Impulse no. 1 – 2010 (PDF) - Leine & Linde

IMPULSE
News
from Leine & Linde
Autumn / winter 2010
CONTENTS
CEO speaks (p. 2) I Customer references - Application report from SSAB (p. 6-7) and Dalkia & Outokumpu Press Plate (p. 3) I Expansion in Asia (p. 5) I Technical
information - Managing pulse encoder cables (p. 6) and The art of choosing the right shaft coupling (p. 8) I Trade fairs (p. 2) I A day in the optics department (p. 4-5)
SSAB, a world player that focuses on its customers
Leine & Linde’s pulse encoders play a crucial role in the creation of SSAB’s thin
plate. “The encoders must be of good quality to cope with the harsh environment
in this industry,” says Hans Bondegård, an electrical engineer at the rolling mill.
SSAB has a history stretching back to the 1800s in the area surrounding Borlänge in
Sweden. For the manufacture of the company’s thin plate, Leine & Linde’s encoders are
installed at several critical points along the line. The plant is so big that you pretty
much have to get around by car and the staff look out over the process from a position
of safety. Read more about the rolling mill on pages 6-7.
Production never stops at SSAB. Here thin
plate is shaped according to the customer’s request,
in the right thickness, width and length.
Here encoders
are created with
μ precision
”Leine & Linde
are different from
other companies”
French Dalkia helps Outokumpu Press
Plate with maintenance of its machines
in Avesta, Sweden. And there
are particular reasons why they use
Leine & Linde’s pulse encoders to give
us consumers the latest in kitchen
cabinet door design, for example.
See page 3.
At Leine & Linde’s optics department, the keywords are precision and accuracy. One
of the qualifications for being able to cope with this demanding work is a skilled and
experienced eye. When the pulse encoder code discs need to be centred, a maximum
deviation of 4-8 micrometres is permitted. To give you an idea, a hair is 50-70 micrometres
thick. Read more in the article on pages 4-5.
The art of choosing the right shaft coupling
Leine & Linde help you choose a shaft coupling. Page 8.
Welcome to
the India
office !
“It’s important to be able to
speak the customers’ language and
to be near them geographically,” says
Somnath Mukherjee, our new office
manager at our New Delhi branch.
Read about Leine & Linde’s expansion
in Asia on page 5.
Leine & Linde AB | PO Box 8, SE-645 21 Strängnäs, Sweden | Visiting address: Olivehällsvägen 8
T: +46-(0)152-265 00 | F: +46-(0)152-265 05 | E-mail: info@leinelinde.se | Website: www.leinelinde.com

CEO SPEAKS
Asia makes 2010 a record year
2009 was a testing year for most
companies. Fortunately we managed
pretty well.
The exceptional growth we had seen in
previous years was not followed by an
increase in turnover. In spite of that we
are incredibly pleased with how well we
managed during the global financial crisis.
We look back on the year as a breathing
space for all our employees, whom we
have also managed to retain.
The fact that 2010 looks like being a record
year for Leine & Linde is therefore
a source of great pleasure. One factor
that strongly contributes to this year’s
growth is our continued efforts in Asia. An
establishment that started many years
ago and came at precisely the right time,
with improving market conditions and new
business opportunities opening up. These
efforts will naturally continue, and we
We constantly adapt
to the requirements
and wishes of our
customers
already expect to make further appointments
in Asia.
On the product side, we are continuing to
adapt to the requirements and requests
made by both the authorities and our
customers.
We also look forward to meeting many of
you at our fairs in 2010 / 2011. If you are
unable to visit us at any of the 20 fairs we
have planned, you are always welcome to
visit our website, www.leinelinde.com, to
read our product news.
You are now holding the latest edition of
our customer newsletter IMPULSE. I hope
you will find it interesting and well worth
reading. Until we meet again, I would like to
wish you, our customers, all the best, and
hope your autumn is filled with interesting
new challenges.
Björn Zetterlund
CEO
Autumn fairs s!
Feel free to visit Leine & Linde at the
following fairs during autumn 2010. 0.
Sweden
6-7 October EuroExpo, Malmö
China
15-17 September China Paper Shanghai, ai,
Shanghai
Leine & Linde will be represented at a number of other
fairs via our distributors. Please visit our website,
www.leinelinde.com, for further information.
Fairs as a meeting place are an important part of
Leine & Linde’s communication work, and we look
forward to seeing you at one of them.
India
21-24 September Automation 2010,
Mumbai
Germany
21-25 September Husum Wind, Husum
23-25 November SPS, Nürnberg
Finland
5-7 October Teknikka, Jyväskylä
Spain
26-29 October Matelec, Madrid
2

Uninterrupted production at
Outokumpu Press Plate
”Since we started using Leine & Linde’s products, we’ve had
no interruptions to production. Unlike other companies,
deliveries are very fast and the service is faultless.” So says
Roland Åhlund, an engineer at Dalkia in Avesta, Sweden.
Dalkia Dalkia deals with
maintenance of machines
at Outokumpu
Press Plate’s plant in
Avesta. Oskar Orre, who
works as production
manager for Outokumpu
Press Plate, joins us as
our tour guide.
Outokumpu Press
Plate is a subsidiary of
Outokumpu Stainless,
which has been processing
stainless steel for
press plates for 70 years.
Press plates are used for pressing patterns
into laminate flooring and kitchen
cabinet doors. Oskar explains that Outokumpu
Press Plate makes the semi-finished
goods needed, which are then sold
on to their customers.
The company also manufactures
stainless steel kitchen work surfaces
and cisterns that must maintain a high
hygienic standard. A relatively new niche
market is pattern ground plate for decorative
purposes, for decorating building
façades, for example. These plates are
ground in
various patterns,
producing
a 3D
effect.
Oskar explains
how important it is to achieve the correct
hardness and flatness. This is what builds
up the company’s brand.
”The tiniest defect can ruin a whole
plate. The plate is first stretched to remove
all tension, then it is blasted to
remove oxides and to achieve as clean a
surface as possible. When everything is
FACTS
ready, the plate is heated up and cooled
down until it reaches its renowned hardness.
If requested by the customer, the
plate is ground for its intended purpose.”
”The customer’s needs are always
paramount! Both the material and the
work performed are expensive, so any
slipshod work could have devastating
consequences,” Oskar continues.
In order to be able to manufacture this
high-quality plate, the machines must be
working properly.
Roland Åhlund is very pleased with
Leine & Linde’s products. One gantry
crane is fitted with a multiturn absolute
encoder with a draw-wire unit and
PROFIBUS interface. This encoder indicates
the position of the plate. There is
also an absolute encoder installed in the
blasting machine on the same production
line. This too indicates the exact position
of the plate.
”The quality of Leine & Linde’s encoders
is very high,” explains Roland, adding
that he is looking forward to continued
cooperation.
Dalkia
Dalkia is a leading European company providing energy and technical services for
companies and the public sector. Dalkia in Avesta focuses on maintenance of machines
in the steel industry. The parent company is located in France, and the group has around
53,000 employees in 41 countries.
Outokumpu Press Plate
Outokumpu Press Plate is a subsidiary of Outokumpu Stainless. It processes stainless
steel. Today the company has 28 employees and is a leader in its field.
On site are PROFIBUS encoders from Leine &
Linde that control the position of the plate.
Inside the production plant at Avesta are
Oskar Orre (Outokumpu Press Plate),
Roland Åhlund (Dalkia) and Håkan Karlsson
(Leine & Linde).
NOTICE
24-hour
service in Asia
Leine & Linde’s Asian customers
can ring for service 24 hours a
day now that the company is
beefing up its service and support
organisation.
Leine & Linde is establishing a new
organisation for service and support
in Asia. One of the things they
are doing is setting up a telephone
service which customers can ring
24 hours a day. Service engineers
will be on hand to answer questions
relating to pulse encoders.
Field support can also be offered if
required.
”Rapid local help guarantees our
customers maximum availability
and optimum performance for
every pulse encoder application
installed. So it was absolutely natural
to develop the new service
organisation,” says service engineer
Zhu Feng, who is in charge of the
Chinese section of the new support
organisation.
3

Precision and accuracy are keywords
Words such as exposure, pattern and developing make you think of photographers and developing
labs, but they are also used by Leine & Linde’s optics department. Cleanness, quality and accuracy are
required when critical components for pulse encoders are manufactured with micrometre precision.
For an encoder to work, a code disc and
a reference pattern are needed. Once the
two components have been produced and
installed with micrometre precision in
an encoder, an LED can send a beam of
light through them. Depending on what
the pattern looks like and how fast the
encoder shaft is rotating, light pulses are
created and
then converted
into electrical
pulses. It
is these electrical
pulses
that are used
to measure
the speed or
position of the
pulse encoder.
”On Time is a key concept for this department.
The customer must get their product
when they want it,” explains Resadija
Saljunovic at the optics department. In
this article we follow Resadija as she
shows us round the production process
that is central to Leine & Linde’s pulse
encoders.
Leine & Linde manufacture on demand
from customers and do not keep stocks
of code discs. This means that planning
is crucial, as all line counts between 1
and 10,000 can be manufactured, even in
small batches.
Once the daily planning is finished, the
work list for the day is printed out, with
information on which variants of code
discs are to be produced. They are made
of either glass or plastic material, using
special exposure equipment developed
in-house. An original pattern is used in
the manufacturing process, and it is the
appearance of the original pattern that is
copied onto the actual code disc.
As the entire work process is extremely
sensitive to dirt particles, all work is
performed in a cleanroom.
After exposure, the code disc undergoes
a development process in order to
develop the pattern copied during the exposure
process. Developing is performed
using an automated machine that lowers
the code discs into various tanks containing
developer and water.
It is important that there are no spots
left on the code discs from water or
chemicals. So the machine does not just
develop the code discs; it also washes
and dries them.
”It’s like spots being left on a glass
after it has been washed. There must be
absolutely no spots like that on the code
discs, because that could disrupt the
pulse encoder’s function,” Resadija explains.
Once developing is complete, the code
disc has been given its special pattern
and is ready for inspection.
”Here it’s important to be extremely
accurate, as the slightest error in the
pattern can cause errors that lead to the
finished pulse encoder not working properly.
It is partly a visual assessment of
results, which demands skilled and experienced
staff. In addition, all code discs
are checked in an automatic system for
their optic signal quality. Therefore, accuracy
and quality are two keywords for the
optics department,” Resadija says.
After the code disc has been made a
reference pattern is also required so that
the finished pulse encoder will have the
right function. The reference pattern
is developed on a piece of glass that is
glued firmly inside the pulse encoder.
This gluing is performed by a gluing robot,
and once it is finished the reference
pattern is exposed on the piece of glass. It
is extremely important for the reference
pattern to be perfectly straight so that it
can function correctly with the code disc.
The piece of glass with the reference pattern
undergoes the same process as the
code disc, with exposure, developing and
inspection.
”Just as in the code disc work, there
is a visual assessment in the inspection.
A skilled and experienced eye checks
whether there are any errors in the pattern.
No quality without accuracy,” explains
Resadija.
Finally the code disc and reference pattern
are installed in the encoder. Here too
precision is a keyword. The code disc is
centred on the encoder shaft and if this
is not done properly there is an accuracy
error.
Using special equipment, Resadija
centres the code disc in its correct position
on the shaft, extremely precise work.
The maximum permitted deviation from
the nominal position is 4-8 micrometres.
By way of comparison, a single hair is
around 50-70 micrometres thick.
When the centring work is finished,
the glue holding the code disc to the
encoder shaft is hardened using UV light,
and the department’s work is done. The
finished robust optic module then moves
to final assembly, where the complete
encoder is assembled.
4

in the optics department
NOTICE
Leine & Linde
establish a
presence in
India & Korea
CLEANROOM RULES
The cleanroom guarantees product quality and is necessary for stable manufacturing
processes.
The following rules and requirements apply for a cleanroom of ISO class 6, which
corresponds to Leine & Linde’s cleanroom:
Particle concentration
Max 35,200 particles ≥ 0,5µm/m 3 air.
Temperature
Always 21°C and a relative humidity of 45 per cent.
Clothing
Always special cleanroom clothing with overalls, cap and special shoes.
Work methods
Follow a specific work method, no fast or expansive movements.
Cleaning
All materials must be washed and cleaned before being taken into the cleanroom.
Overpressure
The cleanroom has a constant overpressure. Higher pressure in the cleanroom than
outside prevents dirty air and particles being sucked in.
Earlier this year Leine & Linde
opened two new branches in
New Delhi and Changwon. Now
the company can provide a better
service to local and global
customers operating in southeast
Asia.
There is a huge market for pulse
encoders in Asia and Leine & Linde
are continuing to increase their
market share.
”It’s important to be able to
speak the customers’ language and
to be near them geographically,”
says Somnath Mukherjee, office
manager at Leine & Linde in New
Delhi.
”Leine & Linde have had an office
in China for some time, and
the new Changwon and New Delhi
offices are part of a strategy aiming
to provide high levels of availability
and service to all customers,” says
CEO Björn Zetterlund.
”Many of our customers are also
moving elements of their production
and exporting more and more
to India and Korea. So it’s logical
for us to have a permanent presence
in the region.”
Leine & Linde’s New Delhi office is
opened by Dr. Ewa Björling, Sweden’s
Minister for Trade; Håkan Eriksson,
Leine & Linde’s Global Key Account
Manager and Somnath Mukherjee,
Leine & Linde India.
5

TECHNICAL INFORMATION
Handling pulse encoder cables
When a pulse encoder is installed, attention must be paid to the fact that the
connection cables can only tolerate a certain level of stress. The cable specifications
must always match the requirements of the application. Cheap cables
often reduce system function and are seldom a good investment in the long run.
If cables are pulled, coiled, bent or subjected
to pressure they can be damaged.
Cables subjected to this kind of impact
should always be replaced.
Leine & Linde recommends that connection
cables for pulse encoders always
be laid in a separate cable duct. In combination
with other measures, this improves
the EMC properties for the entire
installation. If there is only one combined
cable duct available for signal and power
cables, the signal cables should be bundled
together and positioned as far away
as possible from power cables. There are
several advantages to separation:
Better EMC properties
Better protection from damage, for
example if bigger power cables are laid
in the same duct at a later point
Simpler fault tracing during maintenance.
If despite everything there is disturbance
from surrounding equipment, Leine &
Linde’s Optolink solution can always be
used. Transmitting pulse encoder signals
via an optical fibre cable eliminates the
risk of disturbance.
Unused cables in multiconductor
Cable conductors should always be
regarded as live, during installation as
well as when the system is operational.
Unused cables must therefore always be
insulated to prevent short circuits.
Mechanical damage to cabling
Pulse encoder cables should always be
laid in an earthed aluminium or steel
pipe when they are placed near to moving
machine parts. When the cable is laid,
particular care must always be taken to
ensure the cable is not subjected to mechanical
impact.
Storage and transport
During storage, transport and installation,
pulse encoder cables should be kept
sealed at both ends or be kept in their
protective packaging. This is to prevent
oxidation of the individual cables, their
shields and protective sheaths. It is also
important to prevent moisture collecting
in the cable.
Surrounding environment
If the pulse encoder’s stated maximum or
minimum temperature is exceeded, this
can damage the electrical or mechanical
properties of the cables. The temperature
readings for installed cables should
always match the temperature readings
for the pulse encoder at the installation
point. In flexible installations, where the
cable moves, the temperature readings
for the cable and the encoder may differ.
In such cases, always contact Leine &
Linde for more information about your
cable variant.
Elasticity
Cables should not be subjected to more
stretching than they can cope with during
handling and installation.
Pressure on cables
Always avoid pressure on the cable. This
can arise in connection with incorrect
installation.
Twisting / rotation of cable
Twisting or excessive rotation of the cable
can lead to destruction of the wires
or insulation of the cable. Cables should
therefore not be twisted unless they have
been specially designed for that purpose.
Bending radius
The cable’s permitted bending radius
must be maintained. Failing to do this
can lead to damage or to a reduction in
the transmission capabilities of the cable.
Please note that the permitted bending
radius is often higher when the cable
moves in its application than when it is
installed in a fixed position.
Loops
Try to ensure that the cable does not
form loops when it is installed in an application.
This can lead to poorer EMC
resistance and mechanical damage. The
cables must be installed without being
twisted. When you install the cables,
make sure that they cannot be subjected
to any unpermitted impact at a later
point once they
are installed.
Dirt, grease, oil and vibrations… An environment
that Leine & Linde’s encoders
are well able to cope with. The picture
shows the assembled product at one of
SSAB’s plants.
SSAB, a wor
Hans Bondegård, electrical engineer on
the format line, meets us at the gates to
the huge SSAB Borlänge plant in Sweden.
After we have been issued with visitors’
passes and protective clothing we drive
into the area. Here you don’t walk from
door to door; you have to drive around
this enormous area.
Hans has worked at
SSAB for 32 years,
and during our
visit it becomes
clear that he is
extremely knowledgeable
about
his field.
Hans shows us the
way in to the production line belonging to
the format line production section.
”Here thin plate is shaped according
to the customer’s request with regard to
thickness, width and length. The thinnest
plate is just 3 mm thick and the thickest
is around 16 mm. The raw material is
supplied in large coils in pre-determined
thicknesses, direct from SSAB’s rolling
mill,” explains Hans.
The format line produces around
350,000 tons a year and the staff work in
five shifts. Production never stops. The
whole process operates as a single line
and the department is therefore called
simply the format line. There’s hardly
anyone along the production line. Hans
laughs and points to a cabin. The staff sit
in there, controlling the whole work process
via monitors and control systems,
which explains the lack of people in the
area.
6

Impulse visited steel manufacturer SSAB in Borlänge to see how Leine & Linde’s encoders function in the
harsh environment they are made for. The encoders play a crucial part in the production of SSAB’s thin plate.
Jessica Zetterberg from Leine & Linde visits
SSAB. Here she is seen in front of the coils.
–
ld player that focuses on its customers
The start of the line is where the actual
coils are centred. The positioning of the
coil is important, as it must be centred in
the straightener. Along the line are several
encoders, both absolute and incremental.
Hans says that he is just about to
install a multiturn absolute encoder with
a draw-wire unit from Leine & Linde. This
encoder will provide information on the
position of the large coil. Hans has great
hopes for the new encoder, as previous
measurement methods have not been
satisfactory.
In the double straighteners the plate is
bent and stretched to remove all tension
in the material. The straighteners also
have Leine & Linde pulse encoders, used
to reset the gap to suit the thickness of
the raw material.
Once the tension is gone, the plate can
be trimmed and cut to the correct length.
The cutting is done using dividing shears.
Here there is an absolute encoder making
sure the material is cut to the right
length.
Three samples are taken from each coil,
one from the start, one from the middle
and one from the end.
”Quality is absolutely crucial for SSAB
and our customers are always at the
centre of what we do. Poor quality means
no customers,” Hans explains.
Once cut correctly, the plate must be
straightened once again to remove any
remaining tension. As soon as the final
straightening is complete, the plate is
labelled to make it traceable – quality is
considered here too.
We are now approaching the end of
line. This entire process takes about 15
minutes per coil. All that is left is stacking
of plates by weight and height according
to the customer’s request, and,
of course, packaging. The machine that
stacks the plates has several Leine &
Linde encoders installed. The most important
is an absolute encoder that indicates
the positioning of the plates. Then
it’s time to move the plates to the warehouse,
from where they will be picked up
by a transport company for delivery to
the customer.
Why did you choose Leine & Linde
”They are easy to get hold of and provide
a good service. And the new website really
deserves praise. The encoders have
to be durable if they are going to cope
with the harsh environment in this
industry,and I’m a satisfied Leine & Linde
customer,” concludes Hans.
Roots in the 1800s
Today’s Swedish steel industry started
to take off at the end of the nineteenth
century. At that time small-scale steel
mills were being replaced by larger
steelworks to cater for growing international
competition. In 1872 it was
decided that a new steelworks should be
built in Borlänge by the Domnarv rapids,
Domnarvets Jernverk. The decision was
taken after the railway line was built
between Falun and Göteborg. Borlänge
provided the ideal location. By the
middle of the twentieth century, Domnarvets
Jernverk had grown into a large
company. Thanks to modernisations
and rationalisations, at the beginning
of the 1970s Domnarvets Jernverk had
as many as 6,300 employees. In the
mid-70s the steel industry had to undergo
restructuring once more due to
the energy crisis. The result was that the
steelworks at Norrbotten, Domnarvet
and Oxelösund merged following a Riksdag
resolution in 1977. SSAB – Svenskt
stål AB – was formed. Today SSAB is a
world-leading supplier of high-tensile
steel with customers and companies
all over the world. The group’s sales
amounted to SEK 29.8 billion in 2009
and it has been listed on the Stockholm
stock exchange since 1989.
7

IMPULSE Autumn / Winter 2010
TECHNICAL INFORMATION
The art of choosing the right shaft coupling
To put it in simple terms, the purpose of a shaft coupling is to transfer rotational force from one shaft to another. To do this effectively,
the coupling must have a high torsional rigidity. Factors that should be taken into account when a shaft coupling is to
be specified are: torsional rigidity, backlash, torque, environmental factors that affect the shaft coupling and its mounting system.
Common to all installations of pulse
encoders with a solid shaft end is that
a good quality shaft coupling should be
chosen. This ensures a good service life
and measurement accuracy.
Choosing the right shaft coupling
The following guidelines will help you
choose the right shaft coupling:
The coupling must be able to tolerate
the displacements that can occur between
the shafts
The coupling must be able to transfer
the required torque
The coupling must be able to cope
with the required rotation speed
The coupling must comply with environmental
and space requirements on
site.
Installation and handling
Like a pulse encoder, a shaft coupling
is a component that must be handled
carefully by trained staff. Leine & Linde
recommends that you always replace
the shaft coupling whenever a new pulse
encoder is installed.
The following guidelines will take you
through a correct installation that will
give the coupling the maximum service
life:
Make sure that the shafts are smooth
and undamaged, and that they can
penetrate the bore of the shaft coupling
Install the coupling by holding the
encoder while at the same time rotating
the coupling back and forth as you
pass it along the shaft
Do not use any more force than the
coupling can cope with when it is extended
or pushed together.
Properties of different shaft couplings
Nickel
bellows coupling
High-performance
precision coupling
with excellent kinematic
properties.
First-class applications
with strict
requirements for
measurement accuracy.
Membrane
coupling
Precision coupling
with excellent kinematic
properties.
Dynamically balanced
construction.
High-speed applications
where exactness
is required.
Harsh environments
with independent
drive shafts.
Description
Areas of application
Speeds
Sliding disc
coupling (Oldham type)
Multi-purpose
coupling. Robust,
user-friendly threepart
coupling with
replaceable components.
Easy to fit.
Applications where
simple installation
and electrical insulation
are required.
Double loop
coupling
Exceptional tolerance
for angles
and radial and axial
movements.
Normal applications
with limited
speeds and with low
requirements for
accuracy.
Max 5000 rpm Max 5000 rpm Max 3000 rpm Max 3000 rpm
Max torque for a ø10mm shaft coupling
328 Ncm 5,6 Nm 4 Nm 1,8 Nm
Angle 8º
Radial 0,46 mm
Axial 2,07 mm
Max displacement compensation for a ø10mm shaft coupling
Angle 3º
Radial 0,2 mm
Axial ±0,2 mm
Temperature
Angle 0,5º
Radial 0,2 mm
Axial ±0,1 mm
Angle 15º
Radial 3,2 mm
Axial ±7,5 mm
-40ºC to +120ºC -40ºC to +120ºC -20ºC to +60ºC -40ºC to +100ºC
Electrical insulation
No No Yes Yes
Clamping or set
screw
Type of fitting for encoder shaft
Clamping or set
screw
Clamping or set
screw
Set screw
Leine & Linde AB | PO Box 8, SE-645 21 Strängnäs, Sweden | Visiting address: Olivehällsvägen 8
T: +46-(0)152-265 00 | F: +46-(0)152-265 05 | E-mail: info@leinelinde.se | Website: www.leinelinde.com