure 3. Once the O-ring has
compressed, if pressure or temperature is changed – again,
using the example of turning the machine off and then back
on – the seal will no longer hold. Selecting the correct polymer
for the pressure and temperature your application will face is

June - July 2017 | Global MDA Journal 39

focus - plastic & Polymers industry

is being sealed into the system. In the AC system example, Selecting the Right Material for your
that material is likely a refrigerant, such as R-1234yf, the Application
latest AC refrigerant on the market. The differing properties
of each polymer mean that an O-ring built for an AC system Choosing the right O-ring size, design and material might
may not function as well in a system where it is sealing in oil seem like a small decision, but it can have huge implications for
instead of refrigerant – and vice versa. your machine and your bottom line.

There are many, many combinations of thermoplastic
and rubber that can be used when manufacturing an O-ring.
Companies like Eaton test these different materials to help
customers and machine designers understand which will work
best in any given application.

To select the best O-ring, machine designers must first
understand the application.

• What is the critical temperature? A machine operating in
South America may need O-rings made with a different
polymer than a machine working in Northern Canada.

Figure 5. Test results demonstrate the variations in polymer compatibility with new • What type fluid is the O-ring sealing? An O-ring compatible
R-1234yf refrigerant. with oil may not also be compatible with refrigerant.

Chemical incompatibility can lead to excessive When specifying an O-ring, designers must consider
elastomeric material swelling and loss of properties, which all of the factors. Frequently, only the required hardness
can make the O-rings more susceptible to degradation and is indicated, which can lead to a poor quality O-ring being
failure during use. Poor chemical compatibility can lead to chosen for the application. By using an ATSM D2000 “call
failure very quickly, some studies show failure in as little as out,” along with necessary morphology and dimensions, a
70 hours. By understanding the application’s temperature and designer can specify not only the hardness but all required
fluid requirements, a designer can select an O-ring with the properties and temperatures that your O-ring requires,
appropriate chemical composition for the machine. including tensile strength, compression set, temperature
resistance and more. O-ring manufacturers and suppliers can
Comparing Cost vs. Quality match the ASTM D2000 parameters to the right component
for your application, helping extend machine life and prevent
A standard rubber formulation includes a polymer (which unexpected downtime.
can vary), carbon black, mineral fillers, antioxidant, plasticizer,
curative and process aid. To reduce costs, some manufacturers Once you have selected and installed the right O-ring for
replace some of the carbon black or reinforcing mineral fillers your application, equipment owners should plan to replace
with cheaper fillers such as talc and kaolin (Dixie Clay). These O-rings each time the system needs to be opened. Recalling
materials can provide the rubber with the same hardness as a the significant costs of repairing or replacing a leaky system,
typical formulation, but at a lower cost as compared to rubber correct O-ring material selection, design, installation and
formulated with more expensive carbon black or mineral filler. maintenance serves as a low cost insurance against leakage.
While hardness is one important factor, there are many other
factors to consider, so it is important to choose a reputable O-rings, the common components that help keep
manufacturer that can meet requirements for hardness, equipment running, might not seem critical at first glance.
tensile strength, chemical compatibility, and more. Using the correct, high quality O-ring for your application
will require a small investment up front but pay dividends in
reduced downtime and equipment maintenance costs.

40 Global MDA Journal | June - July 2017

focus - plastic & Polymers industry

Wearable Technology: Smart printed sensors
monitor movement sequences

Wearable technology has caught on to progress health and fitness. Simply worn on the body, smart garments
can, for instance, track activity. Sensors in functional clothing could also help optimize exercises by monitoring
movement sequences. A novel transparent sensor material developed by Fraunhofer ISC enables movement
measuring sensors to be printed onto textiles.

© Photo K. © Photo K.
Selsam-Geißler/ Selsam-Geißler/
Fraunhofer ISC Fraunhofer ISC

Image 1 and 2 show contrast between the transparent and non-transparent printed sensors.

Accessories like smart bracelets well as wear and washability tests. applicable in whatever form, the wearer
or smart watches are trending will hardly notice them embedded in a
as »personal health coaches«, prompting The sensor materials coming to use garment. There’s yet another benefit: the
the bearer to provide for sufficient sleep are flexible, transparent and suitable sensors do not require any power source
and activity or a healthy diet. Sensor- for various applications also beside of like a battery. Instead, they harvest energy.
embedded textile solutions are a far more smart textiles: They register pressure and
challenging and also more expensive deformation and can thus serve as touch Smart textiles like this could be
approach. Often, function will override or motion sensors. Their sensitivity to employed in health care or assisted living.
appearance. The new materials developed temperature deviations further enables In eldercare, everyday life movement
by Fraunhofer ISC might offer a cost- monitoring of temperature changes or sequences could be monitored and failure
efficient alternative with the extra benefit non-contact interaction, e. g. as proximity noticed. Additionally, it would be possible
of more adjustable appearance options. sensors. to monitor body signals of in-patients, such
as temperature or breathing. This could
In cooperation with Fraunhofer ISIT A simple screen printing process be especially beneficial for bedridden
and with support of the project partners is all it takes to apply the sensor pastes patients or babies. Some day, even heart
from the industry, the new sensor onto textile fabrics or plastic films. rate surveillance may be possible. Last
technology will be incorporated into a Manufacturing encompasses two steps: but not least, functional sensor clothing
prototype shirt. This so-called MONI shirt First, the pattern is printed. Then, the could achieve cost reductions in the
will feature a number of functions but is sensors are subjected to an electric field health care system. On top of assuming
foremost designed to monitor movement making the piezolectric polymers align to patient monitoring functions it could add
sequences. In an initial step, Fraunhofer adopt the targeted pressure sensitivity. to preventive health care.
ISC has developed novel piezoelectric The cost-efficient screen printing process is
polymer sensor printing pastes free from a definite plus when it comes to industrial In Addition to printed sensors
toxic solvents while Fraunhofer ISIT has use. It is the key to mass production of on textiles Fraunhofer ISC shows
provided the evaluation electronics. The printed sensors on textiles. textilintegrated pressure sensors made
next development steps are planned in of silicone e. g. to measure pressure in
close dialogue with the industry partners. Thanks to its transparency and shoes.
They will include field tests on several flexibility, the new sensor material offers
types of textiles and applications, the freedom of design in color and form for www.isc.fraunhofer.de
further optimization of the electronics as textiles and garments. As the sensors
are much thinner than a human hair and

June - July 2017 | Global MDA Journal 41

article

Dürr Ecoclean uses Virtual Reality on an industrial level

Service training and instruction in virtual space

Service staff train the various
maintenance operations for Scara
manipulators with the aid of Virtual
Reality

Courtesy of : TEMA Technologie
Marketing AG

Dürr Ecoclean uses Virtual Reality Ecoclean Monschau for its EcoCFlex 3 step in ensuring that our global service
in training its global service staff flexible cleaning cell. In this scenario, the technicians will be perfectly familiar with
to carry out maintenance support on its instructor and the trainee may be located their tasks and can provide excellent
complex manipulators. thousands of kilometers apart. support to our customers in minimum
time”, comments Michael Förster, Chief
Virtual Reality (VR) is a term currently For a realistic rendering of all Executive Officer at Dürr Ecoclean, in
associated mainly with computer games. maintenance operations and workflows, explaining his company’s decision in
However, the rendering and simultaneous a VR model of the manipulator was favour of the use of VR.
perception of reality – and its physical created from CAD data. This model can
properties – in a real-time computer be moved in all directions of freedom via Dürr Ecoclean is a leading supplier
generated, interactive virtual environment slider bars. Every bolt can be slackened of advanced cleaning technology and
also offers plenty of opportunities in and re-tightened in this manner, yet the surface treatment and activation systems
industry. Dürr Ecoclean, as a producer individual jobs are logically structured to automotive manufacturers and their
of forward-looking machinery, systems and interdependent. For instance, in tiered suppliers as well as to a broad
and services for industrial part cleaning performing an oil change in the virtual and diversified industrial market. Dürr
and surface treatment in the automotive system, the transmission cover can only Ecoclean’s tailor-made technology enables
manufacturing and supplier industries be re-closed after oil has actually been customers to tap savings potentials, e.g.,
in addition to a host of other industrial added. This approach ensures that the at the level of per-unit costs, energy
market sectors, relies on virtual space various steps will be trained in their demand and cycle times. Dürr Ecoclean
in training its service technicians all correct and full sequence, thus becoming currently employs around 800 people
around the globe. More specifically, “ingrained”. In order to achieve this, each at more than 10 sites in eight countries
this first VR application was developed service operative can move freely on a around the globe.
by Tema Technology Marketing AG to defined surface area in virtual space,
conduct maintenance training on the e.g., by walking around the manipulator. www.durr-ecoclean.com
Scara manipulator developed by Dürr “This development is an important

42 Global MDA Journal | June - July 2017

June - July 2017 | Global MDA Journal 43

post show report:
HANNOVER MESSE 2017

More attendees, more “
solutions, more international!

“Making the benefits of The show’s chosen lead theme of position in eMobility. The high degree
“Integrated Industry – Creating Value” put a of interest in HANNOVER MESSE among
digitalization tangible – that major spotlight on the benefits of Industrie Polish political circles was confirmed by the
was the declared objective 4.0 and the role of humans in tomorrow’s presence of such high-ranking delegates
of HANNOVER MESSE 2017. integrated factories. As this year’s featured as Jarosław Adam Gowin, Polish Minister
After five action-packed Partner Country, Poland called added of Science and Higher Education, and
days at the world’s leading attention to the need for close cooperation Mateusz Morawiecki, Minister of Economic
trade fair for industrial throughout Europe, while impressing Development and Finance.
technology, the organizers attending professionals with its credentials
spoke of a thriving as an innovative partner to global industry. 225,000 attendees
event. A large number of
solution-seekers gathered Partner Country Poland Of the show’s 225,000 attendees (up
in Hannover to immerse from 217,000 in 2015 as the most recent
themselves in the potential Featured as this year’s Partner comparable event), more than 75,000 came
of intelligent robots, Country, Poland sent a total of 200 from abroad. “This is an unprecedented
adaptive machines and companies to Hannover, highlighting the figure in the 70-year history of HANNOVER
integrated energy systems, country’s strong credentials as a dynamic MESSE,” commented Köckler, adding: “This
taking attendance to new and innovative industrial location. Research impressively proves that decision-makers
heights. and startups are a special priority for the from around the world rely on HANNOVER
Partner Country. This was the message MESSE as their definitive source of Industrie
conveyed by Polish Prime Minister Beata 4.0 orientation and solutions.” The largest
Szydlo in her address at the HANNOVER number of foreign visitors came from
MESSE Opening Ceremony, and these China (9,000), followed by the Netherlands
themes were also at the forefront of the (6,200), India (5,300) and Poland, whose
exhibits during the event. Poland also 5,000 visitors set a new Partner Country
succeeded in underscoring its leading record. The long-term impact of Partner

44 Global MDA Journal | June - July 2017

HANNOVER MESSE 2017

Country participation was underscored by products onto the market faster, at lower “More attendees,
an impressive 3,000 visitors from the U.S. cost.
as last year’s Partner Country. more solutions, more
Energy systems of the future international – that aptly
Triumph of the cobots sums up HANNOVER
Exhibitors in the energy halls showed MESSE 2017,”
A new generation of robots was also how the energy systems of the future
in the limelight: the so-called “cobots”, might well operate. According to Köckler, commented
i.e. collaborative robots, which are about “our Integrated Energy Plaza created a
to fundamentally transform the way we central hub for the energy industry. The Dr. Jochen Köckler
work in factories. Their connectivity, exhibits showed how the revolution in
artificial intelligence, innovative sensors power generation can segue into a true Member of the Managing Board
and intuitive operation allow them to energy transition, including the heat and at Deutsche Messe
communicate directly with humans, mobility markets.” The main focus was
as they learn autonomously and swap on new energy storage technologies,
instructions with other cobots. As Köckler which included serial production-ready
pointed out: “There was huge interest electrolysis stacks, making hydrogen
in the displays in the robotics halls. Not solutions a viable alternative even today.
only are cobots an exciting prospect for Some totally new approaches were also
large companies – many SMEs were also in evidence in the solar technology area,
at HANNOVER MESSE to find out about with several companies displaying ultra-
these new helpers for their manufacturing thin, flexible solar foils that generate
operations.” electricity even in low-light conditions,
opening up new options for the practical
From sensors to platforms application of the technology.

Previously sensors were viewed as Growth in the startup segment
the main technology item connecting
up different machines, but this year’s Following on the heels of last year’s
event put platform solutions to the successful launch, the “Young Tech
fore. Concretely, this refers to cloud- Enterprises” segment of the fair enabled
based network connections for the young businesses to introduce themselves
entire production operations, including to potential investors, customers and
data collection and analysis. “The trend partners. More than 150 startups were
towards the ‘digital twin’ concept in the on hand, exhibiting storage devices for
production environment is opening up renewable energy networks, operating
entirely new vistas for industry,” reported systems for augmented reality and mini-
Köckler. If testing can be carried out wind power plants for cars and trains:
in virtual reality – for example, to see
whether a new production line is going to The next HANNOVER MESSE will run
work out – this makes it possible to bring from 23 to 27 April 2018, with Mexico as
its official Partner Country.

June - July 2017 | Global MDA Journal 45

PRODUCT SPOTLIGHT ISO 9001:2008 CO. ISOLATION ALTRA ISOL. & AUTO TRANSFORMER
LINE CHOKE & LINE FILTER
Dart Camera Extension AIR COOLED & OIL COOLED SERVO STABILIZERS
Module INDUC.MOTOR HIGH FRQ. MOTORISED SPINDLE

Basler will offer an extension module that lets users SHRI GURU NANAK ELECTRICALS PVT. LTD.
operate its dart camera modules via the MIPI/CSI-2
camera interfaces of important embedded processing platforms 17 DLF Industrial Area Ground Floor Moti Nagar
(CSI-2:Camera Serial Interface 2). New Delhi - 110015 - Delhi - INDIA

In the CSI interface, that is popular in the embedded world, Phone :91-011- 45656381, 25413041, Mobile :9810076381
many users in the machine vision field are missing the ability to E-mail : [email protected], [email protected]
use established standards such as GenICam and cables that are
longer than 20 to 30 cm. So far, these limitations have hindered Website : www.newgold.in
the application of this technology particularly in industrial
environments. The dart extension module eliminates these
impairments.

Basler’s approach closes the gap between MIPI/CSI-2 and the
requirements of the machine vision field. With the new extension,
the dart BCON continues to be a fully GenICam-compatible and
plug-and-play-ready camera which can be operated through
the CSI-2 camera interface of important embedded processing
platforms. No software expertise, e.g. for driver development, is
required.

The powerful Basler pylon Camera Software Suite provides
the camera API. This allows unrestricted access to all camera
features and facilitates the migration of existing camera
applications, such as from USB3.0/Windows to CSI-2/Linux – on
ARM as well as x86 processors.

Now it is possible to operate highly professional, industrially-
suited camera modules with excellent image quality in extremely
affordable embedded systems without a significant integration
effort or having to dispense with the benefits of industrial
standards.

www.baslerweb.com

46 Global MDA Journal | June - July 2017

PRODUCT SPOTLIGHT

New halogen-free, flame-retardant
polyesters and polyamides

• Non-reinforced, flame-retardant PBT compound with high
elongation at break

• High-modulus materials for mechanically stressed components
• Polyamides for thermal management

Specialty chemicals company LANXESS stressed components. Despite their high glass fiber content of 60 percent
introduced new, halogen-free, flame-retardant by weight, they are just as free-flowing as standard polyamides with a
PBT compounds and highly reinforced polyamide significantly lower filler content.
grades with and without a flame retardance package,
and thermally conductive, electrically insulating Durethan TC
polyamides
(Thermally conductive) polyamides for thermal management. The
The halogen-free, flame-retardant PBT new polyamide 6, Durethan TP 723-620. This combines excellent light
(polybutylene terephthalate) compounds in the reflection and thermal conductivity with very good flame retardance
Pocan BFN product line are a good alternative to based on a halogen-free, flame-retardant package. Potential applications
their counterparts containing halogen-based flame include heat-dissipating components, such as heat sinks and LED
retardants. modules.

For example, they display better electrical www.lanxess.com
behavior and higher thermal and color stability. They
pass the UL 94 standard fire tests of the U.S. testing
organization Underwriters Laboratories, achieving the
best classification of V-0 for a test specimen up to 0.4
millimeters thick.

Apart from product grades with a glass fiber
content of 13 to 25 percent, LANXESS also introduced
a new, non-reinforced compound that boasts a high
elongation at break of over seven percent despite the
halogen-free, flame-retardant additives

Another area of focus is material grades that
display high glow wire resistance. In the glow wire
ignition temperature test (GWIT) to IEC 60695-2-13,
they achieve minimum values of 775 °C and therefore
meet the requirements of standard IEC/EN 60335-1 for
household appliances.

Durethan BKV 45 FN04.

This free-flowing polyamide 6 with 45 percent-
by-weight glass fiber content passes UL 94 V
testing, achieving the best classification of V-0 (0.4
millimeters). The structural material is unusually
stiff and strong. Its tensile modulus is 16 gigapascals
(freshly molded). Further advantages include its high
tracking and thermal aging resistance. The material
is predestined for use in structural components, for
replacing thermosets and die cast metals, and for large
connectors.

Durethan BKV 60 EF and XF

Highly reinforced polyamide 6 grades with no
flame retardant, suitable for highly mechanically

June - July 2017 | Global MDA Journal 47

PRODUCT SPOTLIGHT

Brushless Variable Speed Angle
Grinder

Hitachi Power Tools announced Additionally, Hitachi AC Brushless just 4.2 lbs, the G12VE is lightweight for
a new addition to its growing tools integrate electronic controllers easy operation.
commercial product line with the that compensate for reduced power
launch of a 4-1/2” AC Brushless Variable loss due to voltage drop. The G12VE AC This grinder comes with electric
Speed Angle Grinder- model G12VE. Brushless Grinder is also designed for overload protection, kick-back reduction
Hitachi leads the commercial industry in compatibility with a generator thanks and zero voltage restart protection.
North America by delivering unique AC to Hitachi’s compact and highly efficient Electronic overload is a feature that stops
Brushless products that permit the use of inverter circuit. This circuit cleans up the motor when too much pressure is
extra-long extension cords with reduced and modulates the electricity before it is applied. The grinder automatically shuts
power loss, eliminates maintenance of used in the motor providing steady, stable off to protect the motor from overload,
armatures or carbon brushes, and delivers operation and greatly reducing the risk and the gearbox from damage. The tool
superior performance when powered by a of damage to the internal circuits. This must be switched to the “off” position,
generator due to internal inverter circuits is ideal for mobile contractors without a and then turned back “on” to resume
for ultimate jobsite convenience. The permanent power source on the jobsite. work. Kick-back reduction quickly shuts off
AC Brushless motor results in the ultra- the power in the event of a bound wheel
slim grip circumference of this grinder; The G12VE offers a 12 Amp motor to extend the life of the gears and protect
reducing fatigue and improving control with 1,300 watts of input power. The the user from potential harm. Lastly,
during continuous use applications. variable speed dial is adjustable between zero voltage restart protection prevents
Hitachi’s AC Brushless motor is more 2,800- 10,000 RPMs (no-load speed) the grinder from restarting if power is
efficient; leading to longer run time, allowing the user to determine the best temporarily cut during operation.
increased power and extended durability speed for the application. A soft-start
with essentially no maintenance. function reduces the load felt by the user Covered by Hitachi’s 1-Year Warranty,
Eliminating the need for carbon brushes at start-up. Trigger lock-on is available the G12VE 4-1/2” AC Brushless Variable
means freedom from issues with the for convenience and comfort during Speed Angle Grinder from Hitachi
motor armature burning out, and continuous use applications. It accepts is unique in the marketplace, and is
experiencing layer shorts or commutator 4-1/2” wheel accessories to tackle a designed to last while stone polishing,
wear in severe environments. Also, brush multitude of applications, and an easy- surface finishing, removing rust & paint,
wear and resulting armature damage from to-manipulate spindle lock located at the light grinding, finishing concrete and
lack of maintenance is the most common front of the grinder makes it simple to performing applications using wire cup or
service issue. This is completely eliminated change out the accessories as needed. wire wheel attachments.
by the Brushless motor resulting in more The included side handle can be moved
uninterrupted run times. to either side of the grinder for added www.hitachipowertools.com
control and maneuverability. Weighing

New TRIO string inverter

TRIO-TM offers m3arket leading return on investment for
large photovoltaic systems

ABB’s latest addition to the It also benefits from the most complete Meanwhile, efficient commissioning
TRIO family, the TRIO-TM is a wiring box configuration available, is guaranteed with an embedded web
three-phase string solution with power including up to 16 DC inputs, AC and DC user interface through any WLAN device.
ratings up to 60kW, for cost efficient switches and monitored type II AC and DC And, once in use, the double stage
large decentralized photovoltaic systems. surge arresters. The TRIO-TM provides the conversion topology offers the advantage
Suitable for both commercial and utility advantages of a string inverter combined of a wide input voltage range for
applications, and for both rooftop and with the power of a centralized unit offers maximum flexibility of the system design.
ground-mounted installations, the TRIO- a high performance and cost efficient A Sunspec compliant Modbus protocol
TM has been designed with flexibility in solution for any large PV installation. also enables easy integration with third
mind. party monitoring and control systems.
The forced air cooling system within
The TRIO-TM comes with separate the TRIO-TM is designed for simple www.abb.com
and configurable AC and DC compartments, and fast installation, with the option of
which can remain separately wired from horizontal or vertical mounting brackets,
the inverter module inside the system. enabling the best use of space beneath or
behind the solar modules.

48 Global MDA Journal | June - July 2017

PRODUCT SPOTLIGHT

The next-generation PS65 and PS105

vertical machining centers

Advanced technologies and increased capacity drive new levels of productivity
for job-shop production environments

Building on its highly successful of machine elements of the PS65 and and effectively removed from the cutting
PS-Series product line, Makino PS105. Core-cooled ball screws maintain zone.
announced the next-generation PS65 critical motion component temperatures
and PS105 vertical machining centers. by combating heat for improved axial The machine table moves toward
Both models feature enhanced design motion, accuracy and extended reliability. the operator to minimize reach to the
characteristics and next-generation By delivering this thermally controlled table and is designed at a comfortable
technologies that expand upon the lubrication oil through the ball screw and height for operators to readily access the
capabilities of their predecessors. With support bearing, component life span and spindle and workzone. Additionally, the
an ideal blend of power, accuracy, speed accuracy are extended. “L-shaped” operator access doors provide
and reliability, the PS65 and PS105 are open ceiling accessibility to facilitate easy
redefining the standard for vertical Equipped with a standard 14,000- handling of large, heavy workpieces and
machining center productivity within rpm, CAT #40 spindle (HSK-63A optional), fixtures that require an overhead crane
the aerospace, medical, automotive and the PS65 and PS105 provide the power,
general manufacturing industries. torque and RPM capability to support Professional P Control
today’s cutter technologies offering the
With the new PS105, Makino has highest levels of material removal in even The Makino Pro P Control features
expanded upon the PS95 providing a larger the toughest materials. This capability is a 10.4 inch, color LCD screen that
work table, a 14 percent increase in X-axis complemented by a stiff, rigid, balanced is “touch” sensitive with on-screen
travel and overall work volume, providing spindle design, featuring large, 85- navigation providing instant access
additional work space for more parts or mm (3.35 inch) that eliminate spindle to information that is literally at your
larger parts as needed. Increased rapid deflection. The result is a stable cutting fingertips. The Pro P Control combines
traverse rates on both machines provides process that is capable of delivering both the high number-crunching power and
further reduction in part processing times, great metal removal rates and producing data processing capacity of the latest
improving productivity and reducing costs. high-quality machined surfaces. high-speed microprocessor, a user-
In addition, the machines are production friendly interface and the proven stability
ready, touting a list of standard features Fast, Easy Machine of Fanuc hardware. It provides a highly
including an integrated lift-up, scraper- Management integrated, embedded control system
drum chip conveyor (LUCC) and 3.0 Mpa capable of fast commands, high reliability,
(435 psi) through-spindle coolant system Tool loading on the PS machines is flexibility, integration capability and ease
complete with cyclonic filtration easily facilitated from either an exterior of operation.
loading station or directly into the spindle.
PS65 PS105 Both machines feature a standard 30-tool Boosting Machine Utilization
capacity ATC magazine, which can be
X-Axis 660 mm (26.0”) 1050 mm (41.3”) upgraded to an optional 60-tool capacity For production environments
Travel magazine. Each configuration provides interested in optimizing machine
fast and smooth tool changing to support utilization, materials usage and human
Y-Axis 510 mm (20.0”) 510 mm (20.0”) high-speed machining applications. resources through automation, the PS65
Travel To push productivity even further, the and PS65 can be equipped with a variety
machines are configured with a dual- of options. These optional capabilities
Z-Axis 460 mm (18.1”) 460 mm (18.1”) speed tool change system that recognizes may include 4th axis tables, tool length
Travel lighter tools and will speed up the tool measurement, spindle probe, light curtain,
exchange cycle. auto doors, robot loading and a variety
Table Size 510 x 920mm 510 x 1,300mm of other features commonly applied to
(W x L) (20.0” x 36.2”) (20.0” x 51.2”) Created with the production automated machining processes.
environment in mind, the PS-Series chip
Maximum 600 kg (1,323 lbs) 800 kg (1,763 and coolant management systems help An optional interface for hydraulic
to enhance productivity. Configured fixtures and rotary work heads can be
Workload lbs) with steep internal side slopes, coolant added to the machines, accommodating
flush on the tele-covers, spiral chip a variety of hydraulic ports, pneumatic
ATC 30 tools (60 tools 30 tools (60 conveyors and nozzle and flush coolant ports and coolant ports facilitating adding
as standard features, chips are efficiently automation features to the machine.
Capacity optional) tools optional)
www.makino.com
Built Tough for Productivity,
Quality and Stability

From the base casting to the
spindle, rigid design characteristics
have been incorporated within a variety

June - July 2017 | Global MDA Journal 49

PRODUCT SPOTLIGHT

CELOS® by DMG MORI simplifies and accelerates the
process from the idea to the finished product
CELOS® APPs allow the user consistent management,
documentation and visualisation of order, process and Key benefits include the new DMG MORI ERGOline®
machine data. CELOS® Control operator terminal, featuring a 21.5’’ multi-touch
combines workshop screen and icon-supported, gesture-driven user interface.
and higher level
company structures But via job-specific software applications, CELOS®
and thereby creates the also combines local shop floor know-how with external
basis for a consistently software solutions, including CAD / CAM and proprietary
digitalised, paperless company production systems (ERP / PPS) - even interactive
production. CELOS®is communication with a global production network is
compatible with PPS- possible.
and ERP-SYSTEMS and
can be linked to CAD • UNIFORM
/ CAM applications.
CELOS® is open for future-oriented CELOS® APP extensions. Uniform, intuitive user interface for all high-tech
machines from DMG and MORI SEIKI
CELOS® as a clear information medium:
• CONSISTENT
CELOS® visualises the current condition of the machine
regarding the process, provides important key figures about the Consistent administration, documentation and
current order and informs the operator with special icons and text visualisation of order, process and machine data.
messages about possible errors.
• COMPATIBLE
Uniform user interface with intuitive touch functionality. As a
control- and technology- independent system, CELOS® optimises the Compatible with PPS and ERP systems. Can be
interaction between man and machine. networked with CAD / CAM products. Open to
trendsetting CELOS® APP extensions.

www.Dmgmori.com

50 Global MDA Journal | June - July 2017