Photonic microprocessors overheat
The Swiss industrial magazine. Since 1972.
INDUSTRIAL MAGAZINE: ON THE TOPIC
DOSSIER: MEASURING, CONTROL AND REGULATING TECHNOLOGY
The current state of industrial networks
DOSSIER: TRANSPORT, STORAGE, LOGISTICS, INDUSTRIAL CONSTRUCTION
360 째 surface inspection in motion
No. 9 September 2018
ellWith quick access
Cope with the heaviest loads with ease
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47th year Switzerland: ISSN 2297-0053 www.maschinenbau-schweiz.ch
Published by Olympia-Verlag AG, CH-8041 Zurich
printed in Switzerland
Editorial staff | Publishing management, subscription management Publica-Press Heiden AG, Editing of Maschinenbau Im Bad 8, Postfach 262 CH-9410 Heiden Telephone +41 (0) 71 898 80 10 [email protected] Editing: Thomas Brosch, [email protected] Peter Göldi, goeldi @ pph .ch Edgar Grundler, [email protected]
Layout Publica-Press Heiden AG
Advertising management Wincons AG Fischingerstrasse 66, PO Box CH-8370 Sirnach Phone +41 (0) 71 969 60 30 Fax +41 (0) 71 969 60 31 [email protected] Sales: Manuel Keel, [email protected] Margit Pfändler, mp @ wincons.ch Rita Räbsamen, [email protected]
Industrial networks on the advance We can now handle office networks well. The exchange of data and information from device to device works. With a view to similar networks in industry, however, we still have a lot to learn. Industry 4.0 has set its goals high. The aim is to achieve continuous networking of all machines and plant components with higher-level IT systems. This is a much more demanding task than in office operations. The requirements for reliability, robustness and data security are increasing enormously. Network errors can hardly be tolerated when exchanging data between different production levels or between individual electronic devices. Automation leaves little time to be able to troubleshoot problems in peace. All positive cost effects of digitization would be nullified. In the industrial environment, the quality of the communication networks is crucial. Where is the journey going? We deal with this in the on-the-topic article starting on page 24. A network design should be conceived in such a way that it exactly matches the requirements of production in the company. Only then can
gdz AG Spindelstrasse 2 CH-8041 Zurich
speak of a high-performance network at all.
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the wired forms of transmission. And traditional field buses
Annual subscription / single no. Domestic CHF 75.00 / 8.– Abroad EUR 85.00 / 9.00 Abroad EUR 100.00 / 10.00 (overseas)
seem to be losing ground in the industrial network market.
Print run: 7800 copies. Appears monthly plus a main annual edition with the October edition
Two trends are emerging: Wireless technologies are displacing
Assembly is also becoming more and more digital. This is confirmed by the MOTEK in Stuttgart at the beginning of October. The trade fair shows the whole world of automation. Anyone who would like to find out about technological innovations relating to assembly will get their money's worth!
Reprint | Reprint All rights reserved. Reprinting and electronic reproduction, even in extracts, only with the written permission of the publisher. For offprints please contact the publisher.
Thomas Brosch editor-in-chief
mechanical engineering 9/2018 | The Swiss industrial magazine. Since 1972.
MASCHINENBAU 9/2018 I N H A LT S V E R Z E I C H N I S
Z U M T I T E L B IL D
Bauberger AG: successfully transported
S Z E NE NEWS
Industry information in brief
MACHINERY MACHINING CENTER
DMG CTX 2500 | 700: Universal turning in the high-performance class
Makino UP6: Productivity and performance increased
INDUST RI EMA G A ZI N
D O S S I ER
ON THE SUBJECT
MEASURING, CONTROL AND REGULATING TECHNOLOGY
58 mbar pressure regulator Calibration of 60 machine tools
The current state of industrial networks All over the world, industrial networks control automated processes in companies in a wide variety of industries, primarily in the area of production. The demands on them are steadily increasing. The development of automation technologies and network structures also places new demands on maintenance in the future.
27 Hans Hess informs about the 2nd quarter Positive business development
tal in the Swiss MEM industry
More innovation is possible The edition of a limited series is a smart move in automobile marketing to be able to stand out from other manufacturers. DS Automobiles, a brand of the French automotive group PSA, was able to establish itself in the premium segment within a few years thanks to its avant-garde vehicles.
32 on the tool structure Higher demands
The new and innovative wire EDM machine UP6 enables highest precision on the workpiece and convinces with a new wire feed and a newly developed threading system.
Paul Horn Spanwerkzeuge: Sharp cutting edges for micro machining
14 15 16
Sandvik CoroMill 331: Proven Solution for Slot Milling ®
ARNO-Mini-Systems AMS: For better tool life HAM 40-5191 / HAM 40-5291: Powerful trochoid burs
The new trochoid milling cutter HAM 40-5191 impresses with its high metal removal rate, smooth running and long service life.
Walter M4130 shoulder milling cutter: Its strength lies in the René Gerber AG system: The long-life formula for drill bits
20 thanks to additive manufacturing GRESSEL grepos-5X-C: 21 For fast 5-axis machining MAPAL: miniaturization
34 screws combined gluing and
36 Series production
360 ° surface inspection in motion ORBITER600 is an image processing system for the 360 ° inspection of surfaces in motion. It checks and detects mechanical defects on the smooth surfaces of work parts that are manufactured in press cycle.
YOU-check is the new test equipment for calibrating machine tools and coordinate measuring machines. Whether during commissioning, service work, periodic machine checks or operational maintenance; an efficiently applicable, precise and traceable test standard is required.
TRANSPORT, STORAGE, LOGISTICS, INDUSTRIAL CONSTRUCTION
Fast-paced shipping When it comes to automating in-house transports, Bachmann Forming AG at the Hochdorf production site relies on a solution with WEASEL® driverless transport vehicles from SSI Schäfer. The project with the innovative AGVS solution could be implemented within just five weeks - and has paid for itself after just a few months.
64 Cope For intensive use 66 The ergonomic reach truck
Heaviest loads with ease
The TERGO series from UniCarriers has grown: The TERGO UHD 160 with load capacities of 1.6 t and a maximum lifting height of 10.8 m is now expanding the product family.
38 for injection molding designers All around 40 movement
67 in its class The Rovolution started in 68
The most compact vehicle
MOTEK: The age of practical 42 70 ergonomics has begun Double-girder bridge crane Calendar: 44 for logistics 72 September to May Workshop production planning 46 optimized Cast or forged EN 48 Metalyss supplies its customers with cast- R3 U B R I KImprint Standard products as a success factor
ne or forged and ready-to-install surface-refined and machined precision parts made of aluminum or brass.
50 and sophisticated technology
The consequence of trust
52 to the world market leader
From one-man operation
22/74 News & Trends | Advertorials 61 Education and training 69 Books, catalogs, encyclopedias 76 Subject indexes | Sources of supply 81 Capacities | Occasions | Miscellaneous 82 List of advertisers 82 Preview No. 10 | October 2018
mechanical engineering 9/2018 | The Swiss industrial magazine. Since 1972.
S Z E NE NE WS
ON THE COVER Successfully transported n A new 7.2 t CNC lathe was brought through the facade to the second floor of the Abnox company in CH-6330 Cham. The machine, which was temporarily stored in the BAUBERGER AG heavy goods warehouse in CH-8353 Elgg, was transported to Central Switzerland, reloaded from the truck to the barelle using a mobile crane and then pulled up the outer facade. Image: Lukas Pitsch / proImageHub
Takuya Ichii, CEO of BIG KAISER, said: «In the 70 years since Heinz Kaiser was founded, BIG KAISER Precision Tools AG has always stood for the very highest quality and perfection. We would like to thank our customers, friends and colleagues who have actively supported us over these seven decades. "
From the Barelle, the CNC lathe was pulled into the building and moved to its new location. There it was positioned according to the customer's layout, lowered to the machine feet and prepared for installation and commissioning. Security is a top priority at BAUBERGER AG. All employees have the basic PPE training required by SUVA (personal protective equipment against falls from a height). In addition, the use of PPE was practiced and deepened in an all-day company-specific training course.
70th anniversary n BIG KAISER celebrates the 70th anniversary of the founding of KAISER in CH-8153 Rümlang. On the occasion of the anniversary, the parent company BIG Daishowa invited the entire BIG KAISER team to the headquarters in Osaka, Japan. The employees traveled in two groups of 40 participants each and were warmly welcomed by the German-speaking Japanese employees. Info: www.70yearsbigkaiser.com
Environmentally friendly n The 59 m long and 14 m wide Farge ferry is something very special. It now transports people, cars, trucks and bicycles across the Weser from Berne in Lower Saxony to the Farge district of Bremen. What is special about it is that it is now driven in hybrid form, with only electric motors from the drive and automation specialist Baumüller being driven. This means that the ferry is equipped with three diesel engines that function as generators and thus supply four electric motors with electricity that drive the ship. This is completely new for the ferry company Bremen-Stedingen, and managing director Andreas Bettray explains that the ferry wanted to use the latest technology to protect the environment and save fuel and emissions. That was successful and the Farge, as the first hybrid passenger and vehicle ferry of this size in Germany, is a real novelty.
Telephone +41 (0) 52 368 60 60 www.bauberger.ch [email protected]
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IN BRIEF Personnel 1
n Johannes Ried was appointed Managing Director of MicroStep Europa GmbH with effect from August 21. In future, he will be responsible for the company's business together with Igor Mikulina and Mikuláš Bucinský. Info: www.microstep-europa.de
n The board of directors of Swissmechanic Switzerland has appointed Dr. Jürg Marti elected as the new director. Jürg Marti has many years of management experience at the interface between politics, business and associations. Info: www.swissmechanic.ch
n GF Machining Solutions and 3D Systems, a leading specialist in additive manufacturing, have agreed on a strategic cooperation. The aim is to jointly develop integrated manufacturing solutions based on 3D printing. Info: www.georgfischer.com
n With ORDERFOX.com and Celeritive Technologies, two companies have come together that focus on increasing efficiency. ORDERFOX.com connects CNC manufacturers, buyers and their supplier industries and thus opens up new business opportunities. Celeritive Technologies focuses on using know-how effectively and at the same time has reliable software solutions that «just work». Info: www.orderfox.com
I N FOS | CONTACT Bauberger AG St. Gallerstrasse 19 CH-8353 Elgg
n KEBA can look forward to receiving a globally recognized and coveted design award for the second time this year: the KeMes protractor, which was primarily designed for fully automatic quality control on a sheet metal bending machine, can be awarded a Another award for successful product design - the Red Dot Award - and that in the year in which the Austrian automation company celebrates its 50th anniversary. Info: www.keba.com
The Farge ferry is powered exclusively by Baumüller electric motors, only diesel generators are still on board to generate electricity.
n On August 21st and 22nd, Omron celebrated the opening of the new office in CH-6340 Baar together with its partners and customers. During the event, visitors were able to experience how the company is putting its vision of Industry 4.0 into practice. Info: www.omron.ch
n With the takeover of R. Wick AG, JAG Jakob AG grows in the field of robotics solutions and industrial automation and becomes one of the most important system integrators for robotics systems in Switzerland. Since the beginning of 2018, JAG has also been a system and sales partner for autonomous mobile robots from the Danish manufacturer Mobile Industrial Robots MiR. Info: www.jag.ch
n Schuler takes over the Italian forging line manufacturer Farina Presse. With the acquisition of the mechanical engineering specialist based in Suello in northern Italy, the Schuler Group is completing its own product portfolio in the areas of forging and single-stroke presses. Farina will have access to Schuler's global sales network for its products, which are highly valued in the European market, and will continue to operate under its own brand name. Info: www.schulergroup.com
n NSB Gas Processing is now part of Busch Vacuum Pumps and Systems and, under the new name Busch NSB AG, brings a team of respected engineers paired with an extensive portfolio of liquid ring vacuum pumps, compressors and corresponding systems to the international Busch Group. Info: www.buschvacuum.com
n The Swiss grinding machine manufacturer, Fritz Studer AG, wins a user satisfaction award in China. It was awarded by the magazine “AI Automobile Production” as part of the Chinese engineering trade fair CIMES in Beijing. A total of 38 products and solutions for the automotive industry were awarded. Which products are particularly innovative? Which solutions are intelligent? Which machines are reliable? Renowned users from the automotive and supplier industries were able to give their favorites a voice. The «AI User Satisfaction Prize» is awarded every two years. This is carried out by the specialist magazine “AI Automobil Production”. This summer, 38 products that are used in vehicle technology made it to an award. This also includes the solution for the precise grinding of CVT gear shafts and bevel gears on the STUDER S41. The precise grinding of CVT transmission shafts and bevel gears is a classic application of the STUDER S41. The machine can be equipped with grinding wheels for external and internal cylindrical grinding. A groove grinding unit developed in-house and a CNC-controlled Y-axis enable all grinding sections to be machined in one setting. Together with the in-process and post-process measurements, a high level of precision is achieved without rejects. Fit for Industry 4.0: The STUDER software for an MES system realizes the real-time monitoring of the process and guarantees the complete traceability of all workpieces. With this project solution, STUDER was able to inspire users and fulfill the request of chief editor Gong Shujuan: Motivate the industry to offer users even higher efficiency, quality and better profitability.
n Switzerland regularly ranks top in international innovation studies and renaissance kings and is one of the most innovative countries in the world. Such studies assess the entire economy, including all framework conditions, and say little about the innovative strength of individual industrial classes. The Swiss Academy of Technical Sciences (SATW) has therefore examined the innovative strength more closely and discovered something worrying. Swiss industrial companies, especially SMEs, seem to be increasingly losing innovative strength and competitiveness. The study is based on the data from the innovation survey conducted by the KOF business cycle research center, which is currently available up to and including 2014. It is noticeable that there are fewer and fewer Swiss industrial companies. This development is also shown by the Swiss Engineering Index: Switzerland has been losing around 4,000 full-time jobs in the industrial sector every year for six years.It is worrying that from 1997 to 2014 many SMEs reduced their R&D efforts at home and abroad. Info: www.satw.ch
Invested n Härterei Gerster AG is investing specifically in the renewal of its systems for surface hardening in order to better meet the high demands of customers. The surfaces of drive components are usually exposed to high mechanical stress and wear. As a solution, the Gerster hardening shop offers the three most common surface hardening processes on around 50 surface hardening systems. Info: www.gerster.ch
n The Stäubli Group has announced the acquisition of a 70 percent stake in WFT GmbH & Co. KG, based in D-92237 Sulzbach-Rosenberg. Over the past two decades, WFT has established itself as a specialist in the construction of special machines and mobile platforms. The acquisition is in line with Stäubli's successful growth strategy and makes it possible to enter into innovative partnerships in new, complementary areas such as automated guided vehicles (AGVs) or automation expansion. Info: www.staubli.com
Rolf Grossenbacher, Sales Manager Fritz Studer AG, receives the "AI User Satisfaction Award" at the CIMES in Beijing.
n The Schaeffler Group announced in cooperation with Mr. Roland Arnold and Paravan GmbH. The object of the joint venture, which will operate as Schaeffler Paravan Technologie GmbH & Co. KG, is the further development of the "drive-by-wire" technology SPACE DRIVE as well as the development and sale of mobility systems. For this purpose, the joint venture is acquiring the SPACE DRIVE technology from Paravan GmbH. Info: www.schaeffler.com maschinenbau 9/2018 | The Swiss industrial magazine. Since 1972.
MACHINERY MACHINING CENTER
Universal turning of the high-performance class M
ith its robust and rigid construction, the CTX 2500 | 700 offers a perfect basis for powerful heavy-duty machining with a high surface quality at the same time. The machine structure was developed using FEM analysis. Robust guides in all axes guarantee dynamic rigidity - the rapid traverses reach up to 30 m / min - as well as high vibration damping. Larger dimensioned ball screws as well as a 4-way bearing of the spindle motors lead to a 50 percent higher overall rigidity compared to the predecessor.
"This is definitely the most stable and at the same time the most powerful machine that we at GILDEMEISTER Drehmaschinen GmbH have built in this class in the last 25 years," confirms Managing Director Harry Junge. Grooving up to 12 mm wide and full drills with Ø 80 mm could be used reliably for the first time.
The best of two worlds combined DMG MORI combines the rigidity of the CTX 2500 | 700 with high thermal stability. An oil jacket arranged in a spiral around the spindle unit
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Slideway guides for maximum stability, for example when grooving up to 12 mm wide in CK 45.
controls the temperature rise. Coolants also circulate in the cast components, which minimize thermal shifts. This is only 2 µm. The length measuring system from MA
GNESCALE underlines the quality feature with a standard resolution of 0.01 µm. On the performance side, the CTX 2500 | 700 impresses with its turnMASTER main spindles. A 10 "version with 4000 rpm, 26 kW and 525 Nm and an optional 12" version with 3500 rpm, 30 kW and 1194 Nm are available. The counter spindle has 6 “as standard and comes to 7000 rpm, up to 11 kW and 70 Nm. An 8 “spindle with 5000 rpm, 32 kW and 360 Nm is available as an option. The precision disc turret with active disc cooling and VDI-40 interface is standard in the MC version and the Y version with an additional Y axis. The speed is 6000 min – 1. The maximum torque is 32 Nm. The extension level SY with counter spindle has the 6000 rpm star turret torqueDRIVE with a torque of up to 85 Nm as standard. The BTM interface is optionally available. In addition there is the
MACHINERY MACHINING CENTER
The CTX 2500 | 700 combines the stability, power and precision of the NLX 2500 | 700 and the CTX beta 800.
speedDRIVE turret with 12,000 rpm and 56 Nm available. All turrets offer space for twelve or 16 tools in the optional VDI 30 version (not for torqueDRIVE). With a Ø 366 mm and 705 mm turning length in the case of the CTX 2500 | 700, the new turning center offers space for a wide range of workpieces. The standard chuck size is 250 mm, the bar passage 76 mm. The travels in the X, Y and Z axes are 260x100x795 mm. The ergonomic design of the CTX 2500 | 700 makes the work area easily accessible and also enables crane loading from above for heavy components. There is a pocket in the headstock wall for long tools to avoid collisions. The oil cooler and hydraulic unit are attached to the rear and are easy to reach.
Automation is a future topic. For the CTX 2500, DMG MORI offers a flexible connection to various automation solutions. In addition to the integrable workpiece unloading, a bar loader connection and the possibility of using the Robo2Go, DMG MORI has now taken over the GX gantry loader known from the NLX series.
Ergonomically oriented design The ease of use of the turning center is continued in the control area. An ERGOline Control with a 21.5 “multi-touch screen and CELOS with SIEMENS including ShopTurn 3G are used here. On the one hand, CELOS enables continuous management, documentation and planning of orders in work preparation and the workshop. On the other hand, CELOS APPs such as “CONDITION ANALYZER” or “PERFORMANCE MONITOR” offer the user detailed insights into the machining processes and the status of the machines as the basis for a continuous improvement process. In addition, CELOS is increasingly acting as an IoT interface and creating the basis for cross-company interaction in the production networks of the future.
INFO S | CONTACT DMG MORI Schweiz AG Sulzer-Allee 70 CH-8404 Winterthur Telephone +41 (0) 58 611 50 00 www.dmgmori.com [email protected]
MACHINERY EDMING MACHINE
Productivity and performance increased A
With the UP6, Makino is once again meeting the high standards for which the company is known in the market: thanks to the hollow cast structure, parts of the machine are flushed through by a dielectric at the same temperature, so that thermal growth is a thing of the past. The continuous cleaning of the sliding plates of the tank seal using a water curtain reduces friction so that the X-axis can work without any problems. Extra-long roller guides for maximum precision reduce vibrations and improve the rigidity of the machine. To extend the service life, the high-precision recirculating ball drives are protected from the ingress of dirt by a complete cover. The UP6 from Makino has a newly developed wire guide system and, thanks to improved contour accuracy for inner and outer radii and even more reliable wire threading for demanding geometries and small starting bores, enables smooth processing and high process stability. To improve wire threading, a new wire threading system has been developed that works dry and, if necessary, also with a water jet.
Improved CAM software Makino's new CAM software for die sinking EDCAM 2017 offers the operator numerous advantages. Many processes are running
Furthermore, the lifting speed in the Z-axis increases by 31 percent to 20 m / min compared to the current model thanks to the HS-Rib function. The newly developed H.E.A.T. generator has a higher peak output (80 A instead of the previous 40 A standard with a 44 percent reduction in power consumption). Operators benefit from functions such as the programmable flushing pressure, fine adjustment of the flow rate, an inverter-controlled pump and precise pressure measurement. Thanks to these numerous improvements, the new machines in the EDAF series enjoy significantly increased performance and usability.
Maximum ease of use
The new and innovative wire EDM machine UP6 enables highest precision on the workpiece and convinces with a new wire feed and a newly developed threading system.
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tion of the Makino eroding machine. In addition, EDCAM data can be edited via the machine's operating screen and machine settings can be downloaded automatically.
The new generation of the Hyper i control from Makino can now be operated even more easily and quickly - regardless of the experience of the employee. With swiping, tapping, dragging, enlarging and spreading, the control panel is based on the gesture control of smartphones and tablets. Operators also benefit from the height adjustability of the touchscreen, and the large access door noticeably simplifies loading and unloading of the workpieces.
More than just a facelift The tried and tested EDAF series from Makino has been fundamentally revised. Not only does it look completely different, it now also offers the benefits of the tried and tested H.E.A.T.technology from Makino, with which only the U-series wire EDM machines were previously equipped. The new EDAF machines impress with an improved feed rate of up to 5000 mm / min in the X and Y axes. Of
I N F OS | CONTACT neutec werkzeugmaschinen ag Artherstrasse 60 CH-6405 Immensee Telephone +41 (0) 41 854 45 00 www.neutec-ag.ch [email protected] www.makino.eu
Images: Horn / Sauermann
Sharp cutting edges for the micro-machining of the surface of the workpiece. The surface quality of the rake face also plays a decisive role. In order to counteract built-up edges, the rake face must have very high sliding properties. For this reason it is finely ground or polished.
Change accuracy of 2.5 µm
Thanks to the air cut of the LFV technology, the breaking of the chips is ensured even with long-chipping materials.
Outer diameter of 0.1 mm, grooves of 0.5 mm and feeds of 5 µm. Welcome to the world of micro-machining. Screws for hearing aids, balancing weights for automatic wristwatches or small turned parts for medical assemblies. To manufacture such parts you need know-how, precise machines and special tools. With cutting depths of up to 0.01 mm, users place very high demands on the tools used. With the µ-Finish system for micro-machining with Swiss-type lathes, Horn
suitable solutions developed. Not only for the end customer, but also as an original equipment manufacturer for machine manufacturers. The demands on tools for micro-machining with Swiss type lathes are high. Due to the sometimes very shallow depth of cut, the cutting edges have to be very sharp in order to keep the cutting pressure as low as possible. However, the sharp cutting edges increase the risk of micro-breakouts. Even a small break in the range of a few µm on the cutting edge has a negative effect on the machined
System 262 is also successfully used in cam-controlled Swiss type lathes.
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Clamping the inserts is another important point in tool design. When micromachining turned parts with small diameters, the tip height of the tool must be measured precisely. Even the smallest deviations in the center height have a negative effect on the quality of the workpiece when machining the smallest diameters. In the best case scenario, the machine operator should be able to turn the indexable insert without having to readjust the center height. With the µ-FinishSystem, Horn offers changeover accuracies of ± 0.0025 mm when turning
The systems 262 and 274 with finely ground cutting edges
the double-edged plate. This is made possible by the precise peripheral grinding of the cutting insert in conjunction with the stable insert seat. In addition, the contact surfaces of the square shank tool holder are also ground, which affects the holistic precision of the Horn system. The grinding of a sharp and almost flawless tool cutting edge requires a lot of know-how. Grinding wheels with the finest grains, special grinding techniques and a microscope with 400x magnification are necessary so that the tool will perform as required in later use. It is subject to
The horn system for micromachining is available with a variety of geometries.
Field tests with customers and the subsequent optimizations, the tool system was successfully launched on the market. Horn tool packages are available as initial equipment not only for direct customers, but also for machine manufacturers. Horn offers with its portfolio for long turning and the
Micromachining not just tools for outer contours. The Supermini System 105 is suitable, for example, for processing inner contours from Ø 0.2 mm. In recent years, Horn has also developed into a problem solver and full-range supplier in micromachining on Swiss-type lathes.
I N F OS | CONTACT Dihawag AG Zürichstrasse 15 CH-2504 Biel Phone +41 (0) 32 344 60 60 www.haimer.de [email protected] www.phorn.de
enable the precise machining of very small turned parts.
Clean performance | ENGEL medical
every finished batch of the µ-Finish-System of a 100 percent control. Important criteria of quality assurance are the closely tolerated high surface quality of the chip and flank faces, the height of the centers and, in particular, the chipping of the cutting edge. The following applies: Irregularities on the cutting edge over 0.003 mm are already outside the tolerance with the µ-Finish system.
Micro components The tool system is used in every industry in which small components and micro-turned parts are installed. In medical technology, there are small turned parts for instruments where the surface requirements are very high. Screws with a thread size of less than 1 mm are required, for example, in hearing aid acoustics and for assemblies of smartphones. In the supreme discipline of precision mechanics, the construction of mechanical clockworks, machining tools for micromachining have become indispensable. The Swiss have always been considered specialists in the construction of complex clockworks. It was you who invented the concept of long turning. Long turning is also called "Swiss Turning" or "Swiss Type Turning" in English. With the help of Dihawag technicians, those responsible at Horn developed the µ-Finish system. After the first
ENGEL medical electrical machines impress with their high performance. The ENGEL e-motion medical series combines maximum performance with maximum purity. Optimized for clean room applications, it has an encapsulated mass cylinder to minimize particle and heat load, encapsulated injection unit drives as standard and an oil return device on the toggle lever. The ENGEL e-motion medical is available as a consistent series with a clamping force of up to 500 tons.
Pure and precise. With ENGEL medical. Because it's about life.
Proven solution for slot milling B
Using the latest CoroMill® 331 from Sandvik Coromant, manufacturing companies benefit from trouble-free, precise and easy-to-use slot milling operations. The new, advantageous functions of the indexable insert milling cutter include the internal coolant supply and easy-cutting geometries for stable and safe machining.
With excellent chip evacuation “We have introduced a number of new functions that meet customer requirements such as process reliability, component quality and costs,” he says
With the latest CoroMill® 331 from Sandvik Coromant, manufacturing companies benefit from trouble-free, precise and easy-to-use slot milling operations.
explains Jenny Häll, product manager slot milling at Sandvik Coromant. “The most important thing is the addition of the internal coolant supply, with which the temperature in the cutting zone can be regulated for a long and predictable service life of the indexable inserts. The internal coolant supply is particularly advantageous when processing ISO M and ISO S materials, since both stainless steel and heat-resistant superalloys have poor thermal conductivity. In addition, the internal coolant supply ensures excellent chip evacuation, a key factor in the quality of the groove and process reliability. " The increased process reliability promotes trouble-free machining, which is additionally supported by the newly introduced, slightly cutting geometries.For the materials ISO M and ISO S, the new geometries L30 and L50 replace the existing range for favorable conditions and light applications or for difficult conditions and heavy applications. For the materials ISO P (steel) and ISO K (cast iron), the
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Have even more stable tools available for reliable performance.
Higher processing reliability For manufacturing companies in the energy, aviation and automotive industries, additional process reliability and process stability ensure higher component quality - typical components include valve bodies, aviation brackets, landing flaps and steering knuckles. Due to its great versatility, CoroMill 331 is not only suitable for slot milling, but also for parting off, double-sided milling, shoulder milling, face milling, backward mirroring, block milling and for circular interpolation. A higher processing reliability also increases the performance. The CoroMill 331 enables true 90 ° corners and excellent machining performance that make this milling cutter the most productive of its kind. Ease of use is another requirement of manufacturing companies around the world. For this reason, CoroMill 331 uses spring-loaded cassettes with serrations, which ensure a high level of security and easy adjustment of the desired groove width. In addition, a pin-controlled adjustment range enables the milling cutter to be set with high precision for precise groove dimensions.
New, beneficial features in the latest CoroMill® 331 from Sandvik Coromant include internal coolant supply and easy-cutting geometries for stable and safe machining.
M30 geometry is the existing selection - this was specially designed for safe machining with weak set-ups and large overhangs. Another aspect that affects process reliability is the increased rigidity of the milling cutter: In applications where a large overhang or increased vibrations are to be expected, CoroMill 331 can be used with damped Silent Tools ™ adapters. Thanks to the CoroMill 331's shorter shell mill bodies, the cutting edge is closer to the Silent Tools damping mechanism, so users can get a
I N F OS | CONTACT Sandvik AG, Coromant Alpenquai 14 CH-6002 Lucerne Phone +41 (0) 41 368 34 34 www.sandvik.coromant.com [email protected]
For better service life
The new cutting inserts of the ARNO-MiniSystem AMS have a cooling channel that emerges at different points depending on the application.
Particularly small modules that fit in multi-spindle machines could previously only be produced with one cooling channel. The narrow width made it technically and economically impossible to drill or erode a second cooling channel. Now ARNO Werkzeuge has managed to manufacture a new parting module with a second cooling channel using the additive manufacturing process. And this is so cheap that the tool manufacturer is already mass-producing the module. Up until now, it was not possible to economically produce parting modules in series using 3D printing. The advantage of this new parting-off module is optimized cooling and the resulting increase in service life.
Swiss-type lathe tools for quick change It was not just about cooling with Swiss type lathes. Time and again, customers came to ARNO Werkzeuge and complained about the complicated tool changes in the small interior space of a Swiss-type lathe. The mostly oil-smeared tools tended to fall off when changing, and too many screws had to be tightened. With the innovative long turning system -AFC, only the head of the holder including the new cutting insert is changed. The manufacturer has made stability and ease of use its main goal. In addition, the tool manufacturer is presenting a new slide for long turning systems: Since coolant hoses in particular have to be screwed onto the new tools, which is a time-consuming process, they are an expensive burden. The new
ARNO Werkzeuge's slide is designed in such a way that the cooling is not affected when the tool is changed. The efficient solution -AFC sets new standards in the field of Swiss type lathes.
Mini cutting insert with internal cooling If in the previous ARNO mini system the cutting edge was cooled through the cooling channel in the holder, the new cutting insert enables even more direct and effective cooling. The coolant jet runs directly through the cutting insert. In order to solve the challenges of chip accumulation, especially with blind holes, the tool manufacturer has developed two different variants. The design of the cooling channel is located at different points in order to focus on chip transport or cutting edge cooling, depending on the application. For the internal machining of small bores, this means that the chip is also flushed out deep into the bore, or overheating of the cutting edge is almost impossible.
INFO S | CONTACT Schweizer Maschinen Import AG Schanzstrasse 1 CH-8330 Pfäffikon Telephone +41 (0) 44 953 20 20 www.smiag.ch [email protected] www.arno.de
Powerful trochoid burs M
ith the new high-performance trochoid milling cutters from HAM, users can machine workpieces even faster, with higher quality and more reliably. The tools with cutting lengths of 3xD and 4xD are particularly suitable for machining various types of steel, INOX and gray cast iron.
With a hard-wearing coating With these milling cutters, HAM has expanded its range of trochoid milling cutters in response to the increasing demand for longer cutting edges for shorter machining times. The HAM 405191 in 3xD and HAM 40-5291 in 4xD achieve very good machining results with trochoidal and high-speed milling. The tools are made of special solid carbide (VHM). They are provided with a resistant coating. HAM offers these tools with MMP TECHNOLGY, a new polishing process for a mirror-like display
The new trochoid milling cutters HAM 40-5191 (above) and HAM 40-5291 (below) impress with their high metal removal rate, smooth running and long service life.
Surfaces. Milling tools treated in this way have significantly better surfaces than conventionally polished tools. Thanks to the long service life, users achieve economical machining processes. As a five-flute cutter, the milling cutter impresses with its very high metal removal rate.
The tool is optimally positioned to the component HAM has incorporated its extensive know-how into the development of tools and geometries in the new milling cutters. Important design features are the cutting edge pitch, the spiral pitch and the
geometrically balanced cutting area. As a result, the milling cutters work particularly quietly, hardly cause any vibrations and thus ensure safe processes. When selecting the spiral pitch, HAM made sure that both types have five ACPs (Axial Contact Points). This means that the tool is optimally positioned in relation to the component, which enables continuous processing. Both tool variants have special chip breakers. This creates particularly short chips that can be easily removed. At the same time, it prevents metal
Image: HAM Hartmetallwerkzeugfabrik Andreas Maier GmbH
parts damage the workpiece and disrupt or even interrupt the process. The version HAM 40-5191 is available in Ø from 6 to 20 mm, HAM 40-5291 is available from 10 to 20 mm. Customer-specific tool designs are possible at any time on request.
I N F OS | CONTACT HAM Precision Swiss Andreas Maier AG Alte Landstrasse 50 CH-9450 Altstätten Phone +41 071 757 03 20 www.ham-tools.com [email protected]
Image: Walter AG
Its strength lies in the system
The new Walter M4130 shoulder milling cutter uses existing indexable inserts.
ith the M4130, Tübingen-based Walter AG is introducing a shoulder milling cutter that consistently continues the M4000 system concept: saving costs through the use of universal system inserts across all applications and tools. In the case of the M4130, this applies to the system indexable inserts with a rhombic basic shape with a 15 ° clearance angle, which can optionally also be used in slot and Igel cutters of the M4000 family. The circumferentially sintered, 2-edged plates are available in three sizes, each with three CVD-coated and three PVD-coated types. In addition to high flexibility, they are particularly characterized by their economic efficiency. Thanks to their soft cut, the submersible M4130 shoulder milling cutters are particularly suitable, according to Walter, for rough machining of steel, cast iron and stainless steels as well as for materials that are difficult to machine. Especially for shoulder milling, ramps, pocket milling and drilling
circular milling. The milling cutter with a 90 ° approach angle is available as standard with cutting depths of 8, 13 and 16 mm, in the diameter range 16 to 100 mm. As a special tool in a significantly wider diameter range. The M4130 milling cutter is part of the Walter Xpress fast delivery program and, according to Walter, is produced with CO2 compensation.
INFO S | K O NTA K T Walter (Schweiz) AG Hunnenweg 2 CH-4501 Solothurn Telephone +41 (0) 32 617 40 72 www.walter-tools.com [email protected]
The long-life formula for drill bits D.
he René Gerber AG has relied on the rounding of carbide cutting tools for years. The service life of drills, milling tools and punching tools can be increased significantly. This results in a longer service life for drills, which not least has a positive impact on profitability. The LongLife formula of the cutting edges of drill tips is a specialist area of René Gerber AG, in which it demands itself to continuously improve in this area and to maintain the reputation of the specialist.
A perfect cutting edge has a positive effect on tool life, why? At first glance, it seems illogical for a long-lasting drill tip to have its cutting edge
Process also supported positively.
The drill clamping drum as an option for the brush-polishing machine The drill clamping drum option can be selected for the brush-polishing machine BP-MX, the productive for large volumes, as well as for the flexible BP-Smart. It is also possible to retrofit an existing system. Are you a specialist in regrinding drill tips and looking for more efficient machining or do you have an in-house grinding shop? We are the specialist for the efficient process and tailor the drill clamping drum as well as the workpiece holder to your needs.
Machined drill tips.
to round off. It even seems that the tool can no longer do its job if the cutting edge is no longer razor sharp. The results
Perfect cutting edges increase the service life. n display
CHAINFLEX 18 mechanical engineering 9/2018 | The Swiss industrial magazine. Since 1972.
however, an edge rounding show the opposite. The edge rounding creates a significantly reduced chipping at the tip. As a result, the tools run more smoothly, more precisely and swing less. The result is higher precision, better surface quality and ultimately higher process reliability. In addition, significantly faster cutting speeds and feeds can be achieved with a rounded cutting edge, which increases the efficiency of the
I N F OS | CONTACT René Gerber AG Werkstrasse 35 CH-3250 Lyss Phone +41 (0) 32 384 14 87 www.gerber-maschinen.ch [email protected]
MACHINERY S PA N N S Y S T E M E
Miniaturization thanks to additive manufacturing D
he topic of miniaturization plays a major role in numerous industries. As a result, also for machining production. Chucks must also become smaller, more precise and more powerful. The requirements cannot be met with conventional manufacturing - MAPAL therefore relies on additive manufacturing using selective laser melting. Be it in electrical engineering, medical technology, in the aerospace sector, the watch industry or in robotics and mechanical engineering - many products are becoming smaller and smaller, but designed to be smarter, more user-friendly and more powerful. The issue of space is therefore crucial. Because space is not only limited on the wrist, in the trouser pocket, on board an airplane or in the human body, but also in the company's production halls.
Perfect concentricity and optimal balancing quality This requirement gives rise to the demand for productivity in the smallest of spaces, which transfers the miniaturization cycle to the entire value chain. The machine and tool technology in this micro-sector requires that
Even in the field of clamping technology, more and more functions have to be fulfilled in the smallest of spaces. The concentricity of the chucks for chip thicknesses in the range of a few thousandths of a millimeter must be almost zero. This is the only way to achieve good surfaces at the highest speeds and with a long tool life. In addition, it must be ensured in the process that any contamination by microparticles is excluded. Another important topic in machining in the micro-sector is the supply of cooling lubricant. Too much medium means time-consuming downstream component cleaning, while too little or no cooling in turn leads to a loss of quality and productivity.
Additive manufacturing through selective laser melting If handling also has to be simple, conventional manufacturing reaches its limits. “The smaller the tool and the chuck, the easier it must be to use. Because with every downsizing, the handling of external peripheral devices becomes more cumbersome and difficult, ”says Jochen Schmidt, Product Manager Clamping Technology at MAPAL, in a nutshell. With shrink or collet technology, it also takes significantly longer before the tools are ready for use. In the case of multi-part structures, the individual deviations of the
By using a mandrel with hydraulic expansion technology, workpieces, here using the example of an artificial hip joint ball, are clamped with high precision.
20 mechanical engineering 9/2018 | The Swiss industrial magazine. Since 1972.
Thanks to additive manufacturing, hydraulic expansion technology can also be used for chucks with HSK-E25 mounts and slim contours. In comparison on the right a hydraulic expansion chuck with HSK-A63 holder.
Components to a not inconsiderable chain of errors. "At MAPAL we use additive manufacturing through selective laser melting in all of our product areas," says Jochen Schmidt. And always when additively manufactured products offer clear added value for the customer. Thanks to the innovative manufacturing process, MAPAL has succeeded in manufacturing miniature chucks with HSK-E25 mount, for example for the direct clamping of tools with a diameter of 3 mm, that meet all of the requirements mentioned.
Smallest chucks with the best properties In order to guarantee concentricity, the clamping technology specialists have integrated innovative clamping chamber systems into the new chucks, which cling to the shank of the tool. They are equipped with dirt grooves to displace micro-dirt. The required balancing quality is ensured thanks to the internal balancing geometries including support structures, which also ensure optimization in terms of weight and strength. «All in all, we achieve a homo-
General acceleration and braking of the entire tool system consisting of chuck and tool, which is gentler on the spindle, ”emphasizes Jochen Schmidt. Thanks to additive manufacturing, MAPAL has succeeded in equipping the chucks for the smallest sector with decentralized coolant outlets. Using parameters such as coolant pressure, setting dimension and speed, these outlets are designed in such a way that they deliver the cooling lubricant to the point of action in a targeted manner. In the best case, a metered loss of lubrication, which makes subsequent cleaning of the components superfluous, is achieved.
Easiest handling without peripheral devices The new small format chucks from MAPAL enable the tool to be clamped quickly and easily. “Neither training nor high set-up costs or expensive peripheral devices are required to implement our chucks,” promises Jochen Schmidt. Because: The hydraulic expansion chucks are operated via a simple screw. Thanks to the new, small hydraulic expansion chucks, there are also new possibilities for workpiece clamping. For example, when tensioning hip joint balls. «Here we use the hydraulic expansion external clamping technology. Thanks to specially shaped clamping chambers inside the chuck and a special external geometry, the balls are clamped very precisely and gently at the same time, ”explains Jochen Schmidt. In medical technology in particular, issues such as reproducible precision are extremely important. “And we can ensure this during processing thanks to our chucks,” says Jochen Schmidt happily.
Aluminum, Düsseldorf Hall 9, Stand 9G12 I N F OS | CONTACT MAPAL Dr. Kress KG Gässli 10 CH-4588 Brittern Telephone +41 (0) 32 661 01 80 www.mapal.com [email protected]
MACHINERY S PA N N S Y S T E M E
Images: Gressel AG
For fast 5-axis machining
The new 5-axis power vice grepos-5X-C ensures optimal accessibility for 5-axis / 5-sided complete / simultaneous machining on all types of CNC machining centers.
ith the 5-axis power vice grepos5X presented to the professional world in 2010, the Swiss specialist for workpiece clamping technology Gressel significantly improved acceptance and productivity in 5-axis and 5-sided complete and simultaneous machining on CNC machining centers. Gressel has now further developed the proven technology and with the grepos-5x-C presents a successor to the original, which is characterized by many improvements.
Mobile fixed jaw The basis for the optimization was the experience from numerous applications all over the world. Gressel has retained the tried and tested performance and quality features, but has also introduced practical innovations that ensure even more performance for the user in 4 and 5-axis complete machining. What has remained is the high precision thanks to the fixed jaw principle and the overhead spindle, which makes it a real one
2-sided machining becomes possible. New with grepos-5X-C: The mobile fixed jaw or both jaws can be moved as desired on the base body, with the mobile fixed jaw being clamped using just one screw. This gives the user even more freedom when clamping demanding workpieces and does not have to resort to expensive special clamping devices. Gressel has also retained the complete encapsulation and quick adjustment, optimal accessibility and mechanical power transmission. The same applies to the quick release lever. However, this is now done via a spindle with a hexagon socket and therefore no longer has a key or crank holder on the outside. As a result, Gressel has further improved accessibility. The clamping process with the quick-release lever still takes less than a second, no torque wrench or cranking is required. A tie rod extension increases the clamping range, and a quick-change system ensures easy conversion and a cross wedge for secure locking.
Infinitely adjustable The clamping force of the grepos-5X-C can be infinitely adjusted by hand and without tools from five to a maximum of 40 kilonewtons - and that with the highest repeat accuracy. A ruler supports the quick and easy positioning of the jaws. For very good all-round access, the height of the workpiece support is 211 mm. This means that no substructure is necessary. Since the basic structure is kept particularly low, the Z-axis path remains largely usable. This enables very good machining access from all sides as well as optimal tool adjustment.
INFO S | C O NTAKT Gressel AG Schützenstrasse 25 CH-8355 Aadorf Both jaws can be moved to adjust the center individually. Here a small workpiece is clamped in the middle of a large machine table.
Telephone +41 (0) 52 368 16 16 www.gressel.ch [email protected]
MACHINERY MACHINING CENTER
NE WS & T R E N D S A D V E RT O R IA L S
Employee on site decreases. The connection via simple, three-pin standard cables and M12 connectors also reduces the cabling effort. In addition, there is the advantage that through remote parameterization, entering hygienically sensitive areas can be avoided. The valve control heads are available in various designs with UL approval as well as according to ATEX II Cat. 3G / D and IECEx.
Fakuma, Friedrichshafen Hall A3, Stand 3013 INFO S | K O NTA K T Bürkert GmbH & Co. KG Christian-Bürkert-Strasse 13–17 D-74653 Ingelfingen Telephone +49 (0) 7940 10-0 www.buerkert.de [email protected]
Increased customer proximity
n A year ago, the TRUMPF power tools business area converted its sales system in Switzerland. Since then, sales have been carried out through 31 qualified specialist dealers. An important step for Stefan Anshelm, International Sales Manager for Power Tools: "Our end customers are much closer to our products via dealers, and that is worthwhile for everyone involved." Accordingly, the EW sales manager looks back on a good first year and notes that the cooperation with the experienced dealers works well. According to Stefan Anshelm, several measures are decisive for the great success: “We train and support our TruTool partners on a regular basis
also on site, for technical questions, the introduction of new tools and the organization of in-house exhibitions. On this basis, the Swiss specialist dealers can always provide qualified advice. " For end users of TRUMPF power tools, the physical proximity of the dealers is not only a major advantage when purchasing the product, but also when it comes to repairs. The responsible TruTool partner also organizes these in full for the entire range of TRUMPF power tools. To make the search for specialist dealers in Switzerland easy, the company has set up a dealer search at www.trumpf.com.
Fakuma, Friedrichshafen Hall A4, Stand 4211 INFO S | K O NTA C T TRUMPF Schweiz AG TRUMPF Strasse 8 CH-7214 Grüsch Phone +41 (0) 58 257 61 61 www.trumpf.com [email protected]
22 mechanical engineering 9/2018 | The Swiss industrial magazine. Since 1972.
Image: igus GmbH
n The trend towards digitization also increasingly demands bidirectional communication in process automation down to the field device level. Bürkert therefore now offers the tried and tested valve control heads Type 8691 (picture) with IO-Link and büS interfaces for easy system integration. Especially in food, pharmaceutical and biotechnology, but also in drinking and industrial water treatment or beverage bottling, process fittings are now becoming intelligent thanks to the communicative valve control heads. Thanks to IO-Link, relevant diagnostic data such as the number of switching cycles, maintenance requirements or automatic error detection can be read from the valve system. This allows conclusions to be drawn about the expected service life of the valve and enables preventive maintenance measures. This minimizes downtimes and increases process reliability. The maintenance itself is also easier due to the data storage function and the training effort is easier
3D printing service for wear parts
n The motion plastics specialist igus uses industrial 3D printers to manufacture individual customer components that are subject to friction and wear and tear within a few hours. This also applies to the lack of lubricant-free special plain bearings. Upload the CAD model of the component to the igus website, select printing material - such as iglidur I180, a highly wear-resistant high-performance plastic and order it immediately. Shipping is usually within 24 hours. Igus uses iglidur I180 as a material for 3D printing. The high-performance plastic scores with high
Abrasion resistance. The igus test laboratory has proven its superiority over classic filament made of acrylonitrile butadiene styrene (ABS) in an experiment. Plain bearings moved on a 0.37 m long, hard anodized aluminum shaft at a speed of 0.34 m / s and a surface pressure of 0.11 MPa. The result: The 3D-printed ABS bearing showed a wear rate of 13.3 micrometers / km. With the iglidur I180 bearing, the rate was just 0.8 micrometers. The bearings are not only more durable, they are also more economical to operate. They enable maintenance-free dry running without lubricating oil.
I N F OS | CONTACT igus® Schweiz GmbH Winkelstrasse 5 CH-4622 Egerkingen Phone +41 (0) 62 388 97 97 www.igus.ch [email protected]
One for all
The M15 power connector from LQ Mechatronik-Systeme is compact and powerful as an integrated solution from the control to the motor.
n LQ Mechatronik-Systeme GmbH takes account of the trend towards reducing the complexity of mechatronic components by combining individual connections to form functional assemblies and by using optimized control and installation systems to ensure process-reliable and long-lasting energy management. This ensures space in the control cabinet and quick, easy work on the construction site. LQ Mechatronik-Systeme also sets standards in the industry with regard to pre-assembled energy chains, a core competence that is in increasing demand from mechanical and plant engineering. Dynamic chains are used wherever moving machine parts need to be supplied with energy and data. From engineering to
Image: LQ Mechatronik-Systeme GmbH
Valve control head for Industry 4.0
In terms of logistics, the mechatronics experts guarantee comprehensive support for all aspects of installation technology. All systems are individually designed for the application and movement of the machine and their functionality is checked one hundred percent. The energy supply systems are delivered just in sequence on practical transport racks. Depending on the application and technical requirement, almost every connection variant can be custom-made and precisely tailored to the respective application. An extensive stock of raw parts ensures the ability to deliver in the event of bottlenecks and ensures that customer requests can be met quickly and satisfactorily.
I N F OS | CONTACT LQ Mechatronik-Systeme GmbH TRUMPF Strasse 8 CH-7214 Grüsch Phone +41 (0) 81 354 20 00 www.lq-group.com [email protected]
NEWS & T REND S ADVERT ORI A LS
Transparency about the manufacturing process
n Schwäbische Werkzeugmaschinen GmbH (SW) has developed its own SW cloud platform to make the machine data of their machining centers even more clearly and user-friendly accessible to customers. This creates optimal conditions for continuous performance monitoring and predictive maintenance for customers. By 2020, all functionalities will be gradually transferred from the previous cloud solution to the new system. SW has been offering its customers access to machine data via a portal since 2004 - and is thus playing a pioneering role in the industry. In order to be able to present this information in an even more modern and clear manner in the future, SW has developed its own cloud solution based on the IIoT platform Predix from GE, with which quality and production goals can be achieved even better. With the existing platform, SW has been evaluating machine data for more than 15 years with the consent of customers. Around 2000 machines are currently connected, 700 million data points and 25 million machine events have been collected. The new SW-CloudPlatform is a further development and offers continuous performance monitoring, which guarantees increased transparency over the entire manufacturing process. “A profile is stored for each of the connected machines worldwide, which makes all machine information and process data accessible via a dashboard. A map of the world and various production lines already provide an initial overview of the machine locations and conditions, ”explains Jochen Heinz, Head of Industrial Data Services at SW. In addition, the design of the user interface, including all graphics and statistics, is very clear; Discrepancies and problems in the operational process are particularly
easily identifiable. In addition, attention was paid to an intuitive user interface that enables easy error analysis. SW attaches particular importance to data security. The cloud solution is part of the holistic “life” service concept and is part of the “life data” component: It expands the data services portfolio, which in addition to online services also includes the components of digitization consulting, energy monitoring, factory simulation and data analytics. These service modules are to be further expanded in the future in order to proactively meet all challenges of Industry 4.0.
INFO S | K O NTA K T Schwäbische Werkzeug maschinen GmbH Seedorfer Strasse 91 D-78713 Schramberg- Waldmössingen Phone +49 (0) 7402 74-0 www.sw-machines.de [email protected] maschinenbau 9/2018 | The Swiss industrial magazine. Since 1972.
INDUSTRIAL MAGAZINE ON THE TOPIC
The current state of industrial networks All over the world, industrial networks control automated processes in companies in a wide variety of industries, primarily in the field of production. The demands on them are steadily increasing. The development of automation technologies and network structures also places new demands on maintenance in the future.
Withstand moisture, mechanical stress, electromagnetic influences and the like more. All of this can lead to an impairment of the data transmission quality and thus reduce the process result. In most cases, troubleshooting is only carried out when there are visible and noticeable symptoms up to an unplanned machine / system downtime. In these cases, investigating the cause often becomes Sisyphean work, as there can be many possible reasons. Due to its steadily increasing complexity, it makes sense to assume that the network is the cause of the malfunction.
A look into practice The practical relevance of this is shown in a current study by Indu-Sol GmbH . The technology company has been pursuing the mission of sta
No or too little technical know-how for countermeasures, so that a service provider had to be called. These figures raise the question of the right maintenance strategy that ensures continuous production and predictable maintenance. Ten years ago, a non-representative survey by Indu-Sol at the maintenance level among its customers revealed an interesting finding about what keeps them busy in their day-to-day work. Among the most frequent responses were things like “Acknowledge an emergency stop”, “Check power feed” or “Check drives” - the network felt it was in 25th place. A recent repetition of this survey clearly shows the change in awareness and importance of the network for maintenance - it now ranks fourth here! This results in the real need for a supporting monitoring system, since not only the network structures themselves, but also the task of their maintenance are becoming more and more complex. In order to cope with this, the electrician today would have to be a mechanic and IT specialist in addition to his actual job - that is, not
Images: Indu-Sol GmbH
Always full supermarket shelves, very short parcel delivery times, fresh food every day - a matter of course? In fact, these things are primarily the result of many hardworking workers in the areas of planning, production, maintenance and logistics in numerous industrial companies. At the same time, industrial networks, among other things, ensure efficient work processes thanks to a high degree of automation. Just like people, the networks must continuously deliver maximum performance every day, as they control the respective processes as the «lifelines» of the machines and systems and thus have a significant influence on the result. In addition to the stress caused by the mere operation itself, the network components used must also include factors relating to the production environment such as heat / cold,
to ensure stable networks in the industrial environment. Of the more than 100 employees at Indu-Sol alone, 20 measurement engineers travel many thousands of kilometers around the world every year as a kind of rapid reaction force in order to measure newly installed networks, evaluate the current quality of data transmission using measurement technology or to troubleshoot. Around 600 measuring missions come together every year! What is noticeable here is that more than every second use involved troubleshooting. In almost every third case, the measuring operation was even preceded by an immediate machine or system shutdown. Uncounted are the cases in which the operator suspected the network as the cause of the malfunction, but ultimately a process malfunction turned out to be the real reason. Such so-called SOSE operations were particularly necessary when there was no early warning system that provided information about the first symptoms that could have prevented the failure. In most cases, the technical staff in the companies concerned then had it
Literature  Since 2016, the summary of the findings from the measuring operations of Indu-Sol GmbH in the previous calendar year has been published annually under the name «VORTEX».
Fig. 1: Decentralized data collectors like the PROFINET-INspektor® NT here analyze the network passively and continuously and determine the respective status. The first diagnostic information of the alarms that have occurred can also be viewed on the display.
24 mechanical engineering 9/2018 | The Swiss industrial magazine. Since 1972.
Image 2: PROmanage® NT brings together the status data determined by the INspektoren® from several networks centrally on a server. In addition to the INspektoren®, the manageable switches built into the network can also be read out.
INDUSTRIAL MAGAZINE ON THE TOPIC
To avoid overloading the daily work of the maintenance staff with manual monitoring of the network conditions, Indu-Sol has also equipped the PNÜ with an alarm function. Thanks to them, both the INspektoren® and PROmanage® NT are able to assist the operator with the
to warn about exceeding or falling below adjustable threshold values for the data communication quality.Thanks to the clear, graphic presentation, the determined diagnostic data can be analyzed quickly and easily. In this way, maintenance measures can be carried out as required and planned.
cash - thus efficiently. Another advantage of the PNÜ: It can be used on different network types. A corresponding data collector (INspektor®) must be integrated per controller or master in each network. PROmanage® NT also manages the data
Image 3: The PROmanage® NT chronicle quickly shows the current overall status of the network and the last time there were faults. A click on the respective diagnosis point opens up more detailed information via quick access.
recently, in view of the rapid technical progress, hardly reasonable.
Permanent network monitoring (PNÜ) Indu-Sol has therefore developed a system for permanent monitoring of industrial networks (PNÜ) that helps operators to achieve condition-based and, above all, needs-based maintenance right from the start over the entire life cycle of the machine / system. The concept provides that passive data collectors, so-called INspektoren® (Fig. 1), analyze the respective network permanently and without any feedback. To a certain extent, they bring together the individual states of the sometimes very extensive networks. The PROmanage® NT monitoring software brings together the data from all INspectors® centrally on a server and forms them into an overall picture (Fig. 2) that provides reliable information on the current overall network status at any time (Fig. 3) - the digital management report. With the help of the INspektoren®, the status of the individual networks can also be tracked. As the determined diagnostic data remain available to the minute for up to a year, they provide valuable information for investigating the cause in the event of troubleshooting - even if it is only that the network is not responsible for the malfunction and thus a large number of possible sources of error can be excluded. In order to deal with the already bulging mechanical engineering 9/2018 | The Swiss industrial magazine. Since 1972.
INDUSTRIAL MAGAZINE ON THE TOPIC
together across networks and even across fieldbuses.
Network monitoring in the future It is already becoming apparent that sensors are increasingly being used to obtain maintenance-relevant data, for example temperatures, fill levels, number of revolutions, etc. Map processes. With the help of appropriate analysis methods, minimal deviations from the normal state can be determined and reported immediately. In addition, this data can be used to assess the status in addition to what the network itself provides - predictive maintenance or troubleshooting 4.0, to a certain extent. InduSol is already offering the first cloud solutions here, which on the one hand provide storage space and computing power and on the other hand are able to preprocess the steadily increasing volume of data. Nonetheless, these technical diagnostic options remain just an aid - but one that provides people with valuable input and reduces unplanned incidents to a minimum. n display
Fig. 4: The web interface of the PROmesh P9 switch shows all essential information on port assignment and status at a glance. Operators can thus take countermeasures in a targeted and needs-based manner.
In particular, the increasingly extensive network structures and the desire to have several applications run on the same network in addition to those required for actual production make permanent condition monitoring indispensable. In addition, the importance of intelligent infrastructure components that are able to prioritize data streams and deliver reliable performance even with consistently high data throughputs is increasing. The next logical step is therefore that the infrastructure components also have a network
carry out a diagnosis and be able to provide the operators with relevant information in a nutshell. This requirement applies in particular to switches, as Ethernet-based protocols are used more and more frequently in the industrial sector and, with their technical possibilities, provide the basis for Industry 4.0. Indu-Sol recognized this trend at an early stage and launched the PROmesh P9, the first switch that was developed in the spirit of the ideas described above. It was particularly focused on one
Attention is paid to handling that is tailored to the needs of automation. The web interface immediately shows all the relevant information on port assignment and status at a glance (Figure 4). In addition, a function for monitoring the current shield current level was provided in order to detect electromagnetic influences on data transmission. The development of the PROmesh P9 is a first step towards meeting the challenges for data communication of the future that are already apparent today. Whether big data, cloud technologies or time-sensitive networking (TSN) - all of this will change automation as we know it today. Change has started and we need to prepare for it.
I N F OS | CONTACT WITO Automation AG Oberfeldstrasse 2 CH-8570 Weinfelden Telephone +41 (0) 71 626 58 80 www.wito-ag.ch [email protected] www.indu-sol.com
INDUSTRIAL MAGAZINE W E R K P L AT Z S C H W E I Z
Positive business development Incoming orders in the Swiss MEM industry rose by +24.2 percent in the second quarter of 2018 compared to the same quarter of the previous year. Over the entire first semester, incoming orders grew by +24.1 percent. Revenues in the MEM industry also increased by 16.3 percent in the second quarter of 2018 compared to the same period in the previous year. Overall, they increased by 16.4 percent in the first half of the year. In the first half of 2018, the index values for incoming orders and sales averaged the highest values for ten years.
In the first quarter of 2018, 325,500 employees worked in the Swiss MEM industry. That is 2.6 percent more than in the same period of the previous year. The employment figures from the second quarter of 2018, which are collected by the BfS, are not yet available. The capacity utilization of the MEM companies reached 91.9 percent in the second quarter and was thus well above the long-term average of 86.4 percent.
Export growth in all sales regions According to figures from the Federal Customs Administration, goods exports by the MEM industry rose by +7.5 percent in the first half of 2018 compared to the same period in the previous year and reached a value of CHF 34.8 billion. The export of goods grew in all important sales markets and product areas. Exports to the EU (+9.1 percent) and the USA (+7.3 percent) developed particularly well. The export growth to Asia was significantly weaker (+1.5 percent). Although exports to China rose by +10.8 percent, declining exports to the other Asian countries and especially to the Middle East put pressure on the overall result for Asia. Looking at the individual product areas, exports of metals increased by 11.1 percent, mechanical engineering by 9.2 percent and precision instruments by 7.9 percent
Percent and electrical engineering / electronics by +7.0 percent.
Pleasing overall situation The situation in the Swiss MEM industry is overall very positive. This also has an impact on employment. Within just one year, the MEM industry made up for two thirds of the job losses caused by the abolition of the minimum exchange rate. Hans Hess, President of Swissmem, said: “I am very pleased that the majority of MEM companies are doing better again. I assume that the good business development will continue for another six to twelve months. After that, the economy could flatten out, especially since cyclical industries are already feeling a slowdown in growth momentum. " The entrepreneurs in the Swissmem membership see it similarly. In the com-
High pressure on their retraining initiative, which is intended to enable adults with a completed initial training to receive a second training in a new professional field. In addition, various measures for the promotion and further training of employees have been anchored in the new GAV of the MEM industry, which increase the attractiveness of the MEM industry as an employer. It also contains recommendations on how the employability of young people, women and older employees should be supported in a targeted manner and how the compatibility of family and work should be improved. All of this is intended to help ensure that the MEM industry continues to have enough qualified specialists in the future.
Hans Hess: "By far the most important sales market for the MEM industry is the EU."
According to the latest survey, 51 percent of businesspeople are expecting the same orders from abroad at the end of the twelve months. The number of those who expect higher orders, on the other hand, decreased by 12 percentage points in the second quarter of 2018 compared to the first quarter (Q1 / 18: 48 percent, Q2 / 18: 36 percent).
Challenges Shortage of skilled workers One of the greatest challenges for the Swiss MEM industry in the coming years is the shortage of skilled workers. Swissmem is therefore working with us
180 160 140 120 100 80 60 40
I N F OS | CONTACT
20 2012 total
Incoming orders from the MEM industry (basis: Q1 2001 = 100)
Swissmem Pfingstweidstrasse 102 CH-8005 Zurich Phone +41 (0) 44 384 41 11 www.swissmem.ch [email protected]
mechanical engineering 9/2018 | The Swiss industrial magazine. Since 1972.
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ISO 27001: Leadership Chapter 7 of ISO 27001 deals with the topics of resources, competence, awareness, communication and documentation.
he standard requires that the necessary resources are also available. It shouldn't just pay lip service to “we operate an ISMS”, but the necessary resources that it needs for this are not made available. Often it is enough to set up the ISMS. Everyone is still excited. But as soon as the certification is passed, it is neglected. "It's going well, we no longer have to do something all the time." Shortly before the maintenance audit, great efforts are made again and everything is brought into shape. But an experienced auditor will notice this immediately. An ISMS requires constant activity
and not just once a year. The topics are too diverse for this to be done in a night exercise. Therefore, chapter 7.1 also requires the maintenance and continuous improvement of the ISMS. The necessary competence, i.e. training and knowledge, must also be proven (7.2). For this purpose, a corresponding catalog of requirements must be drawn up for all persons (or roles) involved: What experience does this person need to have? Which training courses are necessary? How can the regular updating of knowledge be ensured? If something is missing, it is not tragic
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