world of industries 3/2017 (EN)

www.world-of-industries.de
Hannover Messe 2017:
Adding value
with Industry 4.0
in cooperation with

MDA Events Worldwide
Join the No. 1 Trade Fair Network for Motion, Drive & Automation
Germany Hannover 24 - 28 Apr 2017
23 - 27 Apr 2018
China Shenzhen 28 - 30 Jun 2017
Shanghai 31 Oct - 3 Nov 2017
Canada Toronto 25 - 28 Sep 2017
Montreal 2 - 4 Oct 2017
Italy Milan 4 - 6 Oct 2017
USA Chicago 6 - 9 Nov 2017
Chicago 10 - 15 Sep 2018
Turkey Istanbul 15 - 18 Mar 2018
www.hannovermesse.de/worldwide

WELCOME
Welcome to the
world stage for the
factory of the future
Robots that are as easy to operate as smart phones. Machines that
learn from their own mistakes. Products that also carry services.
These examples represent only a small sample of what is possible in
the age of networked production; they also illustrate how the
borders between traditional engineering and IT are disappearing.
Whichever you choose to call it – Industry 4.0, Integrated Industry or
Industrial Internet of Things – the outcome is clear: Digitalization is
transforming industry.
Consequently, business leaders face important decisions about the
future. Which Industry 4.0 applications and solutions best suit their
purposes? How does Industry 4.0 integrate with existing manufacturing
and energy systems? Will the investment help create new
products or lines of business? And perhaps most importantly: How
do they remain competitive?
HANNOVER MESSE is the only event in the world that showcases
digitalization’s full potential for industry. Our lead theme this year,
“Integrated Industry – Creating Value”, once again sets the stage for
the world’s leading industrial event: From 24 to 28 April, 6,500
companies will gather in Hannover to present their latest products
and services for the factory of the future.
So it is no wonder that HANNOVER MESSE attracts managers from
small and medium-sized companies as well as CEOs from global
enterprises like Apple, Foxconn, Microsoft, and Volkswagen.
Everyone wants to keep up with the trends, and that is exactly what
they find in Hannover – from applied research, cobots and digital
twins to Integrated Energy, predictive maintenance and smart
materials. Plus, they can participate in more than 80 conferences,
forums and matchmaking events.
In 2016, about five-and-a-half million business contacts were
generated at the fair. Clearly, HANNOVER MESSE is also a great
place to do business. So save
the date in your calendar
and let us know how we can
help you plan your visit.
I look forward to seeing you
in April.
Warm regards,
Marc Siemering
Senior Vice President,
HANNOVER MESSE
-Deutsche Messe AG-
Editors-in-chief:
Dipl.-Ing. (FH) Winfried Bauer
Email: w.bauer@vfmz.de
Dipl.-Ing. (FH) Dirk Schaar
Email: d.schaar@vfmz.de
Dipl.-Ing. (FH) Michael Pfister
Email: m.pfister@vfmz.de
Editorial board:
Peter Becker
Dipl.-Ing. (FH) Nicole Steinicke,
Dipl.-Ing. Manfred Weber
Svenja Stenner
Assistant editor:
Svenja Stenner
Design/Layout:
Sonja Schirmer, Doris Buchenau,
Anette Fröder, Mario Wüst
Epaper designer:
Katja Rüdell, Mathias Göbel
Managing editor:
Dipl.-Ing. (FH) Winfried Bauer
Publishing house:
Vereinigte Fachverlage GmbH
Lise-Meitner-Str. 2, 55129 Mainz, Germany
Commercial Register No.:
HRB 2270, District Court of Mainz
VAT-ID:
DE149063659
Managing director:
Dr. Olaf Theisen
Publishing director:
Dr. Michael Werner, Email: m.werner@vfmz.de
Correspondent India:
Sushen Haresh Doshi M.Sc.
Advertising sales director:
Beatrice Thomas-Meyer
E-Mail: b.thomas-meyer@vfmz.de
Advertising sales manager:
Oliver Jennen, Email: o.jennen@vfmz.de
Andreas Zepig, Email: a.zepig@vfmz.de
Sales representatives
Austria
Heinz-Joachim Greiner
Email: verlagsbuero-greiner@vfmz.de
France
Marc Jouanny
Email: marc-jouanny@wanadoo.fr
Great Britain, Ireland
Roberto Tondina
Email: roberto@ts-communications.co.uk
Italy, Switzerland
Hermann Jordi, Email: info@jordipublipress.de
Sweden, Finland, Norway
Malte Mezger
Email: verlagsbuero-mezger@vfmz.de
USA, Canada
Bill Fox, Email: bfox@hfusa.com
Advertising disposition:
Annemarie Benthin, Email: a.benthin@vfmz.de
Helge Rohmund; Email: h.rohmund@vfmz.de
In cooperation with:
Hannover Fairs International GmbH
Messegelände, 30521 Hannover, Germany
Internet:
www.world-of-industries.de
WORLD OF INDUSTRIES 3

TABLE OF CONTENT
14
20
03 WELCOME TO THE
WORLD STAGE FOR
THE FACTORY OF
THE FUTURE
06 WORLDWIDE NEWS
08 GERMANY: THE
EURO ZONE’S
GROWTH ENGINE
10 HANNOVER MESSE
2017 TO EMPHASIZE
ON THE BENEFITS OF
INDUSTRY 4.0
14 PARTNER COUNTRY
2017: POLAND AT
ITS INNOVATIVE
AND DYNAMIC BEST
16 INNOVATIONS YOU
DEFINITELY
SHOULDN’T MISS AT
HANNOVER MESSE
18 POLYMER BEARINGS:
LONG-LASTING AND
COST-EFFECTIVE
ALTERNATIVE TO
METAL BEARINGS
20 HIGH PERFOR-
MANCE ROLLING
BEARING MATERIAL
FOR PARTICULARLY
DEMANDING
APPLICATIONS
22 PRODUCT NEWS
24 TECHNOLOGIES FOR
SMOOTH PORT LOGISTICS
26 CONTROL TECHNOLOGY
THAT MOVES AIRCRAFTS
ON THE GROUND SAFELY
30 USER-FRIENDLY
VARIABLE-FREQUENCY
DRIVES FOR INTRALOGIS-
TICS SYSTEMS
MOTION, DRIVES & AUTOMATION
like us on facebook
INDUSTRIAL AUTOMATION
30
WORLD OF INDUSTRIES
HANNOVER MESSE
4 WORLD OF INDUSTRIES

44
52
36 BLOCK I/O
MODULES SIMPLIFY
THE DIRECT RFID
INTEGRATION
38 INDUSTRIAL PC
– EXTREME SPACE-
SAVINGS AND
FLEXIBILITY
40 VISION-GUIDED
COLLABORATIVE
ROBOTS
52 COMPRESSED AIR
FOR THE SMART
FACTORY
54 FULL-SERVICE
PACKAGE FOR
COMPLETE PEACE OF
MIND
56 PRODUCT NEWS
42 STABLE LOGISTICS
THANKS TO
PERMANENT
NETWORK
MONITORING
44 WHEN E-CHAINS
CARRY SENSORS
HANNOVER MESSE
46 SURFACE FINISHING
AND FILTER EXPERT
OPTS FOR
CONSISTENT
ENGINEERING
COMPRESSED AIR NEWS
54
WORLD OF INDUSTRIES 5
Turkish-Machinery.indd 1 17.03.2017 14:59:23

1
Escha and fortop intensify partnership
With fortop automation & energy B.V., the German
connectivity specialist Escha has had a new sales partner in the
Netherlands for about a year now. So far, both companies have
been very satisfied with the partnership development and want to
extend their cooperation in 2017. In addition to the Netherlands,
the cooperation should also be intensified in Belgium and Great
Britain.
1
www.escha.net
2
Endress+Hauser with confidence into
the current year
Despite difficult market conditions last year, Endress+Hauser grew
the business on a local currency basis. In euros, however, consolidated
net sales declined marginally by 0.2 percent to slightly more
than 2.1 billion euros, mainly due to the impacts of exchange rates.
With a global workforce of 13,003 at the end of 2016, an increase of
51 on the previous year, employment remained constant within the
Group.
www.endress.com
3
Faulhaber strengthens its presence
in Malaysia
Products and services of Faulhaber drive systems have been
distributed in Malaysia by Faulhaber Malaysia Sdn Bhd. since
January 2017. The recently founded sales company is headquartered
in Penang. “The Malaysian market has become increasingly
important for us. On the one hand we have business transfers to
Malaysia, on the other hand there is a growing demand for products
offered by domestic companies,” explains Marcus Remmel,
Managing Director of Faulhaber Malaysia.
2
www.faulhaber.com
4
Reintjes opens a new office in England
Drive specialist Reintjes offers another contact point in
the market. The new Reintjes Britain & Ireland office was the
outcome of the previous sales partner, European Marine and
Machinery Agency, shutting down in the mid 2016. The office will
be managed by the Reintjes Benelux subsidiary in Antwerp,
Belgium.
3
WORLD OF INDUSTRIES
www.reintjes-gears.com
5
Schaeffler increases net income
by 45 %
Schaeffler continued its successful run in 2016. The company
increased its revenue to € 13.3 billion. At constant currency, this
represents a growth rate of 3.4 %. Net income of the parent company
increased by 45 % to € 859 million. The company lowered its net debt
by € 2.3 billion in 2016. Last year, Schaeffler invested around
€ 1.1 billion for capacity expansions and machinery.
www.schaeffler.com
6 WORLD OF INDUSTRIES

NEWS AND MARKETS
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1/2017

Germany: the euro zone’s growth engine
WORLD OF INDUSTRIES
Despite all the geo-political volatilities, like the Brexit,
US election, China losing its economic momentum and
the refugee crisis in Europe; Germany has still
managed to keep its economic growth engine right on
track.
For German economy, 2016 ended on a positive note. The strong
economic activity in the last quarter of 2016 accelerated the
annual GDP more than any analysts could have predicted. The
annual GDP rose to 1.9 % in 2016, beating a 1.8 % estimate. This
growth is mainly attributed to stronger private and government
consumption. Private and household consumption benefited from
a drop in the unemployment rate, which is now at the lowest level
since the country’s reunification more than a quarter of a century
ago. At the same time, government spending was boosted by costs
related to the provision, assistance and shelter for more than 1 million
refugees. Exports grew by 2.5 %, with imports also registering
a growth of more than 3 %. Adding to the positive storyline, the
German government achieved a record fiscal surplus of € 24 billion
(0.8 % of GDP) in 2016 for the 3rd consecutive year, despite the
high added cost of the refugee crisis. The positive trends witnessed
in 2016 could also be seen in the first quarter of 2017. According
to the monthly evaluation reports, German manufacturing PMI
(purchasing managers’ index) stood at 56.4 in Jan and 56.8 in Feb
2017. This was slightly below the preliminary estimates of 57.0. This
index reflects the manufacturing activity, new orders, export orders,
and employment numbers. A score above 50 indicates expansion
in the sector. Some leading economists have raised the forecast for
German GDP and now expect the economy to expand 1.6 % in 2017
instead of the 1.3 %.
Forecasts for engineering sector: Steady export
growth expected
For more than 50 years, industrial exports have been the backbone
of Germany’s constant rise on the world stage. Automobiles, industrial
machinery, electrical machinery and precision machines are
responsible for nearly 50 % of its export revenues. The U.S., China
and major EU economies have been Germany’s top export partners
for a long time. Economists at the German Mechanical Engineering
Author: Sushen Doshi, International
Correspondent for World of Industries
Federation ‘VDMA’ see good reasons to anticipate positive development,
albeit moderate and weighed down with risks of setbacks
due to political uncertainty in US and Brexit.
In 2015, export revenue as a percentage of total revenue reached
49.7 % in the manufacturing sector. Since exports represent such
a large share of German industrial revenue, let’s take a look at the
mechanical and electrical engineering sectors, which represent the
majority of Germany’s exports.
Mechanical engineering:
Germany’s mechanical engineering industry with an export ratio of
62.5 % relies heavily on domestic production. In 2015, total German
mechanical engineering exports rose by 1.7 %. Exports to China
have started to show decline in the last 2 years mainly due to a slowdown
in capital investment and growing competition from local
suppliers. However, exports to the USA are rising with some sectors
recording double-digit growth. German mechanical engineering
should receive a slight boost from the sluggish but relatively stable
economic recovery in western Europe, as well as the robust economic
climate in eastern Europe (excluding Russia).
Electrical engineering:
In the electrical engineering sector which includes computer, electronics,
optical products and electrical equipment, total exports
rose by 6 % in 2015. The demand for computer, electronic and
optical products is expected to be stronger in western Europe as
compared to the demand for electrical machinery. In China, even
though the mechanical sector was struggling to gain some traction,
the electrical engineering products are seeing a decent rise in
demand. In the coming years, Poland is set to become one of the
three most important drivers of macroeconomic demand. Exports
to Poland, the Czech Republic and Hungary together accounted
for over 11 % of total exports by the German electrical engineering
industry in 2015.
In the last few years, China is losing momentum and uncertainties
in other major markets are set to make German exports vulnerable.
Therefore, in order to maintain high volumes and growth rates,
Germany needs to increase its focus on exports to countries like
India, Saudi Arabia, Iran, Vietnam and Indonesia.
Germany’s trade surplus
Steady economic growth and low unemployment led the German
government to record a total surplus of € 23.7 billion (0.8 % of
GDP). In absolute terms, this was the highest surplus achieved by
the government since German reunification. Recently, Germany
was fiercely criticized over its massive trade surplus from Eurozone
8 WORLD OF INDUSTRIES

NEWS AND MARKETS
politicians and Trump’s administration in the US, who are blaming
Germany’s export policy and the Euro for the economic imbalance.
Critics believe that Germany’s trade balance can be systematically
manipulated with the exchange rate. But with today’s integrated
global value chains, even industrial exports now consist many
imported inputs, which means, the effect of exchange-rate fluctuations
on prices and the trade balance is no more a dominant factor.
Germany owes its export success to its strong market position, competitiveness
through innovation and the pricing power of its highly
specialized manufacturing champions. Even Prior to adopting the
common currency, these were the central features of Germany’s
Wirtschaftswunder (“economic miracle”).
Germany’s trade surplus reflects the competitiveness of its exports
but at the same time it also shows the lack of imports and government
spending and investments. It has one of the lowest publicinvestment
rates in the industrialized world. Germany should
improve its digital and transportation infrastructure; strengthen
market mechanisms to encourage more renewable-energy development;
address its shortage of skilled labor; change its taxation policy
provide incentives to invest; and reform its regulations to reduce
uncertainty. With a general election coming up in September, Chancellor
Merkel might be under pressure to debate more on the issue
of trade surplus or increase public spending, as voices in Germany
rise for fiscal loosening. But in a country where voters view fiscal
prudence favorably, it is unlikely to see a major turnaround.
Industry 4.0: opening new avenues
In the words of German Chancellor Mrs. Merkel “Industry 4.0 is the
comprehensive transformation of the whole sphere of industrial
production through merging of digital technology and the internet
with conventional industry.” In short, everything in and around a
manufacturing operation including the production process, the
factory, the suppliers and distributors, even the product itself is
digitally connected, providing a highly integrated value chain.
Industry 4.0 depends on a number of new and innovative technological
developments:
n The application of information and communication technology
(ICT) to digitize information and integrate systems at all stages
of production
n Cyber-physical systems that use ICTs to control physical processes
and systems involving embedded sensors and intelligent robots
n Network communications including wireless and internet technologies
that serve to link machines, devices, work products,
systems and people, both within the manufacturing and with
suppliers and distributors
n Simulation, modeling and virtualization during product design
and the establishment of manufacturing processes;
‘An application of Industry 4.0 based
technologies in manufacturing set up’
The Siemens electronics plant in Amberg (Germany) produces
customized PLCs in a state-of-the-art ‘smart factory’
where product management, manufacturing and automation
systems are integrated. Intelligent machines coordinate the
production and distribution of 950 products with more than
50,000 different variants, for which roughly 10,000 materials
are sourced from 250 suppliers. By linking intelligent machines
with data-rich components and workers, innovation cycles can
be shortened, productivity raised and quality improved: the
Amberg plant now records only 12 defects per million (versus
500 in 1989) and has a 99 % reliability rate.
n Collection of vast quantities of data, and their analysis, immediately
on the factory floor or through big data analysis and cloud
computing; and intelligent tools of predictive maintenance.
In all these sectors, be it ICT, Cyber-physical systems, Network
communications or Simulations, German companies already
have immense technical expertise, which makes Germany and its
companies not just relevant but in fact market leaders right from
the start. Industry 4.0 is expected to have a major effect on global
economies. A report from the European Commission says industry
4.0 can deliver estimated annual efficiency gains in manufacturing
of between 6 % and 8 %. The Boston Consulting Group predicts
that in Germany alone, Industry 4.0 will contribute 1 % per
year to GDP over the next ten years, creating up to 400,000 jobs.
Historically, technological revolutions have created new jobs and
the requirement for different kinds of roles. The nature of manufacturing
work has been shifting from largely manual labor to programming
and control of high performance machines. As in the
past, some jobs will evolve, some will be eliminated, and others
will be created. Workers who are able to make the transition to
Industry 4.0 may find greater autonomy and more interesting or
less arduous work. Employers need personnel with creativity and
decision-making skills as well as technical and ICT expertise. By
2020, labor markets in the EU could be short of more than 800,000
professionals; this shortage may be even more pronounced in
advanced manufacturing settings where big data analysts and
cyber security experts are required.
Photograph: Lead Fotolia z
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Hannover Messe 2017 to emphasize
on the benefits of Industry 4.0
WORLD OF INDUSTRIES
Over the last few decades, Hannover Messe, the
world’s largest industrial trade fair, has been a place
for demonstrating leading industrial technologies and
innovations. In a lot of ways this event showcases the
direction in which the industrial world is heading.
On April 24 th , the gates for the world’s largest industrial trade fair,
‘Hannover Messe’, will be open for everyone. The show organized
by Deutsche Messe AG, runs from 24 th - 28 th April in Germany’s
northern city of Hannover. Over the last few years, the focus of
this event has been digitalization of the entire industrial ecosystem.
Many innovative companies have displayed various applications
in this context, but at this year’s Messe we can see the technologies
needed for the successful digitalization of industries are fully
developed and ready to be implemented. Small or large, all sorts of
companies have a multitude of high end technologies like Industry
4.0, integrated energy networks, machine learning, predictive
maintenance and collaborative robots (cobots), to choose from.
Decision makers, at all levels often find themselves in a spot, where
it becomes difficult for them to predict what value these modern
technologies can add to their organization. This is where Hannover
Messe 2017 comes in. The challenge now is to make these decision
makers and industry professionals understand the direct and long
term benefits that digitalization offers to their organization.
Speaking at an event, Deutsche Messe’s Managing Board member
Jochen Köckler said that “Challenging people to ‘think outside
the box,’ highlighting the various ways in which digitalization can
add value, and opening up new markets - that’s what this year’s
Hannover Messe is all about, with its lead theme of Integrated Industry
- Creating Value. The show will have around 6,500 exhibitors
and will feature Poland as its official Partner Country .”
Trade Fair Line Up
Hannover Messe covers a wide range of themes with its 7 international
leading trade fairs, at the same time and under one roof. The
topics and exhibits covered at Hannover represent the most fundamental
industry sectors like - Industrial Automation, Motion Drive
and Automation, Digital Factory, Energy, Compressed Air and
Vaccum Technology, Industrial Supply and Research Technology.
The Industrial Automation show is one of the world’s leading trade
fair for factory and process automation and Robotics. At the Motion
Drive and Automation show, manufacturers of power transmission
and fluid power technologies feature prominently in Hannover.
It is one of the most important trade fair for the manufacturing
sector, attracting more than 1200 exhibitors and 80,000 visitors
from around the globe. The strength of the show’s international
reach can be seen from the fact that it draws about two thirds of its
exhibitors from abroad. The Digital Factory is a unique trade fair for
industrial IT solutions and integrated processes. The exhibitors at
Digital Factory present a full array of solutions for tomorrow’s smart
factories – for example, production planning and control software,
data exchange concepts, virtual product development systems and
tools for predictive analysis.
Cobots, Artificial intelligence, these are exciting topics in the
manufacturing industry. But neither the factory of today nor
10 WORLD OF INDUSTRIES

NEWS AND MARKETS
tomorrow runs without compressed air and vacuum technology.
The ComVac show covers the complete range of compressed air
and vacuum technology, from generation and processing to pumps
and measuring instruments to financing and management. The Industrial
Supply show covers wide variety of sectors from lightweight
construction, sheet metal working, surface technology, engineering
ceramics and highly complex machining technology. The visitors
benefit from the sheer range of solutions this trade fair provides.
Creating new business models
When Jochen Köckler talks about opening new markets at this
year’s Hannover Messe, it means a lot more than just acquiring
new clients and customers. A lot of companies all over the globe
talk about smart factories and advanced manufacturing, but Hannover
Messe with its lead theme of Integrated Industry means
much more than smart factories and smart production. The goods
produced by smart factories will stay connected with their manufacturers
throughout their service lives, supplying a constant
stream of valuable data. This data will enable the manufacturers
The motto of Hannover Messe 2017 is
“Integrated Industry - Creating Value”. What does it mean?
Decision makers in the manufacturing and energy sectors need
to identify which advantages of digitalization they can use to
increase their competitiveness. Hannover Messe showcases the
complete value-adding potential of digitalization, so expect to
see not only the latest products and technologies, but also new
concepts, new business models and new markets.
Which innovations do you expect for the show – especially in
the field of Industry 4.0?
Why should engineers and technicians come to this year’s
Hannover Messe?
Because Hannover Messe covers all important industrial topics,
from Integrated Industry and Integrated Energy to lightweight
design, applied research and startups. No other event in the
world provides such a complete picture of global industry.
The Hannover Exhibition Center is completely booked with
6,500 exhibiting companies this year. The highlights include
robots that are as simple to operate as smartphones, machines
that learn from their mistakes and digitally integrated and controlled
energy systems. Plus, we have top trends like Industry
4.0, Digital Twin, Predictive Maintenance, and Smart Materials.
Workforce development is also crucial in the digital age, so
expect more technologies like augmented reality, smart glasses
and tablet computers.
Poland will be the partner country. What do you expect from
this partnership?
Partner Country Poland will promote three key points at Hannover
Messe: reindustrialization, increasing foreign trade and
promoting Polish innovation in industry. Many Polish companies
offer Industry 4.0 technologies, which makes them attractive
partners for foreign companies. Poland will showcase
roughly 150 exhibiting companies across all sectors of the fair,
with especially big contingents in the energy and industrial
subcontracting halls. Partner Country Poland will further
strengthen business and scientific cooperation between Poland
and all countries at Hannover Messe.
Dr. Jochen Köckler, Member of the Managing Board
Deutsche Messe AG
WORLD OF INDUSTRIES 11

WORLD OF INDUSTRIES
to develop additional web-based services and to pursue new business
opportunities outside the boundaries of traditional industries.
At Hannover, companies demonstrate how digitalization can
create innovative and highly customized solutions more quickly
than ever before. The biggest potential of digitalization lies in the
development of completely new business models. Hannover Messe
is increasingly turning into a platform for partnerships between IT
companies and engineering firms, or between startups and major
corporations; something which was previously unheard before.
Rise of the ‘Cobots’
Hannover Messe gives prime importance to collaborative robots
or ‘Cobots’, as they are known. Cobots are designed to work alongside
human workers, assisting them with a variety of tasks. The biggest
advantage these Cobots provide is that they are as simple to
operate, just like a smartphone. Moreover, they are affordable, selflearning
and they can be placed in small-spaced assembly lines.
They are highly adaptable and they are flexible to handle repetitive,
boring and ergonomically challenging tasks. As time goes on, these
Cobots are getting cleverer and cheaper to buy, making them a
cost-effective gateway to the benefits of Industry 4.0, particularly for
smaller companies. Much like drones today, cobots will eventually
develop into a mass market that will give rise to a wealth of totally
new business ideas.
The Energy show: showcasing tomorrow’s energy
system
Digitalization is transforming the energy industry. The energy
system of tomorrow will be fundamentally different from today’s
system which is based on centralized power plants. Creating a
futuristic energy system is not just about digitalizing all the individual
components. It requires a highly co-ordinated effort involving
all the key players and technologies from energy generation, storage
and transmission to distribution. Under the banner ‘Integrated
Energy’ at Hannover, leading companies from all over the industrialized
world cover a wide spectrum of topics including integrated
and smart grids, renewable energy, decentralized supply, energy
storage, energy efficiency. With more than 1200 companies taking
part in the Energy Show on a combined display area of 43,000 m 2 ,
Hannover Messe is about to shape the future of our energy systems.
The Integrated Energy Plaza’s forum programs are organized by
the German Energy Agency (dena) in partnership with a number
of German industry associations, including the VDMA and ZVEI,
offers the visitors a chance to learn more about the key issues
affecting industry.
Poland: the partner country at Hannover Messe
2017
For Germany and many other EU nations, Poland is an important
international trade partner. Poland’s biggest trading partner
is its neighbor, Germany. Machinery, automobiles and electronic
equipment are amongst Poland’s strongest segments. In 2016,
imports and exports generated total foreign trade of more than
€ 350 billion for Poland. Germany is responsible for 23 % of all
Polish imports and 27 % of Poland’s exports. As the Partner Country
at this year’s show, Poland wants to send a clear signal that
the Polish government sees re-industrialization as one of its most
important objectives. Hannover Messe 2017 will be officially inaugurated
by German Chancellor Angela Merkel and Polish Prime
Minister Beata Szydlo.
Photographs: Deutsche Messe AG
www.hannovermesse.de/home
12 WORLD OF INDUSTRIES

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Partner Country 2017: Poland at
its innovative and dynamic best
WORLD OF INDUSTRIES
At the world’s leading trade fair for industrial
technology, Poland will be stepping on the stage in
front of an international audience to make its case as
an attractive partner in a large and diverse range of
industries.
Innovation and growth are two key areas in which Poland is set
to shine as the official Partner Country at Hannover Messe 2017.
Apart from domestic re-industrialization, the country’s main economic
focus is on opening up foreign markets and supporting
innovative Polish companies. Poland has been enjoying rapid and
stable economic growth for many years and is one of the five most
dynamic economies in the European Union. According to Germany
Trade & Invest (GTAI), Poland’s combination of strong gross fixed
capital formation and EU funding are a boon to the mechanical
and plant engineering industry, with Poland’s machinery imports
increasing by 12 % in 2015 alone. Sales of metalworking machinery
also grew by a double-digit figure over the same period. Demand
for new technology is booming in Poland’s energy sector. In 2015,
the sector’s import-to-GDP ratio increased by 16 % on the back of
sustained investment in electric generation and distribution infrastructure.
“Being next-door neighbors, Poland and Germany are already
strong partners. At Hannover Messe 2017, Poland’s industrial sector
will demonstrate its innovative spirit and its dynamic uptake of
digitalization – factors that make it a key player on the global stage,”
remarked JochenKöckler, a member of the Managing Board of
Deutsche Messe, the trade show’s organizer. A Polish Economic Development
Ministry official explains his country’s objectives heading
into Hannover Messe 2017: “As the Partner Country at this year’s
show, Poland wants to demonstrate that it is not just interested in
rapid economic development for its own sake. Our country’s development
must be sustainable and it must be driven by an innovative
industrial base. Among the core components of this base I would
name industrial automation and industrial IT, energy, alternative
powertrain solutions, and compressed and vacuum-air technologies.
Another objective of our Partner Country showcase is to send
a clear signal to the EU that re-industrialization is the way forward
for us all.”
14 WORLD OF INDUSTRIES

NEWS AND MARKETS
Poland’s Morawiecki Plan
Poland’s government has in fact clearly set out its economic policy
direction in what has come to be known as the ‘Morawiecki Plan’.
Apart from re-industrialization, the plan gives priority to support
for innovative companies, to digitalization, and to greater development
of foreign markets. Under the plan, Poland also wants to
remain an attractive destination for foreign direct investment, while
at the same time encouraging private domestic investment. Digitalization
of Poland’s manufacturing processes is certainly proceeding
rapidly, with digital manufacturing technology accounting for
4.1 % of the nation’s GDP in 2015. Moreover, the Polish government
is actively supporting the process of economic digitization with an
extensive program of financing options for the R&D sector. Another
core focus of Poland’s overall economic strategy is energy. The
renewable portion of the country’s total energy mix currently sits at
just 7 % but is prioritized for expansion.
Around 150 Polish companies will exhibit on about 43,000 sq. ft. of
display space spread across all of Hannover Messe’s 7 constituent
trade shows. The Partner Country showcase will comprise themespecific
group pavilions in many of Hannover Messe exhibition
halls. For instance, NCBR, the National Center for Research and
Development, will be running a pavilion at the Research & Technology
show in Hall 2. Meanwhile, the Polish government’s central
pavilion will be in Hall 3. This is the heart of the showcase and will
feature group presentations by ten of the country’s provinces. There
will also be Polish group pavilions dedicated to industrial subcontracting
(Hall 4), the foundry industry (Hall 5/6), electrical engineering
(Hall 13), heating and cooling supply technology (Hall 27)
and electric transportation (open-air site).
Photograph: Deutsche Messe AG
www.hannovermesse.de
COVERING THE 4TH INDUSTRIAL REVOLUTION
CUSTOM TAILORED
DRIVE SOLUTIONS FOR
Machine Tool
Aerospace
Automotive
Renewable energy
www.world-of-industries.de
Brandenburger Strasse 10 D-88299 Leutkirch im Allgäu
phone +49 7561 98248-0 info@ate-system.de
www.ate-system.de
Please find media informations
here: www.vereinigte-fachverlage.info
WORLD OF INDUSTRIES 15
WIN_Anzeige_Hinweis_Homepage_90x130_2017_03.indd 1 27.03.2017 13:57:47
ATE.indd 1 21.03.2017 15:17:26

Innovations you
definitely shouldn’t miss
at Hannover Messe
CHOICE
Encoders with high precision
and signal quality
Highly reliable
couplings for engine
New high-tech seal
materials from COG
HANNOVER MESSE
Faulhaber expands its portfolio with
the high-precision IER3 and IERS3
encoders. Both encoders are highly
precise and have an excellent signal
quality, thanks to the optical measuring
principle. A DC-micro-motor or
brushless servo can be positioned
with an accuracy of 0.1 to 0.3° with the
IER3 and IERS3. Encoders are
therefore the ideal solution for
high-precision positioning applications.
These encoders form a singlechip
opto-reflective system, as the
LED, photo-detectors, the analysis
unit and interpolation levels are
installed in one chip. Both encoders
are available with Line Driver, which
generates complementary output
signals and makes the transmission of
data particularly resistant to electrical
interference. The IER3 provides the
highest resolution for its class (up to
10,000 lines per revolution). The
encoder achieves an angular resolution
of 0.009° with the evaluation of
40,000 edges per revolution. The high
resolution results in high control
dynamics and precise speed control.
www.faulhaber.com
The couplings experts at Reich-Kupplungen
have designed the new highly
flexible TOK couplings specifically to
meet the high requirements of engine
manufacturers and test bench
operators. The design of the TOK
series manages the critical resonance
frequencies of the drive train to below
the operating speed range. By
employing torsional vibration
calculations and dampening the
alternating torques generated by the
engine’s combustion process, all the
drive components are protected
against critical shocks and loads, thus
increasing the service life and
availability of the entire installation.
Designed for speeds of up to 10,000
rpm, they offer a high torsional
flexibility and torque transmission
capacity from 100 up to 70,000 Nm
and are particularly well suited in test
benches for combustion engine
testing. Their design also permits them
to be used on flexibly mounted
engines in various drive trains. It
comprises coupling sizes for a torque
range from 1 600 to 140,000 Nm.
www.reich-kupplungen.com
Today, the requirements for seals are
getting more and more complex.
Companies now require seals to be
temperature, vapour, pressure and
chemical resistant. For such applications,
the company, COG has developed
a new range of high quality
‘FFKM’ material ‘COG Resist’. The
company launches 4 new compounds:
2 universal materials, 1 special FFKM
compound for use in the oil & gas
industry and 1 for the food & pharmaceutical
industry. The 2 universal
materials, COG Resist RS 75 AL and RS
80 AL demonstrate outstanding
resistance to chemicals, acids and a
low gas permeability. RS 75 AL is heat
resistant up to temperatures of 325 °C,
and RS 80 AL up to +260°C. The COG
Resist RS 92 AED seal material was
developed for applications where
resistance to explosive decompression,
high pressure, extraordinary
chemical and thermal resistance is
required like the oil and gas sector.
COG Resist RS 75 HS developed for
the highest demands of the food and
pharmaceutical industries.
www.cog.de
16 WORLD OF INDUSTRIES

NEWS AND MARKETS
IMI Precision Engineering
launches 4 new products
Visitors to IMI Precision Engineering’s
booth can experience various fluid and
motion control technologies through a
highly interactive display. The company
is transforming its IMI Norgren product
range by launching a new generation of
3 platform pneumatic products.
ISOLine, an advanced range of ISO
standard pneumatic cylinders offers
improved performance and a ‘fit and
forget’ system that adjusts the cylinder
cushioning to changing loads. A new
generation of flange valves is being
added to the IMI Buschjost range. The
valve piston features a proven Labyrinth
technology that makes it robust enough
to withstand surges in back pressure.
www.imi-precision.com
Energy and data
transmission
The single-cable technology can
contribute greatly to save material
costs and space, by achieving power
supply and data transmission through
one single cable. Kübler’s single-cable
technology is based on the proven
RS485 hardware architecture - this
architecture is a widely established
standard in many frequency converters.
The interface is fully digital,
open-source for the sensor and the
drive system, SIL3 - capable and
perfectly suited for dynamic axes with
very high accelerations, uniform
speed control and best positioning
accuracy possible. Kübler encoders
with the single-cable technology are
ready for Industry 4.0.
www.kuebler.com
Baumüller’s servo converters
talk Powerlink
Baumüller, is now offering its servo
converter series ‘b maXX’ with a
certified powerlink interface. The
series consists models such as b maXX
2 500, 3 300, 4 400 and 5 000, all of
which are now available with a
certified Powerlink interface. In
addition to EtherCAT, Baumüller also
supports powerlink and standard
Ethernet as well as fieldbus systems,
such as Sercos, EtherNET/IP, CANopen,
ProfiNet IRT and Varan. With the
software modules from Baumüller,
mechanical engineers and machine
users benefit from pre-programmed
comprehensive features, which
simplify the commissioning of its
servo converters on powerlink
networks considerably and thus help
achieve a faster time-to-market and
high level of error security.
www.baumueller.de/en
DERANTRIEB■ Reliable
■ Versatile
■ Global
NORD DRIVESYSTEMS:
■ Worldwide available
■ Subsidiaries in 36 countries
■ Agents in 52 countries
24–28 April 2017
Please visit us!
Hall 015, Stand No. H31
www.nord.com/locator
Headquarters:
Getriebebau NORD GmbH & Co. KG
Fon +49 (0) 4532 / 289-0
info@nord.com
Member of the
NORD DRIVESYSTEMS Group
The
Gear Unit
■ Strong bearings
■ Quiet running
■ High power density
The
Motor
■ High efficiency
■ Global standards
■ All operating conditions
The
Drive Electronic
■ Compact design
■ Easy implementation
■ Scalable functionalities

Polymer bearings: long-lasting and costeffective
alternative to metal bearings
Today high-performance plastics are used in a
multitude of applications from kitchen appliances to
industrial environments. Bearings made from
high-performance plastics are lubrication and
maintenance-free and are increasingly superseding
metal solutions.
The “motion plastics” of igus, the plastics specialist based in
Cologne, Germany, are resistant to rain, extreme temperatures
and are impervious to oil and chemicals. They are also lighter and
more energy-efficient as compared to metal solutions and most
importantly are cost-effective. Design engineers from all over the
world are now considering plastic bearings as a long-lasting and a
cost-effective alternative to metal bearings. This is due to the special
material properties as well as the excellent performance in motion
that these high-performance plastics offer. The ability to withstand
stationary stress says little about a bearing’s performance capability.
The degree of wear-resistance of a bearing and how low its
coefficient of friction is do not become apparent until it is used in
moving applications, where wear is unavoidable. And this is exactly
where the strengths of high-performance or motion plastics are.
Largest combination of materials and dimensions
The company, igus has been developing and producing polymer
bearings for over three decades under the brand name “iglidur”. The
bearings are self-lubricating and therefore maintenance-free; they
can withstand enormous loads and are light in weight. The materials
are developed and tested in the industry’s biggest test laboratory.
In an area of around 2,750 sq. metres, more than 135 billion test
movements are executed each year. The result of more than 30 years
of R&D, is the largest standard range of lubrication-free polymer
bearings. Around 50 materials are available, including 16 full-range
materials. They are in stock in at least 113 dimensions and
up to a shaft diameter of at least 50 mm in accordance
with DIN ISO3547; the largest catalogue bearing has an
inner diameter of 195 mm. In addition, there are many
materials available in the form of bar stock, liners or for 3D printing,
filament or SLS powder. Polymers enable a great deal of design freedom:
with little effort, even extremely complex parts can be made
or their characteristics can be significantly influenced by means of
specific additives. This is precisely the core competence of igus: the
optimisation of technical polymers for use in moving applications.
Wear-resistant and lubrication-free
HANNOVER MESSE
About Igus
Igus GmbH is a leading manufacturer of energy chain
systems and polymer plain bearings. The Cologne-based
family business has offices in 35 countries and employs
around 2,950 people around the world. In 2015, igus
generated a turnover of 552 million euros with motion
plastics, plastic components for moving applications. igus
operates the largest test laboratories and factories in its
sector to offer customers quick turnaround times on innovative
products and solutions tailored to their needs.
To this end, igus has its own material development department,
which is continually coming up with new iglidur materials to match
specific areas of use. The individual components of the compounds
are mixed homogeneously during the injection-moulding process.
The excellent performance of iglidur plastic bearings derives from
this homogeneous structure, whereby the basis of an iglidur bearing
consists of thermoplastic polymers that ensure the bearing’s
good basic resistance to wear. Fibres and filling materials increase
the bearing’s load-carrying capacity. In addition, solid lubricants
have been included in the material. All the components work
together and result in very good sliding and abrasion properties.
In contrast, rolled metal bearings have a layered structure. The
inner layer is very thin and, in the event of high loads, edge pressure
or vibrations, can easily be stripped off or damaged by dust particles.
Moreover, the sliding layer represents a limit to the degree of possible
wear. The homogeneous composition of the plastic compounds,
in contrast, is considerably more robust as the wall thickness of the
bearing acts as a ‘wear zone’. Unlike iglidur bearings, which made
of high-performance plastics, bearings made of metal alloys have
to be permanently lubricated, a disadvantage that is cost-intensive
18 WORLD OF INDUSTRIES

MACHINE ELEMENTS
01 Igus bearings are developed and tested in the
industry’s biggest test laboratory on 2,750 m 2
02 Igus offers the largest standard range of lubrication-free polymer bearings.
Around 50 materials are available, including 16 full-range materials
and also time-consuming. What’s more, lubrication with grease or
oil is becoming increasingly unpopular for hygienic and ecological
reasons. Sinter bearings that are commercially available also have oil
lubrication incorporated into them and are therefore not dry-operating
bearings. The same applies to rolling bearings, which, especially
in the case of needle bearings, are often being replaced with iglidur
plastic bearings for technical and economic reasons.
Application in agricultural machinery sector
The agricultural industry alone is a good example of the potential of
plastics bearing technology from igus. The iglidur bearings that are
used in agricultural machinery are extremely wear resistant and can
cope with high surface and edge pressures. They are non-corrosive and
resistant to impacts. Fertilizers, slurry or fuels have no effect on their
ability to function. The machines can therefore be used reliably even
after being out of use for a long time. Especially in agricultural environments
where machines can be exposed to extreme amounts of dirt,
iglidur bearings guarantee optimum functionality and long operating
times. The Cologne-based company has developed special materials
in the form of ‘iglidur Q2’ and ‘Q290’, which are specially suitable for
typical agricultural applications involving slow pivoting at high loads.
Application in the food industry
In the food and packaging industry, the absence of lubrication also
plays an important role in view of the strict hygienic and safety standards
in these sectors. According to the regulations of the Food and
Drug Administration (FDA), it must be ensured that products are not
contaminated by lubricants or other substances. As a consequence,
only plastics that are FDA-compliant and suitable for use with food
are used in these sectors. In contrast to metals, plastics are always
non-corrosive due to their organic structure and are also resistant to
inorganic media, including acids, dyes and aqueous salt solutions.
Plastic bearings from iglidur are being used by various manufacturers
of food processing machines. The biggest advantage being that
polymer bearings are not sensitive to water, penetrating through the
seal during cleaning and maintenance, as the metal bearings are.
The plastic machine elements, on the contrary, are characterised by
a low level of water absorption and are resistant to chemicals.
cases. Which material is the right one for the respective use can be
quickly determined with the help of online tools such as the Product
Finder, the Configurator or the Service-life Calculator. Users
can click on their special requirements (“Longest service life with
dry operation”, “Dirt-resistant”, “Vibration-dampening”, “Resistant
to chemicals” etc.) and indicate the permissible static surface pressure
and the upper and the lower operating temperatures.
Cost-effecitve polymer bearings
In all branches of industry, polymer bearings have been replacing
metal bearings. For engineers, the wear-resistance, low coefficients
of friction, the non-corrosiveness of the motion plastics and freedom
from lubricants have become indispensable as they increase the service
life of their machines and are also up to 40 % less expensive than
metal bearings. New materials and properties are continually opening
up further possible uses for polymer bearings, igus is continuing
its research activities in the company’s own technical facility. Given
that development in the area of shaft materials and surface treatment
does not stand still, continuous tests that react to shaft changes
and are aimed at a perfect matching of shafts and bearings are
absolutely critical. Especially the issue of running partners illustrates
the versatility of iglidur bearings, which can be used on very different
shafts – and above all on cost-effective, so-called soft shafts. This is
a clear advantage over many other types of bearing. In addition to
the cost benefits associated with plastic bearings, the user can also
utilise a non-hardened shaft and thus reduce his costs even more.
It is important to choose the shaft that is best in terms of price and
performance, depending on the application in question.
www.igus.eu
03 Find the right
material with the
igus product finder
Special materials for respective application
For most typical bearing applications, five standard iglidur materials
are used. But at the same time the demand for specific materials
used for specific applications is growing. From underwater use to
high-load applications, from medical technology to the automotive
industry: Igus has developed tailor-made materials for all these

High performance rolling bearing material
for particularly demanding applications
HANNOVER MESSE
When rolling bearings fail prematurely in the steel,
mining, or railway industries due to contamination or
inadequate lubrication, this ends up costing the
operator many 10000 of € every day. Schaeffler has
carbonitrided the new Mancrodur rolling bearing
material as a solution for such difficult cases. This
provides more than twice the operating life compared
to standard rolling bearing materials.
For a long time now, materials experts have been trying to make
steels for rolling bearing less sensitive to contamination. This is
because when a particle penetrates into the raceway of the rolling
contact, the displaced material produces a bulge, which is subjected
to a lot of stress every time the rolling element rolls over it. The material
very quickly becomes fatigued at this spot, which leads to the
formation of micro-cracks and causes the bearing to fail prematurely.
Inadequate lubrication gives rise to friction
Inadequate lubrication can also cause micro-cracks, although the
process is a different one. The tangential (tensile) stresses arising
from the rolling contact in the raceway are readily tolerated with the
proper design and full lubrication. However, if the lubrication in the
rolling contact is insufficient, then the rolling partners touch metalto-metal
in places, with the high metallic friction between the rolling
partners, it causes the temperature in the surface to go up considerably.
This rise in temperature not only ages the lubricant, but also
decrease the strength of the steel – even to a point where tangential
decreases are able to produce micro-cracks in the bearing material.
A material needs to be hard as well as soft!
The effects of contamination and inadequate lubrication on the
material can generally be handled well with a ductile surface.
The softer and more malleable the material surface, the better
and faster the bulge will smoothen out, thereby reducing the high
stresses around the foreign particle. No cracks are formed, and material
fatigue is greatly delayed. However, this results in a conflict
of interests that needs to be resolved. It is necessary for bearing surfaces
to be very hard and the material to have high fatigue strength
so that the bearing will attain a load-carrying capacity as high as
possible. Offering solutions to the conflict of interests, Schaeffler
demonstrates its new ‘Mancrodur’ rolling bearing material
combined with carbonitriding. Meanwhile tests results show that
these new bearings have more than twice the operating life under
extremely demanding conditions.
Special heat treatment of Mancrodur
During carbonitriding, carbon and added nitrogen are embedded
in the surface layer. On the one hand, this increases the surface
hardness, and on the other, the heat treatment specially tailored to
the Mancrodur steel forms a microstructure with finely distributed
spherical carbides. In comparison, conventional rolling bearing
steels have carbides with an elongated needle shape. They are not
only embedded in the grains, but are also at the grain boundaries,
thereby increasing the risk of crack formation. In Mancrodur, the
carbides are distributed more uniformly in the material and not
concentrated as much at the grain boundaries, helping to make
the material more ductile. (Fig. 01 and 02). Temperature-stable retained
austenite at a percentage with a tight tolerance increases the
ductility of the new rolling bearing steel even more. The combined
effect of these individual microstructural properties decreases the
risk of crack formation considerably where there is either contamination
or inadequate lubrication. The raceway surface is harder,
more resistant to wear, and yet more ductile.
Higher load rating with full lubrication
The new high-performance rolling bearing steel features two other
properties as well. There is less temperature-related loss of strength
due to inadequate lubrication compared to other steels, reducing the
risk of micro-cracks even further. In addition, the heat treatment is set
up in such a way that residual compressive stresses are concentrated
on the raceway surface. These compressive stresses reduce the resulting
tangential stresses (tensile stresses) caused by the rolling contact.
Under normal lubrication conditions (full lubrication), carbonitrided
Mancrodur offers a 30 % higher load rating due to its material composition
and heat treatment, equivalent to a 240 % increase in the
nominal operating life. Test results with full lubrication have shown
that the operating life of Mancrodur is up to six times longer. However,
in harsh environments with contamination, mixed friction, or inadequate
lubrication and heavy loads – like those that can be found in the
railway and steel industries and sometimes in the area of wind energy
as well – it is endurance tests under difficult conditions and experi-
20 WORLD OF INDUSTRIES

MACHINE ELEMENTS
ence from pilot projects that really count. The field experience so
far with carbonitrided Mancrodur is very promising.
Higher operating life in steel industry
One of the largest hot strip mills of Thyssenkrupp Steel Europe
(TKSE) is located at its Bochum site. The hot strip mill is specially
designed for milling high-tensile quality steels. The rolling bearings
need to be able to withstand 45 million Newtons at high temperatures
and with a large amount of contamination. After downtimes
occurred because of the premature failure of conventional bearings,
TKSE installed four-row FAG tapered roller bearings made of carbonitrided
Mancrodur. The international steel producer has confirmed
that these bearings have a significantly longer operating life.
01 Grinding patterns from case-hardened steels
(left) and carbonitrided Mancrodur (right)
Higher load-carrying capacity in wind turbine
gearboxes
This is how Bernhard Köhler, Business Development Manager in
the Regional Wind Business Unit at Schaeffler, describes the current
situation in the development of wind turbine gearboxes: “Since
design lifetimes of at least 20 years apply in the wind energy industry
– corresponding to 175,000 hours – and the bearing positions
more and more frequently max out the planetary bearings’ load
ratings, the industry is in desperate need of bearing solutions
that will provide longer bearing life even under extreme lubrication
conditions.” With a load-carrying capacity that is 30% greater
and an operating life that has now been all but proven on the test
stand to be at least twice as long, the wind energy industry can once
again tap into margins of higher power density and longer runtimes
by using carbonitrided Mancrodur. “For instance, downsizing
planetary wheel bearings makes it possible to increase the wall
thickness of the planetary wheels or the ring gear within the same
installation space, which is precisely where the limits of feasibility
are often reached. Besides the lower mechanical load of the gear
rings, the greater wall thickness also reduces their elastic deformation,
improving meshing considerably,” explains the specialist.
02 Comparison of the effect of mixed friction on the operating life
of bearings made of standard bearing material with that of bearings
made of carbonitrided Mancrodur
Handling overloading in freight transport
“Occasionally, operators will look for various non-standard ways to increase
the productivity of their machines and facilities. In rail freight
transport, for example, this might be done by regularly overloading the
freight cars with over 10% more payload than specified by the design,”
stresses Schaeffler Senior Manager Matthias Kilian. He goes on to say,
“The overloaded bearings, such as inch-based AAR class K bearings
(AAR = Association of American Railroads) with about a 157 mm bore
therefore need to be replaced early and often unexpectedly. The premature
material fatigue is usually the result of the mechanical overload
combined with mixed friction and excessively long maintenance intervals
for these load conditions.”
By exchanging the axlebox bearings with structurally identical bearings
made of carbonitrided Mancrodur, the operator can still have
the increased payloads while returning to reasonable maintenance
intervals, and it will no longer be necessary to purchase new bearings
as frequently. However, the greatest economic benefit for the operator
comes from the fact that the cars’ existing bogies can still be used.
“Otherwise, the operator would have to resort to the next larger bearing
series, such as AAR class G bearings with a bore that is around 20 mm
larger, which would naturally make larger wheelsets, wheelset shafts,
and other bogie components necessary,” Matthias Kilian explains.
Photographs: Schaeffler
www.schaeffler.com
03 Benefits of Mancrodur depending on application area
About Schaeffler AG
Schaeffler Group is a leading integrated auto motive
and industrial supplier. The company based in Herzogenaurach,
Germany, generated revenues of approximately
13.3 billion Euros in 2016. With around 86,600
employees, Schaeffler is one of the world’s largest
family owned companies. The group has approximately
170 operating locations in more than 50 countries
with a worldwide network of manufacturing plants,
research and development centers, and sales subsidiaries.
Schaeffler makes key contributions towards
‘mobility for tomorrow’ with precision components
and systems in engines, transmission and chassis
applications as well as rolling and plain bearing solutions
for industrial applications.
WORLD OF INDUSTRIES 21

Product News
Measurement becomes nanoprecise
Wittenstein, the mechatronics drive specialist, will unveil the
IDS3010, an Industrial displacement sensor with sub-nanometer
resolution at the upcoming Hannover Messe 2017. IDS3010 is
ultra-compact, highly dynamic and a contactless inteferometric
measuring sensor. With a data acquisition bandwidth of 10 MHz, it
can simultaneously track targets in up to 3 axes at velocities of
2 m/s. The sensor provides 10-12 m position resolution and
reaches working distances of up to 5 m. As officially confirmed by
the German National Metrology Institute (PTB), IDS3010 enables
accuracies previously unheard of in industrial position sensing.
The sensor is also compatible with extreme conditions such as
ultra high vacuum, very high or low temperature or radioactive
environments. This innovative sensor can be used to calibrate
machine tools, detect vibration amplitudes in machines, measure
the concentricity of motor shafts,
crankshafts and camshafts or implement
ultra-precise pick-and-place
robotic applications, for example
in the semiconductor industry.
www.wittenstein.de/en-en
New manufacturing facility in Romania
for Timken’s roller bearings
As a global supplier of tapered roller bearings, The Timken
Company is all set to increase its market share in Europe, with the
opening of another production plant in Romania. The existing
plant in Romania manufactures large-bore roller bearings. The
new plant will be located nearby and will complement the existing
manufacturing sites for tapered roller bearings in France, Italy and
Poland. This means the company is geographically well-positioned
to be more responsive to customer needs at peak times. The new
facility will have 120 new employees on a space of 15,000 m 2 .
At Hannover Fair, Timken will discuss how optimized
materials, surfaces, geometries, and designs can
benefit manufacturers and end-users by helping
reduce noise, support higher loads and prolong
service life. Timken is also presenting a newly
extended range of spherical roller bearings and
a wide range of long-lasting and low-maintenance
couplings.
www.timken.com
Linear dL wonderbox
esign freedom ... no oil
... low-cost
igus ®
dry-tech ® ...lubrication-free bearings made easy
Lubrication-free technology
and the largest linear toolkit
drylin ®
W: linear bearings for quiet and easy operating,
insensitive to dust and dirt. Configured and installed
quickly and easily. From single bearings to linear
actuators and 3-axis-gantries. Low cost, delivery
time from 24 h.
HANNOVER MESSE
www.lineartoolkit.eu
Order your free sample box today!
plastics for longer life from 24 h
®
Free sample:
Tel. +49-2203-9649-145
Visit us: Hannover Messe – Hall 17 Booth H04
Igus.indd 1 14.03.2017 14:57:51
22 WORLD OF INDUSTRIES

Brake Technology 4.0 at Hannover Messe 2017
With Industry 4.0 gathering momentum, more and
more companies are presenting their applications.
With Brake technology 4.0, Mayr power transmission
is offering reliable safety brakes, which are equipped
for the challenges for the fourth industrial revolution.
Brake technology 4.0 by Mayr stands for monitoring
modules of the latest generation. Modules such as
the ‘Roba-brake-checker’ allow permanent brake
monitoring. These modules monitors the switching
condition as well as the tension path or tension force
reserve without sensors and detect safety-critical
changes in voltage, air gap and temperature. On
reaching the tension path reserve, the module
therefore sends a warning signal indicating that the
brake can continue to be operated for a certain
amount of time at an early stage. During this time, the
machine owner can undertake targeted maintenance. The perfectly-coordinated
system guarantees utmost level of operational and functional safety, and also
increases the productivity of machines through preventative fault detection and
maintenance.
www.mayr.com
Smart motors ready for Industry 4.0 at Hannover
Messe 2017
As an exhibitor at the Hannover Messe 2017, the company Dunkermotoren, is set
to present its wide range of DC and BLDC motors with gearboxes, encoders and
brakes. The company will also display its new planetary gearbox range PLG
63/75/95, a high power version with up to 160 Nm torque. Furthermore, the drive
specialist puts on display, how they set up their products for the future-factory.
Integrated intelligence and sensors inside the motors are the basis for data
analysis, energy and condition monitoring and predictive maintenance. For the
communication inside the network, Dunkermotoren offers their motors with the
latest industrial field-Bus and Ethernet interfaces. With motors and various
drive systems from Dunkermotoren working at a high efficiency, they
are able to support the factory’s demand-based distribution
of energy. A visit to company’s exhibitor booth at
Hannover Messe 2017 sounds fun, as the company offers
the opportunity to participate in ‘cash box’ which
promises light hearted action and prizes.
www.dunkermotoren.com
High-temperature grease for rolling bearings
The new ‘Klübersynth BHE 46-403’ grease has been developed to meet the
long-term requirements for lubrication of rolling bearings subjected to high
loads. The innovative lubricant design of the fully synthetic, high-temperature
grease reliably contributes to extending the component life across a wide service
temperature range. Additives were carefully selected to provide wear and
corrosion protection, and reduce frictional resistance for long runtimes. Thus, a
lasting increase in efficiency can be attained depending on the component
design. It was especially developed for the lifetime and high-temperature
lubrication of rolling bearings subject to sliding friction, i.e. tapered roller
bearings, cylindrical roller bearings and spherical roller bearings. Klübersynth
BHE 46-403 can also be used as a sealing grease or for the lubrication of rolling
bearing seals, thus contributing to product streamlining and minimising the risk
of lubricant mix-ups.
www.klueber.com
WORLD OF INDUSTRIES 23
Turkish-Machinery.indd 1 17.03.2017 14:59:23

Technologies for smooth port logistics
Ports facilitate international trade and commerce. The
giant cranes and ground conveyors that handle the
loading and unloading of cargo are one of the most
important piece of equipment for any port to be
successful. In order to ensure smooth operation of
these gigantic machines, hydraulics plays an extremely
important role.
Ports are an important aspect of the modern economy. They play
a key role as important shipment hubs for a variety of goods.
They are complex, high-performance centers and a key economic
factor all over the world. In this busy environment, the international
tech giant ‘Continental’ is doing its bit to ensure fluidity in operations,
and plays a vital role in the construction of new ports.
Jade Weser Port, Germany’s only deepwater port, during the
construction of this mega-project, the contractors were in need of
floating hoses. They contacted Continental for their hose requirements.
Special-purpose hoses were used for shifting 12 million
cubic meters of sand from the dredgers. Continental also supplied
the high-quality, special-purpose hoses for transporting concrete to
HANNOVER MESSE
24 WORLD OF INDUSTRIES

MACHINE ELEMENTS
01 In the Batumi terminal in Georgia, highly resistant bunkering hoses
from Continental transport fuel oil, carburetor fuels, and hot asphalt to
and from the ships
02 The special TractorMaster tire has been specially designed for tractor
units deployed for handling operations in port terminals and forwarding
agent’s yards
container terminals under construction. Whether it is deepening of
the port on the coast, river deepening for inland water transportation,
or land reclamation for expanding terminals, companies have
counted on Continental and its technological expertise wherever
they require regular clearing of waterways. For these tasks, companies
need highly wear-resistant hoses that are not only durable and
flexible, but also meet individual customer requirements. Along with
wear-resistance and flexibility, safety is of equal importance here.
The floating hoses are designed to withstand three times the pressure
stipulated in the planning data. The floater dredges deployed
to perform such tasks are also equipped with conical mounts from
Continental to ensure the required stability. These components continuously
compensate for the movements and shifts in weight that
occur as a result of the extreme stresses. Installed on the ring mount
in the dredger, the mount ensures that the water engineering vehicle
always stays on course during construction operations.
Solutions for mobile dockside logistics
Wireless signals allow the crane operators to locate the assigned
bays for goods from all over the world. Everything works fully
automatically. In tandem operation, the LHM 600 Litronic from
Liebherr – a mobile dockside crane for heavy goods and project
cargo – can load up to 320 metric tons of general cargo. The dockside
cranes move very slowly and avoid tight curves. Continental
offers a range of special tires for these mobile colossi. The ‘Crane-
Master’ tires can support extremely heavy loads and, thanks to their
low rolling resistance and, in turn, lower energy consumption, meet
the stringent demands of these vehicles. Meanwhile, Continental’s
drive solutions ensure maintenance-free, low wear solutions for lifting
systems and ground conveyors. As alternatives to chain drives,
polyurethane flat belts featuring ultra-high-strength steel cord tensile
members are ideal for a host of challenging applications.
Continental’s technology and products are also deployed for
forklift trucks as well. Axle boxes help to cushion the front axles,
ensuring that the chassis runs quietly. For Linde’s electric stacker
386’, two special axle boxes made from natural rubber were developed.
These take up very little space and ensure mobility when the
lift pole is tilted. The boxes absorb the three-dimensional loads generated
when the stacker is in operation as follows: The load from the
lift pole is absorbed vertically, while the load generated when the
stacker is in motion is absorbed horizontally. In addition, the noise
emissions from the forklift truck are permanently reduced. Continental
also offers the special ‘TractorMaster’ tire for port logistics.
This product has been specially designed for tractor units deployed
for handling operations in port terminals. These tires allow large and
heavy loads to be transported – and all that with uniform wear to
prevent the tread from tearing. The tire is highly damage-resistant,
has extremely low wear, and helps to cut not only fuel consumption
but also CO 2
emissions. And with StraddleMaster, ContainerMaster,
DockMaster, and Continental CraneMaster, the highly resistant
‘V.ply’ tires for port fleets also help to ensure smooth operations in
port environments.
In the trucks that unload the containers from the ships for onward
transportation, air springs featuring lightweight plastic pistons save
weight and fuel – for example, in the Mercedes-Benz Actros. Continental
also develops sleeve air springs that gently cushion the driver’s cab.
Handling oils and fuels safely
Bunker hoses are used for conveying heavy fuel oil, carburetor fuels,
and hot asphalt to and from the ships. Whether in Hamburg, Rotterdam,
Antwerp, or Batumi, Georgia, these highly resistant hoses from
Continental are essential for conveying these substances either
onto dry land or onto the ships. When in operation, they have to be
absolutely safe and reliable in order to avoid environmental damage.
Decades of knowhow in the production of hybrid hoses lead
to ever-improving product quality. And what’s more, when iron ore
or coal in Rotterdam, Hamburg, or Narvik in Norway needs to be
extinguished, oil-resistant and fire-retardant, energy-optimized
covers from Continental ensure problem-free unloading to the
designated bays – highly efficient and energy-saving.
Photographs: lead and 01 ContiTech, 02 Continental AG
www.contitech.de
About Continental AG
Continental AG develops intelligent technologies for
transportation of goods. The company is known to be a
reliable partner that provides sustainable, safe, comfortable,
and affordable solutions. In 2016, the corporation
generated preliminary sales of € 40.5 billion with its five
divisions, Chassis & Safety, Interior, Powertrain, Tires,
and ContiTech. Continental currently employs more than
220,000 people in 56 countries. As a division in the Continental
Corporation, ContiTech is one of the world’s leading
industrial specialists. With around 43,000 employees
in 44 countries, the company generated sales of approximately
€ 5.5 billion in 2016.
WORLD OF INDUSTRIES 25

Control technology that moves
aircrafts on the ground safely
Continuously increasing air traffic volumes are a
constant challenge for ground operations at the
airports. The aircraft tow tractors from the company
Goldhofer, fitted with STW’s control technology are a
big help - providing safe, economical and flexible
movement of the aircrafts on the ground.
At “Inter Airport Europe 2015”, the world’s largest trade fair for
airport equipment and technology, the company ‘Goldhofer’
presented the ‘AST-2P/X’, its new generation of high speed aircraft
towing tractor. Using the AST-2P/X, a wide range of aircrafts from
Embraer170 up to the Boeing B777-300ER and the Airbus A340 can
be moved.
The AST 2 of the fourth generation is characterized by a new, compact
and modular vehicle concept. The hydrostatically driven steering
mechanism and axle delivers optimum traction, even in case of
low superimposed load. For airport management companies that
require the towing tractors, they can choose between two engine
powers for the vehicle which offers a 3-circuit braking system which
optimally distributes the braking force for maximum stability and
safety. The engines fulfill all required international emission stan-
dards, Euro IIIa or IVf. The airplane power supply during towing
operation is ensured via a Ground Power Unit (GPU), which can be
retrofitted into each of these vehicles. Ground operations at airport
entail a lot of waiting periods. The automatic start-stop function
which is installed in the AST 2 provides a high cost savings potential.
This function provides not only a substantial reduction in the
diesel consumption but it also brings down the maintenance costs,
as maintenance intervals depend directly on the operating hours.
These factors help in reducing the “Total Cost of Ownership” (TCO).
Drive Line Controller (DLC)
The AST-2P/X has a diesel-hydraulic drive system as its central component.
It is built on a pump and two hydraulic engines, which drive
a differential steering axle via a summation gearbox. The pump and
the engines are controlled with electrical proportional adjustment.
The energy for the drive system is supplied by a 231 KW (optional: 283
KW) Cummins QSL9 diesel engine. The drive system is controlled
by the DLC or the Drive Line Controller. The DLC is responsible for
managing the entire drive and limiting the tensile forces depending
on the type of the aircraft. During the towing process, only a limited
tensile force may be applied to the nose wheel (Fig. 1). The tensile
force limitation in the DLC is realized through a dynamic, high pressure
regulation, which again varies from aircraft to aircraft. In addition,
the DLC is also responsible for the automatic start-stop function.
ESX-3XL – Freely programmable control unit by STW
HANNOVER MESSE

Dynamic Solutions Expertise.
For a Dynamic Industry.
Whether hose lines for hydraulic oils and other media, vibration isolation systems,
drive belts, pneumatic air actuators for machine and plant engineering, or many
more solutions – as a leading development partner for high-quality plastic and rubber
components, we offer dynamic solutions expertise for a dynamic industry.
Visit us in
Hall 6, Booth F18
Hannover Messe
24. - 28. April 2017
www.contitech.de
Industrial Competence Worldwide

in cooperation with
Fluidtechnik
Antriebstechnik
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in cooperation with
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Antriebstechnik
REACH INTERNATIONAL
DECISION MAKERS!
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Selection of the DLC control platform
During the towing operation, DLC is the heart of the towing tractor.
Therefore selecting the right DLC is extremely crucial. For
the selection of the drive control, focus was mainly on a flexible
and high power control unit which would be in a position to reliably
execute the functionalities related to safety. The control unit
should be adaptable to other types of aircraft tractors and provide
the required performance to safely cover the current and future
requirements. The 32-bit control unit ESX-3XL Safety from the
company Sensor-Technik Wiedemann (STW) seems like a perfect
solution that caters to all the requirements. The ESX-3XL is certified
according to the DIN IEC 61508: SIL 2 and DIN EN ISO 13849: PL d
standards (Fig. 2).
The control unit is based on a 32-bit Tri-Core controller with
a 150 MHz core, 4 MB RAM, 6 MB Flash and 32 kB EEPROM. In
addition to the flexible adaptation possibilities in the basic version
– e.g. all inputs can be configured via the functions in it as current/
voltage/digital or rpm inputs – the possibility to extend the device
via expansion boards represents an outstanding feature of the ESX-
3XL. Because the control unit can be configured with up to six of
these boards, it simply provides more flexibility to the operation. At
the moment, 14 expansion board versions featuring different inputs
and outputs, in addition to RS232 / RS485 / CAN interfaces and a
programmable Linux system including Ethernet and USB are available.
Generally, development environments for programming in
“C”, Matlab and Codesys are available. For the development of the
DLC, the development environment Codesys in version Codesys
Safety SIL2 was chosen (Fig. 3).
DLC: safety functions and standards
INTRALOGISTICS & DISTRIBUTION
INDUSTRIAL AUTOMATION
01/2017
www.engineering-news.net
www.engineering-news.net
01/2017
MOTION, DRIVE & AUTOMATION
01/2017
01/2017
In accordance with the applied standards, a risk analysis for the
drive functionalities was carried out, which required several
functions to be in a safety level of AgPLr ≥ c. Safety-orientated
development represents a substantial cost factor during product
development and during maintenance of the subsequent product.
Therefore, particular attention was paid during drafting of the
technical safety concept to a clear and unambiguous definition
of the safety functions and their assignment to the appropriate
software components. The focus was placed on keeping safetyrelevant
parts as simple as possible and creating clear interfaces
between safety-relevant and non-safety-relevant software parts.
In the software architecture, this is presented in appropriate safety-relevant
and non-safety-relevant modules (Fig.4). The clear
assignment of functionalities and the precise definition of the
interface between the two software worlds is always meaningful.
But it will only lead to cost reductions for development and
maintenance if the separation of different software components
is supported by the hardware.
www.engineering-news.net
www.engineering-news.net
www.world-of-industries.de
About Sensor-Technik Wiedemann
GmbH (STW)
The company Sensor Technik Wiedemann, based in
Kaufbeuren Germany, develops a wide range of products
in measurement technology, control and automation
systems, telematics and machine connectivity. The company
also offers services in system design, implementation
support and software solutions for communication
and control functionality. STW caters to companies that
are manufacturers of mobile machines and industrial
vehicles both on and off-road. The company has subsidiaries
in UK and USA, and employs more than 440 people.
Please find media informations
here: www.vereinigte-fachverlage.info

MACHINE ELEMENTS
IEC 61508-3, 7.4.2.9 defines that software parts with different safety
classifications are to be developed on a control unit in accordance
with the highest safety level, unless they are suitably independent
through temporal and spatial separations. The ESX-3XL control
unit supports temporal and spatial independence of application
parts by providing appropriate memory protection and watchdog
functionalities. With the supplied safety mechanisms software with
different safety requirements can be independently executed on the
ESX-3XL. This opens up the possibility for the development team to
develop non-safety-relevant parts of the application in accordance
with a simplified development and verification process.
Optimum DLC parameterization reduces costs and
complexity
The objective was to guarantee a standard compliant parameterization
of the DLC. In addition, it was necessary to verify that
parameter changes to non-safety-relevant application parts would
not have any effects on the safety relevant application parts, in order
to keep the required validation and verification expenses as low as
possible here, too. Basically, every additional parameterization provides
additional complexity, additional error sources and therefore
increased validation and verification expenses. Accordingly, attention
was paid in the specifications and design of the safety relevant
modules to limit the number of parameters to a minimum. The
process of safe parameterization is supported via the ‘ESX-Kefex’
toolchain. This Toolchain is part of the ESX-3XL development environment
and comes with a detailed user and safety manual. The
‘ESX-Kefex’ toolchain has been certified for use in projects with
safety requirements in accordance with DIN IEC 61508: SIL 2 and
DIN EN ISO 13849: PL d.
Disconnection of safety-relevant / non-safety-relevant components
The entire development process including risk analysis, hardware
assignment, preparation of safety concept, software architecture,
implementation and verification has been realized in close coordination
between STW and Goldhofer, which has resulted in a safe,
maintainable and optimally tuned drive system.
Photographs: Lead Photo Goldhofer AG, 01-03 STW GmbH
www.sensor-technik.de/en
Power Transmission Engineering
Fluid Power
New Edition: VDMA Directory 2017
Power Transmission Engineering and Fluid Power
„Motion, Drive & Automation“
• Economic/Technical Situation of German Manufacturers
• List of German Suppliers
• Company Profiles
HANNOVER MESSE 24. – 28.04.2017, Hanover
Pick up your free copy at the VDMA booth in hall 19/A52
or contact us: fluid@vdma.org

User-friendly variable-frequency
drives for intralogistics systems
In general, conveyor technology and intralogistics
require drive control systems which can be simply
installed and are easily accessible during operation
and maintenance. Field distribution systems from
Nord Drivesystems provide exactly this as well as
significantly reduced system costs.
About Nord Drivesystems
A developer and manufacturer of drive technology
for over 50 years, Nord Drivesystems employs more than
3,300 people and is one of the world’s leading suppliers
of drive solutions. In 2016, the company’s gross sales
amounted to EUR 560 million. With subsidiaries and
distributors in 89 countries around the world, Nord has
an extensive service network. Nord’s wide variety of gears
covers torques from 10 Nm to 250 kNm and more. The
company also supplies motors with outputs from 0.12 kW
to 1,000 kW and manufactures frequency inverters up
to 160 kW. Nord’s inverter line-up features conventional
models for installation in control cabinets as well as fully
integrated drive units and the all-new field distribution
systems for decentralized automation environment.
The company Nord Drivesystems has developed a new line-up of
user-friendly, low-maintenance electronic drives for intralogistics
systems. These new frequency inverter and motor starter models
for distributed installations are especially easy to deploy and operate.
Coded plug-in connectors ensure comfortable handling throughout
a system’s lifetime, from the initial installation, to maintenance, to
eventual replacement. Branded as the Nordac Link series, these
devices provide very flexible feature customization options that can
be configured to individual requirements: interface ports, manual
switches, and a range of functions that even include closed-loop
control and sequential control managed by an integrated PLC.
Distributed drives must execute commands from a higherlevel
central control system with absolute reliability. In many
scenarios, however, operating staff and service technicians may
also require optional direct access to individual drives or drive
axes on location. Such access enables them to quickly resolve small
problems like a jammed conveyor belt that might otherwise lead
to a shut-down of the entire line, sometimes putting hundreds of
conveyor modules out of work for a considerable amount of time.
Nord Drivesystems has therefore developed the new ‘Nordac Link’,
an electronics drive for particularly convenient and time-saving
operation and maintenance.
Key features of the new drives are coded plug-in connectors for
all power and communication lines, as well as for various sensors,
actuators, and encoders. These greatly facilitate accurate, quick,
and safe connections. LEDs on the field distribution systems
enable error diagnostics on the production floor, and operators can
HANNOVER MESSE
Featuring plug connectors and flexible
switch and interface configurations, the new,
compact Nord field distribution systems make
installing, operating, and servicing conveyor
installations easier than ever
30 WORLD OF INDUSTRIES

DRIVE TECHNOLOGY
Basic data for Nordac Link
n Protection class: IP 55, IP 65
01 Nord configures complete drive systems,
combining field distribution systems with
high-efficiency geared motors
n Power range: 0.55 – 7.5 kW
n Voltages: 1/3~200-240 V, 3~380-500 V
Functions
n High precision with current vector control
n PLC for motor-related functions (PLC on Board)
n Energy-saving function for partial load operation
n Control and parameterization tools and simple parameter
structure
n Integrated line filter for compliance with EMC regulations
n Operation with synchronous and asynchronous motors
n Control and closed loop regulation
n ‘Posicon’ – Integrated positioning mode and synchronization
n STO and SS1 – Integrated functional safety
n Integrated brake rectifier for motor brake control
n Load monitor
n Hoist and lifting gear functionality
n Master / Slave operation
remedy problems then and there using the maintenance and control
switches on the drives. The compact units are designed for wall
or frame mounting. Featuring a busbar for the mains supply, they
can be daisy-chained with short cabling from one drive to the next,
which saves time and expenses. The field distribution systems are
able to control asynchronous or synchronous motors. They come
with comprehensive certifications for operation everywhere in
the world. The drives support Profibus, CANopen, DeviceNet, and
AS-i communication, as well as the Industrial Ethernet protocols
ProfiNet, Ethernet Powerlink, EtherCAT, and EtherNet/IP.
Expert solutions for conveyor applications
Distributed conveyor drives have been a focus for drive technology
developments at Nord for many years, resulting in a versatile portfolio
of distributed drive electronics that cover a considerably wider
range of functions than competing products. In 2009, the company
first introduced motor-integrated frequency inverters featuring
rotary encoder feedback, position control, hoist functions, and
Safe Stop. 2015 saw the addition of a PLC in motor-integrated drive
units. Now, years of experience in various sectors and close cooperation
with customers have led to the new line of field distribution
systems. These intelligent drives with a proven user-friendly user
interface can be flexibly configured for a wide range of conveying
tasks. An integrated PLC and PI controller functions even enable
the establishment of autonomous modular systems. Frequency
inverters and motor starters in the 0.55 to 3 kW performance range
are immediately available. Now in 2017, inverters for motors up to
7.5 kW rated output will also be added to the line.
Reliable drives with a high overload capacity
Nordac Link series motor starters control soft starts and stops, as
well as reversing operation in fixed speed applications. Just like
inverter-type field distribution systems, these wear-free electronic
switches integrate extensive monitoring and protection functions
– this saves the cost for typical control cabinet components
such as motor circuit breakers and reversing contactors. In more
demanding drive applications, frequency inverters ensure efficient
and precise speed control and wear-free brake actuation. Employing
field-oriented vector control, they deliver the required speeds
reliably even under great load fluctuations and provide full torque
even at standstill. These AC vector drives have a high overload
capacity of 150 % for one minute and up to 200 % for brief periods.
An integrated load monitor prevents damage to the equipment in
case of blocked applications. The inverters also support direct connection
of incremental and absolute encoders. Multiple drives in
master/slave operation can synchronize speed or positions. Additional
optional features include the STO (Safe Torque Off) and SS1
(Safe Stop 1) safety functions according to EN 61800-5-2.
Photographs: Getriebebau Nord GmbH & Co.KG
www.nord.com
02 The Nordac
Link line comprises
soft and reversing
starters (a) and two
frequency inverter
sizes for motors
from 0.55 to 7.5 kW
(b + c)
a b c
WORLD OF INDUSTRIES 31

Product News
HANNOVER MESSE
EtherCAT measurement technology
modules - accurate and fast
With accurate data
arriving from Beckhoff’s
new EtherCAT measurement
modules, the raw
material and energy
consumption can be
optimized, while it also
forms the basis for
condition monitoring and
predictive maintenance.
With these modules,
high-end measuring
devices and traditional
automation technology
can be combined into one universal system. For this purpose,
Beckhoff offers a combination of a comprehensive I/O system that
supports all common sensor types, and TwinCAT as a central
software platform. This new generation hardware ensures extremely
high-quality measurement data, with measurement accuracy of
100 ppm at 23 °C, precise synchronization of < 1 μs, and a high
sampling rate of up to 50,000 samples per second. Beckhoff offers
11 modules with different interfaces and input circuitry. They can
cover, for example, voltage measurement of 20 mV to 30 V, current
measurement of ±20 mA, thermocouples, RTD (PT100/1000), or
load cells. The measuring ranges of the input channels can be
flexibly parameterized, both electrically and on the software side.
www.beckhoff.com
Direct operated DC
valves for closed
loop controls
Parker Hannifin, the
specialist in motion
control technologies,
has completed its range
of direct operated proportional DC valves with the new zero lap
spools for the D1FC/D3FC series. This option makes the use of
the valves for closed loop controls possible. The most important
innovation for the D1FC/D3FC is a position feedback system
which is completely integrated in the housing. The direct
coupling of the sensor to the spool also facilitates precise control
of the spool position. Thanks to the integrated position feedback
sensor, there is no need for an exposed cable connecting to the
position control; this alleviates the risk of potential faults through
inadvertent breaking of the connection. The robust, compact
valves stand out with their new zero lap spools as well as their
high dynamics and repeat accuracy in closed loop controls.
Thanks to the inbuilt digital electronics, the valve parameters can
be flexibly adapted with Parker’s ProPxD parameterization
software.
www.parker.com
Danfoss debuts new generation of
‘O rbital X’ motors
Danfoss Power Solutions recently
launched the new product line of
motors ‘Orbital X’. The new
motors will replace the current
OMP, OMR, DS and DH motor
models. In comparison to existing
models, Orbital X has up to 15 %
higher torque capacity than current OMP or OPR motors, and up to
45 % more than current DH and DS motors. It also offers to
improve the bearing capacity by 20 % over DH and DS motors.
Furthermore, the shaft seal lifetime is improved by 50 % and the
motor has a finish that meets the corrosion class C3 standard. Two
new modular platforms will replace six existing options. With new
modular platforms, Orbital X increases flexibility in use, improves
application performance and reduces the total cost of ownership
for OEM customers. Along with the physical product launch,
Danfoss also debuted a line of Orbital X app to improve user
experience and customer response time. OEMs will have direct
access to the product conversion tool, which simplifies the process
of integrating an Orbital X motor.
www.powersolutions.danfoss.com
IO-Link makes sensors fit for Industry 4.0
Industry 4.0 needs sensors that not only collect data but also
communicate the data up to controller and enterprise level. For
this, the company Ifm, opts for IO-Link technology. With IO-Link’s
digital data transmission, the measured values cannot be distorted
by any cable interferences. With IO-Link, the parameter settings
during sensor configuration can be directly adopted from an IO
master, hence saving a lot time. Ifm’s new generation of IO-Link
masters is extremely
robust and offers 2
Ethernet ports with a
switch for Profinet.
The ‘LR Device’
software is used to
configure the
connected sensors
and actuators.
Something completely
new about the
software is that, it
finds all IO-Link
masters in the
Ethernet network and
creates an overview
of the whole plant.
Additionally, ifm offers the Line-recorder, which enables bi-directional
communication between sensors and higher-level ERP
systems. With this system, the data can be transmitted directly to
the ERP system without putting additional strain on the PLC.
www.ifm.com
32 WORLD OF INDUSTRIES

PRODUCT NEWS
Fan blades inspired
from nature
Taking inspiration from
humpback whales, the company,
Ziehl-Abegg is developing its
new radial fan, that allows for
energy savings of up to 10 %. To
improve further, it was essential
to optimize the angle of
incidence between the air flow
and fan blade, which in turn
depends on the flow volume. The
movement of the whale fins
causes the angle to constantly
change. If its pectoral fins were at
an angle too steep to the flow this
would produce a lot of turbulence
as the water passes over
them. Changes in the fan blade
design, create an optimum angle
of flow over the entire span,
hence keeping the turbulence in
control and minimising the
losses. The bionic design of the
blade surfaces reduces the noise
level and its corrugated shape
gives additional strength and
optimises the weight.
Unique technology for stroke measurement in hydraulic
cylinders
Measuring the stroke of a hydraulic cylinders used in mobile machines
is an important task, as this enables the monitoring of the motions
further to be carried out. The company, Siko has developed a unique
system SGH10, for direct stroke measurement in hydraulic cylinders.
Other systems in the market are based on magneto-restrictive, inductive,
or hall based technology. In contrast to these systems, a wire-actuated
mechanism installed directly in the piston head is used to measure
the stroke. This means the entire system is built into the cylinder and cannot be influenced by the
environment. Another advantage is the reduction in costs as this does not need the sensor rods to be
integrated into the piston over the entire measuring path. In the SGH10, just one small thread is
needed in the piston to mount the cable. This allows the system to offer major potential cost savings
for hydraulic cylinders. Another highlight is that, this can even be used in telescopic ylinders.
www.siko-global.com
Visit us at:
Hanover Fair
24 - 28 April 2017
Hall 20 I C50
www.ziehl-abegg.com
Saving time during
assembly
Layher AG is expanding its
product line with the addition
of pressure switches with
integrated plugs. With types 471
and 472, Layher AG adds to the
previous models with integrated
plug, now with two and
three-pin Deutsch plug. This
eliminates the need for
connecting the cable. The
electrical contact is made
reliably and without complications,
simply by bringing
together the mating connectors.
Plug variants such as
M12x1, bayonet plug DIN72585
and Deutsch plugs 2P and 3P
are now available. Depending
on the plug variant, protection
classes up to IP67 or IP6K9K
can be achieved. The pressure
switches are available as
normally open, normally closed
or changeover contacts. They
are also available as a membrane
or piston switch in the
range from 0.5 bar to 350 bar.
www.layher-ag.de/en
nobrox ® – a new, versatile
thermoplastic material for seals
and engineered components
nobrox ® delivers top performance in all relevant material properties
for sealing, guiding and anti-extrusion elements. In adddition, high versatility
and extensive freedom of design make nobrox ® perfectly suited
for engineered components as well. As your partner, Parker Prädifa
helps you meet your sealing and engineering challenges.
Extreme wear resistance and high resilience
Robustness against abrasive particles and rough surfaces
Broad media compatibility and wide application range
www.parker.com/praedifa-hannovermesse

Product News
Linear technology and customized solutions from Rodriguez at Hannover Messe
The power transmission specialist Rodriguez, based in Eschweiler,
Germany manufactures and supplies customized
solutions in motion based industrial applications. The company’s
extensive portfolio for precision bearings covers a wide
range of applications with Kaydon
thin- section bearings, turntable
bearings, large diameter slewing
bearings and many other highquality
components. In the last few
years, the company has expanded
its production capacity for high
precision bearings. Rodriguez has
also optimized some the administrative
tasks regarding purchasing
of small components, which reduces the processing costs and
benefits the customers. Finally, the state-of-the-art machine
park allows the realization and manufacturing of its customized
solutions, the Value Added Products (VAP). At the
Hanover Fair, visitors can also
get information about the
comprehensive product
portfolio of rotary components
and linear tech nology, including
round rails, screw drives
and complete linear systems
from Rodriquez.
www.rodriguez.de/en
A common I/O system for safety and automation
www.pilz.com
Automation specialist, Pilz is launching a new generation of field level devices with
the decentralised I/O system ‘PSSuniversal’ 2. It processes both, safety and nonsafety-related
control signals. Safety and automation are physically mixed but
logically separated. Users can also connect the remote I/Os to higher level control
systems via common industrial communication protocols. Its 3-part system design
allows precise diagnostics and enables errors to be located and rectified quickly.
Modules can even be hot-swapped, the head module can be swapped without
having to re-configure and dismantle the system. Users can themselves build the
system structure on screen via “drag & drop”. With the new configuration tool from
Pilz, users are guided through the manual installation step-by-step. This helps to
avoid errors and the system can be put into service quickly and simply. The merging
of automation and safety functions along with both technical and mechanical
improvements help users to save time and costs right from the planning phase.
HANNOVER MESSE
tailor made
in germany.
The internal gear pump EIPS3.
Visit us:
Hall 21, Booth D39
eckerle.com
Robust power supply with 40 A for adverse ambient
conditions
The new versions from Trio Power, the power
supply range of Phoenix Contact provides a reliable
supply even in adverse ambient conditions. Like its
predecessor, the new 40 A device is robust, both
electrically and mechanically. High system
availability is a top priority for all machines and
systems. This power supply therefore provides
dynamic boost, which also starts heavy loads, with
60 A and thus 150 % of the nominal current for 5
seconds. The robust design, with its high electric
strength, high MTBF (Mean Time Between Failure)
values of over 1 million hours, along with active
function monitoring with an LED and floating signal contact, ensures that all connected
24 V DC loads are reliably supplied. With an overall width of 110 mm, and tool-free
wiring with Push-in connection saves time and space in installation. The extensive
temperature range of -25 to 70 °C guarantees a high level of flexibility in applications. The
wide input voltage range from 320 to 575 V AC enables its use worldwide.
www.pheonixcontact.com
34 WORLD OF INDUSTRIES
Eckerle.indd 1 08.03.2017 09:50:36

Floating caliper brake with one-piece
brake caliper
KTR has developed a floating caliper brake with one-piece brake
caliper being made of special LT nodular iron. This qualifies the
floating caliper brake for applications in the cryogenic temperature
range down to – 40 °C. All other components such as pad
retainers, pistons and guide pins are made of steel. The brake
pads are made of powder metal. Depending on the application’s
preference and basic conditions, the brake can be operated
either hydraulically or electromechanically, with clamping
forces up to 15 kN being generated in the passive design and
16.5 kN in the active design. With the one-piece design, there are
no more bright contact surfaces, hence improving the brake’s
corrosion resistance and making the power transmission from
the brake caliper to the base plate more consistent. The new
float- ing caliper brakes series ‘XS’ are intended for use in
the most demanding environments and can
be used both as service brakes, for
high numbers of cycles and as
stop brakes, even above
ground or underground,
onshore or offshore
applications.
www.ktr.com
Precision roller pinion system in stainless
steel
Nexen Group, Inc. introduces its stainless steel version of ‘RPS’, its
patented precision roller pinion system. RPS engages 2 teeth
simultaneously to achieve superior accuracy and zero backlash.
The system is quiet, efficient and stainless steel makes it extremely
corrosion resistant. RPS provides a low maintenance, durable
alternative to rack and pinion, ball screw and belt drive technology.
This system uses needle bearings to support the rollers that
engage the teeth. This eliminates the sliding friction found in
many other motion control systems, leading to
an efficiency greater than 99 %. High
efficiency means lower frictional and
thermal losses, and wear, providing a
long life of 60 million pinion revolutions
or up to 36 million meters.
Further key features include high
speeds of up to 11 m/s, superior
accuracy of +- 50 µm, zero backlash, and
customized long lengths. The company,
Nexen holds 120 US and international
patents. Headquartered in the U.S it
has its European office in Belgium.
www.nexengroup.com
Eaton showcases integrated industrial technologies at Hannover Messe 2017
Eaton offers machine manufacturers a comprehensive range of
solutions in energy and automation for both electrical and
hydraulic applications. Its cooperation with T-Systems, allows it
to offer industrial applications with cloud based services. A visit
to Eaton at Hannover Messe 2017, visitors can learn more about
the fully integrated industrial technologies that Eaton and its
partners provide. Also the company showcases its developments
in hydraulic and electro-hydraulic systems. The company is now
focusing on helping machine manufacturers to make their
products ready for Industry 4.0. Furthermore, Eaton is actively
supporting the implementation of the OPC-UA standard, both
for M2M and for machine to cloud communication. The
company is presenting a range of innovative energy storage
systems and power distribution systems that can be utilised
within industrial and commercial applications.
www.eaton.com
© GÜDEL
More power !
ROBA ® -guidestop rail brakes
–more braking force
–more holding force
–more safety
www.mayr.com
Visit us at: Hannover Messe, Hall 25 Booth D30
your reliable partner
MAYR.indd 1 16.03.2017 10:28:26
WORLD OF INDUSTRIES 35

Block I/O modules simplify
the direct RFID integration
HANNOVER MESSE
RFID integration must get easier so that it can provide
total transparency in the industrial production of the
future. That is why Turck is presenting two compact
Ethernet RFID interfaces based on its block I/O series.
The multiprotocol devices bring data from HF or UHF
read/write heads via Profinet, Ethernet/IP or Modbus
TCP to the controller. The compact RFID module
enables integration without programming or function
blocks and thus simplifies implementation.
There are many unanswered questions for several aspects of
Industry 4.0. There is, however, a consensus of agreement about
the position of RFID technology in the production of the future: A
highly automated, highly flexible and closely networked industrial
production system requires efficient technology for the identification
of employees, systems, tools, workpieces and products. Due to
its specific benefits, RFID stands out from alternative solutions such
as optical identification – and is therefore without doubt one of the
key technologies for Industry 4.0. The implementation of RFID in
production processes is often still too complicated and time consuming
in many areas. Even though this effort is worthwhile, many
users, particularly in small plants, are put off by what is involved.
RFID applications must become easier to implement if they are one
day to provide total transparency for industrial production.
RFID interfaces simplify integration
With its latest RFID interfaces, Turck has set itself the task of making
integration considerably simpler. Previously, users could essentially
Author: Bernd Wieseler, Hans Turck GmbH & Co. KG,
Mülheim an der Ruhr, Germany
choose between two types of RFID interfaces for Turck’s BL20 and
BL67 modular I/O systems: On the one hand the simple integration
via RFID-S modules (Simple), which transfer data in the bus cycle.
The volume of data here is 8 bytes per cycle – sufficient for a UID
but with UHF communication or large tags with 2 kilobytes the S
module requires long read times. On the other hand, the so-called
A slices (Advanced) are available, which can process larger data volumes
via acyclic bus communication but which require more effort
for their implementation.
The new RFID interfaces are based on IP67 block I/O devices of
the TBEN-S and TBEN-L series and combine the benefits of the two
previous alternatives: a simple integration, combined with high
performance communication. The TBEN-S RFID interfaces in particular
simplify setup in the application by eliminating the need for
controller function blocks. The compact modules communicate
with two RFID read/write heads in the HF or UHF frequency band
and connect an additional four sensors or actuators via the integrated
universal I/Os.
The key feature is the fact that the RFID ports in the controller can
be treated simply like normal I/Os. The difference is simply in the fact
that it is now also possible to process mapped data from read/write
heads instead of the analog or digital value of a sensor. The TBEN-S
interface is set up via a GSDML file instead of via separate controller
function blocks. The data is transferred by the TBEN-S in a prepared
table (mapping table) via the Ethernet interface and can be processed
further by the controller accordingly, i.e. filtered and forwarded to
higher-level systems. The handling of the HF and UHF read/write
heads via the TBEN-S module is largely identical. With UHF read/
write heads it is also possible to set some additional parameters.
Ultracompact and performant
Due to their compact design with a width of only 35 mm and the
high IP67/IP69K degree of protection, the TBEN-S block I/O devices
are optimally designed for retrofitting in production plants. The
user does not require any additional control cabinet since the modules
can be fitted directly in the field – for example, on 40 millimeter
aluminum profiles. Up to two RFID read/write heads in the HF or
36 WORLD OF INDUSTRIES

SENSORS AND MEASUREMENT
Both RFID block I/O modules are suitable for
demanding UHF applications in logistics
UHF frequency band can be connected to each module. Thanks to
the integrated switch, the modules can be configured in a linear topology,
which saves cabling effort. Furthermore, up to 32 HF read/
write heads can be linked via their RS485 interface.
Besides the signals of the two read/write heads, the Ethernet
cable also brings up to four sensor or actuator signals to the controller.
As multiprotocol devices, the modules detect independently
whether communication is being carried out on the Ethernet cable
via Profinet, Modbus TCP or Ethernet/IP and adjust themselves accordingly.
The connection of sensors or actuators also couldn’t be
easier: The universal DXP terminals set themselves automatically
to input or output, depending on whether a sensor or actuator is
connected. The allocation of functions via the controller becomes
unnecessary. Trigger signals can thus be integrated even faster and
actuators such as signal lights can be connected in no time at all.
High performance and integrated web server
In spite of its compact design, the TBEN-S RFID interfaces offer sufficient
performance. They communicate cyclically up to 128 bytes
of user data per channel with the PLC. Through the use of data fragments
in the UHF data interface it is also possible for the module
to process data volumes larger than 128 bytes. Over 100 UHF or HF
tags with 8 kilobytes can thus be detected quickly and conveniently.
This is made possible by the direct transfer of data to the memory of
the TBEN-S module (16 Kbyte per channel).
The integrated web server of the TBEN-S modules enables the
devices to be set up via a PC or via mobile devices. During operation
the web browser is ideally suited for the diagnostics and maintenance
of the connected components and system data. All that
is needed is the installation of an HTML5-capable browser on the
device. Although the “S” of TBEN-S actually stands for “small” – it
could also stand for “simple” on the TBEN-S-2RFID-4DXP.
Codesys 3 on board
The big brother of the TBEN-S adds a bit more weight to the scales,
but also provides added intelligence on board. The TBEN-L interface
offers four RFID ports for HF or UHF readers alike, and eight
universal DXP I/Os for sensors or actuators. The TBEN-L comes
with Codesys 3, thus providing an open system for control tasks.
The mapped RFID data can thus already be preprocessed and filtered
on the module itself. Control tasks can also be programmed
on the basis of the RFID information directly on the module. The
eight universal I/Os can be addressed directly – without any rerouting
via a central controller. This enables smaller machines with
identification tasks to even be run entirely autonomously.
About Turck
Turck is a global, customer-oriented premium partner
for reliable, industry-specific automation solutions. With
leading-edge technologies, wide knowledge and direct
proximity to our customers we optimize your long-term
success. Providing more than 15000 sensor, interface,
connectivity and fieldbus technology products, as well as
HMI/PLC solutions and RFID systems.
The TBEN-Lx-4RFID-8DXP-CDS can also be set to one of the
Ethernet protocols – Profinet, EtherNet/IP or Modbus TCP. However,
this is not automatic, but must be set in the configuration
in the Codesys environment. TBEN-L runs on an 800 MHz CPU,
which accesses a 128 MB DDR3-RAM. The flash memory of the
module is 256 MB. Other differences are in the electrical connection
of the TBEN-L. These are connected via an M12 connector to
the Ethernet and supplied with power via a 7/8” connector. On
the more compact TBEN-S block modules, the power supply and
network connection are implemented via M8 connectors. These
are the most important differences between the two modules.
Other features, such as the integrated switch for linear topologies,
the transfer rate (10 Mbps/100 Mbps), the degree of protection
(IP67/69K) and the integrated web server are offered by both the
L and also the S module.
Outlook
Turck will also offer the TBEN-L RFID interface in a version with
Windows Embedded Compact 2013 for system integrators. This
will thus allow integrators to program middleware functions on the
module in Net, C++ or C#. The communication to the higher-level
system is then not implemented via an industrial Ethernet protocol
but via TCP/IP. Apart from the operating system, the module will
have the same performance specifications as the Codesys RFID
module. Similarly, Turck will also bring a version to the market
with the open Linux operating system – likewise for integrators. The
TBEN-L platform could also provide a system with an OPC-UA interface,
e.g. compliant with the AIM specification for identification
devices. This would thus complete the next step towards Industry
4.0. OPC-UA is the Industry 4.0 blueprint for connecting production
data to higher level MES and ERP systems.
Photos: Turck
www.turck.com
01 In applications using many read/write
heads, wiring effort is reduced by the
possible cascading of the RFID interfaces
02 Compact, robust and simple:
The new RFID interfaces reduce
the effort involved in industrial
identification solutions
WORLD OF INDUSTRIES 37

Industrial PC – extreme
space-savings and flexibility
The new ultra compact Industrial PC from Beckhoff
is designed for universal application in automation,
visualization and communication tasks. As Roland
van Mark, Product & Marketing Management
Industrial PC explains in this interview, the new
model is inexpensive, compact and flexible, opening
doors to application areas that were previously
closed to IPC technology.
Where is the C6015 ultra compact IPC positioned in the Beckhoff
portfolio with regard to potential application areas?
With dimensions of only 82 x 82 x 40 mm, the C6015 is one-third
the size of the C6905, previously the most compact cabinetmounted
IPC in our portfolio. With cost savings of roughly 25 %,
it ranks far below the former lowest-cost x86 PCs from Beckhoff.
This means that engineers can now implement automation, visualization
and communication tasks for small to medium-sized
applications very cost-effectively, with a minimal footprint. Furthermore,
it opens doors to applications where PC-based control
technology was not being used until now, or where motherboards
had to be customized at great expense.
What are the most important features of the IPC?
Author: Stefan Ziegler, Marketing Communications,
Beckhoff Automation, Verl, Germany
The most important feature is its extremely compact size without
compromising suitability for industrial applications. This is dem-
About Beckhoff
The product range of Beckhoff covers Industrial PCs, I/O
and Fieldbus Components, Drive Technology and automation
software, which are used worldwide in a wide
variety of different applications, ranging from CNC-controlled
machine tools to building automation. Headquarters
is in Verl, Germany, turnover amounts to EUR 620
million (2015) and staff amounts 3,350 (January 2017).
Roland van Mark, Product & Marketing Management Industrial PC:
“Despite its compact size and economical price, the ultra compact
C6015 IPC from Beckhoff does not compromise its suitability for
industrial applications.”
HANNOVER MESSE
38 WORLD OF INDUSTRIES

CONTROL AND DRIVE TECHNOLOGY
onstrated by the high performance of the integrated Intel Atom
CPU with up to four cores, and by the design as a passively cooled,
long-term available device in a robust aluminum-zinc die-cast
housing. It also meets other industrial requirements, such as an
extended operating temperature range of up to +55 °C (131 °F) and
exceptional vibration and shock resistance. I don’t believe that this
level of CPU power paired with all necessary PC interfaces has ever
been available for industrial applications in such a small device.
How did you manage to develop such a compact design?
Our extensive motherboard development expertise was a critical
factor in designing this exceptionally compact single-board computer.
We also paid close attention to user requirements and preferences.
Even if it is ultra compact, an IPC must still provide all the
necessary interfaces for typical automation tasks. In addition to
the power supply, these devices include two independent Ethernet
ports, one USB 2.0 and one USB 3.0 port, as well as a DisplayPort.
These interfaces are what ultimately determined the size of the
IPC, because to keep the cabling simple, they had to be located on
the same side, necessitating the 82 mm housing edge length.
How does this design affect the IPC installation in extremely
confined spaces?
With the minimal size of the C6015, the six interfaces with their
connectors and cables almost take up more space than the IPC
itself. Therefore, it is critical that the connection level of the ultra
compact IPC be precisely matched to the orientation of the cable
inlet, usually predetermined by the machine layout. This is particularly
true in space-constrained applications. We accommodate
this with a highly flexible installation concept. Using two
different installation frame types, the IPC can be vertically or
horizontally mounted on a back wall or snapped onto a DIN rail.
Moreover, the C6015 can be positioned anywhere within an
appropriate mounting frame because of its symmetrical cooling
fins. Rotating the IPC will not affect its heat management, because
the cooling fins dissipate the heat equally in all directions. As a
result, the installer can align the connector face perfectly with the
incoming cables. In the past, this was often not possible and
ultimately may have prevented the use of Industrial PCs in especially
small installation spaces.
What are the advantages of the single-board design?
Designing the IPC as a single-board unit means that we can build
a compact device in our own factory according to highest standards
of efficiency and reliability. The user receives a high-quality,
yet affordable industrial-grade product. Another important aspect
is our quality control, which is performed entirely at the Beckhoff
The ultra compact IPC is just one third the size of the C6905, previously
the smallest cabinet IPC available from Beckhoff
factory in Verl. We perform thorough tests of the boards after the
assembly process, before and after installation in the housing and
final tests of the finished IPC.
The C6015 was especially designed for cost-sensitive applications
where space is at a premium. Can you give us some examples?
With its powerful Intel Atom CPU, the ultra compact IPC is especially
well-suited for small and medium-sized applications in the
areas of automation, visualization and communication. It works
particularly well where machine designers otherwise need to integrate
highly individualized electronics, usually because of lack of
space or for historical design reasons. If you want to stay up-to-date
in technological terms, such customized designs can become very
expensive very quickly. In addition, most machine designers’
strength lies in the end process and mechanical engineering, which
is often much easier to implement if they just buy the latest control
electronics from a third party. The same applies to many research
institutions, test-bed builders and process technology companies.
To what extent does this advantage apply to Industrie 4.0 and
the Internet of Things?
Decentralizing the intelligence is critical for Industrie 4.0 and IoT
concepts. I foresee numerous potential applications for the C6015
where users want to collect machine and process data for transmission
to cloud-based systems in very confined installation
spaces. In such cases, the ultra compact IPC can function as an
intelligent IoT gateway, which is also able to buffer large data
volumes or to run remote diagnostics.
Photographs: Beckhoff Automation
www.beckhoff.com
© KUKA KA Roboter GmbH
Brake technology 4.0
for maximum demands
ROBA ® -servostop —compact,
high performance-density
safety brake for robot joints
www.mayr.com
Visit us at: Hannover Messe, Hall 25 Booth D30
your reliable partner
MAYR.indd 1 15.03.2017 09:06:26
WORLD OF INDUSTRIES 39

About Universal Robots
The portfolio includes the collaborative UR3, UR5 and
UR10 robotic arms. The company has experienced
considerable growth with the robots now sold in more
than 50 countries worldwide. The company (part of
Teradyne Inc.), is headquartered in Odense, Denmark,
which more 300 employees worldwide.
Vision-guided collaborative robots
HANNOVER MESSE
Task Force Tips, a manufacturer of firefighting
equipment, wanted to maximize their personnel
tending machining cells into more complex tasks while
keeping spindle time up and product quality consistent.
The Indiana-based manufacturer has now installed four
collaborative Robots delivering savings resulting in a
return on their investment in only 34 days.
CEO of Task Force Tips, Stewart McMillan, still remember his father
looking up at him with pen in hand saying “Are you sure
about this?” when the family-owned company bought their first
CNC machine forty years ago. “It was a huge step. But giving people
the proper tools to do their job is essential to being productive,” says
McMillan, who started integrating robots with machine tools as far
back as 1990. Those robots however, were dedicated to working only
on the machine they were installed with and could not be redeployed
to other tasks: “So what happens is the machine wears out first and
now you have a $100,000 robot that you can’t do anything with. We
had heard of collaborative robots that could be used in a much more
flexible manner, so we decided to explore this new technology.”
Production Supervisor at Task Force Tips, Cory Mack, recalls how
within literally minutes of the Universal Robots demo coming in,
his colleagues were already trying to figure out how to program it
and make it work: “The Universal Robot is so simple and non-intimidating
that our programmers were already in the mindset of I
don’t need any guidance, I can do this on my own.”
Flexible robots as a paradigm shift
Task Force Tips installed one UR10 robot and two UR5 robots to
tend CNC machines, a fourth UR5 is mounted to a table on wheels
and moved between tasks. The UR robots can work collaboratively
right alongside TFT employees due to a built-in safety feature causing
the robots to automatically stop operating when they encounter
obstacles in their route. A scenario McMillan calls “a fundamental
paradigm shift”: ”A major impediment in the past to using robots
was the security fencing required around the machine. The beautiful
thing about the UR Robots is you don’t need all that guarding. We
can roll the table with the robot right up to the machine and in a few
minutes teach the robot to load parts. They become kind of a partner
to a person that goes around and helps them with the drudgery.”
The robot is running for 21 hours unassisted
Task Force Tips has their production layout set up in a non-traditional
cell format with operators running multiple machines simultaneously
round the clock. Mack explains how the UR robots have
reduced staffing requirements from 7 to 3 operators: “Now it only
takes about one hour per operator per shift to operate the robot,
which includes laying out parts and staging the robot. The robot is
running for 21 hours unassisted, so we’re looking at savings of just
about 34 days to pay for the robot,” says the Production Supervisor
mentioning the added benefits: “That’s 7 hours of time in each shift
you’re saving for that person to be off doing something else.”
Two robots working in tandem
Having the two UR5 robots work in tandem has also helped optimize
production. As blanks arrive on an inbound conveyor, the first
UR5 robot uses vision guidance to identify and pick up the blanks,
then inserts the blank into the first milling machine. The UR5 then
takes out the half machined part already in the lathe and hands it
over to the other UR5. The second robot inserts that part into the
second machine, takes out the complete machined part and places
it on the outbound conveyor, where an operator places the parts
onto anodizing racks, completing the cycle.
It’s a process that – as Task Force Tips’ Automation Specialist
Adam Hessling puts it – looks very impressive, but was deceivingly
easy to do. He refers to himself as a “journeyman machinist” with
no specific robotics programming experience: “My background is
all in CNC programming, but I just used the Universal Robots support
website and got a lot of really good information from there and
wound up being able to put together the two-robot machining cell
doing the hose couplings without any external help. If you understand
just basic logic, you can do an unbelievable amount with Universal
Robots.”
40 WORLD OF INDUSTRIES

CONTROL AND DRIVE TECHNOLOGY
Handoff between the two UR5 robots looks very impressive
Vision guidance required no scripting
Both the robot handoff and the vision guidance use the Modbus
communication protocol registers in the UR robots controller. “Using
Modbus made the communication between the two robots very
easy to do. Through the touchscreen that comes with the robot, we
just set the way-points that we want the robots to move through and
the two robots confirm back and forth to each other that they are
where they are supposed to be,” explains Hessling, detailing the vision
guidance: “You can have discreet inputs and outputs just like a
normal PLC would have or you can do register values, which is what
we use to do the coordinates for the camera.
Modbus registers that it can output and we just send the coordinates
to the Modbus registers in the Universal Robot’s controller that
generates the way-points of the parts and directs the robot there. It
didn’t involve any scripting at all,” says the TFT Automation Specialist,
who calls it a very clean installation: “All of the communication
we did was through our computer network, nothing is actually hard
wired together.”
Force detection identifies product issues
When the UR5 places the unmachined part in the lathe, the robot’s
force detection will identify if the part is misshapen, has some burs
from the saw cut or if there are machining chips in the chuck jaws.
“When the robot tries to reach the set waypoint for placement and
there’s an obstruction which causes the force on the end of arm to
exceed 50 N; which I programmed as the threshold, it knows something
is wrong,” says Hessling who has programmed the robot to
then apply an air blast to try and clean whatever debris is in the way.
The robot will go through the air blast several times and if it still
can’t place the part, the robot tells the machine to execute a “chuck
wash” cycle, which uses the machine’s high pressure coolant system
to dislodge debris from the chuck jaws. If the part still can’t load
after the coolant wash, the popup appears on the robot’s touchscreen,
instructing the operator to clear any debris from the chuck
jaws and press continue. If the issue persists, there is another popup
which halts the program entirely. The operator can then diagnose
the problem, fix it, and restart production.
The intuitive interface on the UR robots allow operators with
no programming experience to interact and program the robots
“I would estimate that the robot fixes the “failure to load” issue
about three or four times per hour, which has really helped us eliminate
downtime. The operator only needs to intervene about once
per shift, sometimes never. This is no fault of the robots; it is just the
nature of the aluminum we are machining and the type of chips it
creates,” explains Hessling.
Product quality increased
Freeing up personnel from machine tending has also played an important
role in increased product quality. “When our employees
are not worried about keeping a machine running all the time, they
have a lot more time to visually inspect the machined products. Part
quality has really gone to a whole other level with the UR Robot
in place, while allowing our personnel to come up with new ideas
and better ways to improve our production,” says the TFT Production
Supervisor. CEO McMillan adds: “When you set people loose
with a way to reduce the mundane labor in their daily job, they find
those ways.”
Photographs: Universal Robots, Denmark
www.universal-robots.com
Measuring technology for industry and machine construction
Position indicators Actuators Rotary encoders & Wire-actuated encoders Magnetic measurement
HMI 2017, Hall: 9, Booth: G81
SIKO, a strong partner for industry and machine construction
■ Specialising in measuring technology since 1963
■ Decades of experience in distance, angle & rotary measuring technology
www.siko-global.com
■
■
Individual customisation and developments for our clients
International sales and support through subsidiaries or local representatives

Stable logistics thanks to permanent
network monitoring
The mail order sector creates a broad range of
comfortable opportunities in the previously
catalogue-based trade while massively increasing
the requirements in logistics for short delivery cycles
and drop-off times. One of the most successful
companies in this field is Baur, a part of the Otto
Group. To ensure trouble-free processes, central
monitoring of the implemented systems is entrusted
to a monitoring software from Indu-Sol.
Author: Christian Wiesel, Marketing, Indu-Sol GmbH, Schmölln
In 1925, Friedrich Baur founded the first German shoe mail-order
retail company in the Upper Franconia town of Burgkunstadt. Today,
not only the portfolio has been expanded by jewellery, furniture
and fashion, also Baur has become part of the Otto Group and
operates several subsidiaries. Regarding the business locations, the
growth of the corporation is immense : In Altenkunstadt, there is a
high bay warehouse that primarily contains items that are in great
demand, i.e. merchandise with a high turnover. Since 2002, a main
trade basis – a kind of “lorry hub” – has been built to ensure the
speedy delivery to the point of destination. In combination with the
multi-layered storages which are located in Burgkunstadt and Weismain
due to capacity reasons there is a total of a half a million standard
box spaces to be managed – an enormous logistical achievement
by any standard.
“From the outside, you can hardly imagine all the things happening
from the time you press the ‘Order’ button until the merchandise
is delivered,” says Harald Fiedler with a grin. Working together with
his 25 colleagues in a three-shift operation at Baur Versand GmbH
& Co. KG in Altenkunstadt, he makes sure that all items and pack-
HANNOVER MESSE
The combination of the main trade
base and warehouse at one location
as in Altenkunstadt, Germany is a
unique selling feature of Baur
Versand GmbH & Co. KG and
ensures speedy processing
42 WORLD OF INDUSTRIES

INDUSTRIAL COMMUNICATION
01 The Profinet Inspektor NT shows the current network overall
status on the display and supplies initial diagnosis notifications
02 Promanage NT provides the operator with all important
information at a glance
ages leave the warehouse on time. In an area of about 125,000 m 2 ,
a 13 km long labyrinth of conveyor belts and sorting systems called
“sorters” transports on average 200,000 items per day for dispatch.
“A downtime of ten minutes can hardly be compensated within a
day,” explains Fiedler regarding the high requirements for logistics.
Why permanent monitoring became necessary
Due to the continuous expansion of the facility different technologies
are in action simultaneously. Their operation and maintenance
require the observance of individual peculiarities. Whereas the
emphasis in the 1990s and early 2000s was still based on fieldbus
technology (Profibus and CAN), the implementation of Profinet at
Baur has been mandated for new systems since 2010. Back then as
well as today, the ASi bus is also used. From practical experience it
became clear that a monitoring system is necessary. “In 2001, we
put the loading sorter into operation. This has priority 1 – if it is at
standstill, the whole company will come to a stop in the foreseeable
future,” said Fiedler, describing an actual case. Sporadic malfunctions
and even failures occurred from time to time which soon became
unbearable for daily business. In 2008, the decision was made
to have the installed Profibus network inspected by Indu-Sol (see
panel). The possibilities for the analysis during measurement were
so impressive that the Profibus Inspektor from Indu-Sol GmbH was
purchased as an analysis tool. It permanently and passively monitors
the logical data traffic in the Profibus and alerts the operator at
the earliest indications before visible or noticeable disturbances of
the operational proceedings occur.
“Silent monitors” in the control cabinets
Based on these positive experiences, over time the other systems
were equipped with the appropriate Inspektors from Indu-Sol for
the respective network. There are currently a total of 33 of these
measuring and analysis devices for Profibus, Profinet and ASi
installed as “silent monitors” in the control cabinets (Figure 1).
They monitor the network for quality parameters such as telegram
repetitions and bus cycle times (Profibus) or network load, update
times, or delayed or lost telegrams (Profinet). The systems engineering
team faced the challenge of consolidating the diagnosis information
of the individual devices, to maintain an overview and to
evaluate the overall condition of all networks. This is where the central
network management software Promanage NT comes into play.
It collects the events of all fieldbuses and networks centrally onto
one server, visualises the results and provides numerous options
for analysis – in light of all the branches at Baur, this is quite convenient.
The employees who are responsible for systems engineering
for example, can review the archived and current condition of the
entire system using the network status graph at any time and across
the whole network (Figure 2). Even when no retrofitting measures
are planned, those in the logistics centre in Altenkunstadt constantly
monitor the data traffic in the network in order to be notified
promptly in case there are any changes in quality. Especially convenient
is the alarm function by e-mail as soon as there is an incident.
A further advantage of Promanage NT in this constellation is that
the user can see immediately which of the installed Inspektors has
triggered an alarm. Thus the technical personnel can react quickly
and to the point.
Be save in the future
Looking into the future, the focus is on conveying technology
where some components are already more than 25 years old. In
this regard, Profinet technology will be used for any new systems.
Furthermore, the company wishes to remain at the current status
for the own analysis tools because the challenges for maintenance
are constantly increasing in the light of the steadily expanding networks
– keyword: Industry 4.0. The Profinet Inspektors NT from
Indu-Sol are currently replacing their predecessor versions step-bystep
because they further facilitate the monitoring of the network
with several innovations and contribute to better reliability. A display
makes it possible to view initial diagnosis information directly
at the device and to receive notifications on the network status –
therefore the laptop does not always need to be carried along. The
presence of unknown devices is also reported immediately and also
detected and documented by Promanage NT.
Photographs: lead Baur Versand, 01 and 02 Indu-Sol GmbH
www.indu-sol.com
About Indu-Sol
In order to ensure the continuous function of automated
systems, the company developed a complete system
solution for Permanent Network Monitoring (PNM)
with the goal of sending a warning before a system
is down. As a key partner in practical application, Indu-Sol
also supports its customers in all areas from planning
and commissioning to maintenance and troubleshooting.
To achieve these goals, a comprehensive range of
measuring and diagnostic tools, software, and
infrastructure components is available.
WORLD OF INDUSTRIES 43

When e-chains
carry sensors
Thanks to smart plastics, unforeseen machine failures and imminent
downtimes are detected in good time for an appropriate maintenance
HANNOVER MESSE
Intelligent energy chains and chainflex cables can
inform you when they need to be replaced. A new
series combine sensors with monitoring modules offer
predictive maintenance for production. Unforeseen
machine failures and imminent downtimes are
detected, and appropriate maintenance can be
initiated thus avoiding expensive production losses.
The digital networking of machines and products makes it
possible to continuously collect data about the status of
machine components and integrate them with other systems.
With preditive maintenance, production processes become simpler
and safer, since the constant monitoring of all machines
and components means that faults and wear are detected are predicted
before failure. As a result, measures for the maintenance
and repair of affected parts can be initiated at an early stage. This
reduces expensive downtimes demanded by periodic maintenance.
The predictive maintenance is therefore an important
element within Industry 4.0. Manufacturers in the automotive
industry in particular are asking for components for Production
4.0. Only the products are missing.
Author: Harald Nehring, authorised officer for e-chainsystems, igus GmbH,
Cologne, Germany
Avoid machine downtimes: The isense principle
At the Hannover Messe, igus presented smart plastics for the first
time with the name ‘isense’ - intelligent components for the factory
of the future. The isense series include various sensors and monitoring
modules in or on the plastic components of the energy chain.
Energy chains and the chainflex cables inside them supply energy
and data to machines and plants. If these parts suddenly fail, the
system would be stopped. An interrupted production run costs
the plant operator dearly. It is understandable that plant managers
want to prevent such possible failures. This is possible with the wear
monitoring isense EC.W(ear): A sensor chip embedded in the opening
crossbar of the e-chain continuously measures the status of the
gliding e-chain during the travel. If the abrasion is so advanced that
the end of the service life of the chain is near, the sensor reports by
triggering a signal. A nearby antenna unit receives the data by radio
and passes it on to a reader module. This processes the antenna
signal and then reports it to the central communication unit called
icom. The icom module prepares the data and forwards it to the
plant system. In this way, the system operator does not experience
a machine failure, but can include the replacement of the worn part
into its maintenance process in a timely manner. The fact that there
are no longer unforeseen downtimes increases the availability of its
system.
Conditioning monitoring products for plant safety
A few years ago, igus introduced products for predictive maintenance:
the PPDS push-pull detection system and the EMA diagnostic
tool for identifying a chain-link break. Since then, these
components have been gradually further developed and have been
44 WORLD OF INDUSTRIES

COMPONENTS AND SOFTWARE
integrated into the new isense family. Now, the unit for wear monitoring
(EC.W) can be combined with other conditioning monitoring
products - such as the isense break alarm EC.B (formerly EMA)
and the pull/push force monitoring EC.P (formerly PPDS). In the
case of the pull/push force monitoring, a load cell is installed in the
mounting bracket of the e-chain, which monitors the displacement
forces at the e-chain. For travel distances of more than 100 metres,
the force sensor is integrated into the “floating moving end”, which
compensates for lateral tolerances on the moving end of the travel:
if a foreign body, for example a tool dropped into the travel path of
the chain, blocks the movement of the e-chain, the displacement
forces increase. From a defined threshold value, the sensor issues a
signal - comparable to the abrasion monitoring - which is received
by an evaluation box and is passed on to the icom communication
module. If the permissible forces are exceeded, the system switches
off the plant before it can cause major damage.
Double safe: pull/push force and break monitoring
The plant is double fail-proof with the break monitoring system,
the isense EC.B module. Mechanical action or overloading of an
e-chain can lead to a break in the side links. If this happens, a polymer
sensor installed in special separators signals the information of
the break to a sensor unit. The maintenance signal alerts the user
who can initiate measures to prevent major damage. The replacement
of a single damaged chain link is usually done in a few minutes.
This prevents the second side part from breaking too, and the system
will not come to a standstill due to major damage. Both signals can
be read out via a reader module, since a readout unit can process
up to four antennas. It would therefore be possible to connect up
to four energy chains to one module. All data are processed in the
icom communication unit and forwarded to the system of the plant.
Fail-safe chainflex cables
Even the safest e-chain is little use if the cables in it do not hold. And
the challenges faced by e-chain cables are, as is well known, much
higher than for cables in more general flexing applications. For this
reason, igus has been developing its cables for moving applications
for 25 years under the name of chainflex, ensuring excellent function
and reliability of the cables in all moving applications, from stock.
This too with a guarantee of up to 36 months. However, within the
scope of isense, igus has also taken a step further with chainflex and
developed a failure monitoring module for cables that are running
continuously: isense CF.Q. Intelligent electrical conductor quality
sensors continuously monitor measured values of the cables and
indicate when the limits, based on empirical values from millions of
results from the test laboratory, are exceeded. This means that the
intelligent chainflex cable also informs the user about its remaining
service life before a failure.
The isense as a strategic means of maintenance
Since the first use of polmyer energy chains more than four decades
ago, the igus e-chain has evolved constantly: mechanically by continually
researching ever better materials and designs that have
made the e-chain ever lighter and quieter. As a result, not only
linear motion but also movements in all directions and torsion have
become possible. Now the e-chain has become smart: with the aid
of intelligent sensors, it monitors itself continuously and warns of a
failure in advance. Many thousands of test procedures already provide
extensive data, on the basis of which the exact durability and
service life of the e-chains are calculated and which are integrated in
numerous online tools and apps. However, the use of sensors and ITbased
data analysis has further developed the existing maintenance
A sensor chip embedded in the opening crossbar of the e-chain measures
the status of the e-chain in real operation
strategies. By measuring the actual status of the e-chain in real operation,
the smart plastics can detect the appearances of wear on time
and maintenance can be initiated at an early stage. The key point is
not to respond to failures, but to foresee them and plan accordingly.
As a result, smart plastics are used as a strategic means to save costs
in production: by the optimisation of resources in maintenance and
spare parts logistics, or through higher response speeds within production
processes. In addition, the avoidance of costly production
stoppages from machine downtimes.
The isense sensors in beta use
The first assignments of the isense sensors were in the production
plants of various German automotive manufacturers. However,
they can be used wherever predictive maintenance is required
for cost reasons or to increase plant efficiency and reduce energy
consumption - for example, in e-chains on long travels in port
facilities or crane systems. All isense products can be installed in
a large range of products. Some of the isense products can even be
retrofitted in existing plants.
Application or cloud-based solution
Simple digital I/O signals are still sent when a limit value is exceeded.
The icom module passes the maintenance information about cables
to the user’s systems. If, however, the data of many plants and production
processes are brought together in a structured manner,
more accurate analyses and more reliable predictions would be
possible. A conceivable future solution would be one that not only
evaluates local production data, but is also fed with data from other
applications as well as the many test results from the igus database.
Whether this is done in the form of an application by the user or
cloud-based, ultimately the user could decide for himself.
Photographs: Igus GmbH
www.igus.eu
About Igus
The igus GmbH is a leading manufacturer of energy chain
systems and polymer plain bearings. The Cologne-based
family business has offices in 35 countries and employs
around 2,950 people around the world. In 2015, igus
generated a turnover of 552 million euros with motion
plastics, plastic components for moving applications.
Igus operates the largest test laboratories and factories
in its sector to offer customers quick turnaround times on
innovative products and solutions tailored to their needs.
WORLD OF INDUSTRIES 45

Surface finishing and filter expert
opts for consistent engineering
Surface treatment and finishing requires a wide
variety of highly complex systems for pre-treatment,
powder coating, painting and drying, as well as for
automation relating to transport and the handling
of parts. The relevant engineering is also accordingly
complex. Rippert Anlagentechnik works for this with
Engineering Base (EB), which is developed by the
software developer Aucotec.
The Surface finishing and filter expert Rippert Anlagentechnik
GmbH und Co. KG, which has maintained its position in the
market for over 45 years with painting and filter systems, automation
and industrial fans, is an experienced plant construction
company in this sector. Its growth and the constantly increasing
demands for highly automated systems led the East Westphaliabased
surface finishers to search for a modern engineering system
which would grow in tandem and be viable for the future.
Data and information integration as a topic
Consistency was the central topic in the search conducted by the
plant construction company. The desire for significantly more consistent
processes was the driving force behind the decision. “Out of
all providers considered, only the software developer Aucotec with
Engineering Base (EB) was able to fulfil an Entire project’s requirements
from the process engineering flow diagram (P&ID) to control
technology,” recounted Thomas Quante, Head of I&C Design
at Rippert and EB administrator and key user Thomas Möller. The
North German system house celebrated its 30 th anniversary in 2015
and succeeded in achieving sales growth of around 80 % in the last
six years, mainly due to the database-driven software EB.
From sales via processing and manufacturing to commissioning,
all disciplines access the same common data model to view
or edit engineering information. EB’s database and object orientation
as well as its special multi-layer architecture make it possible.
The central data storage enables even highly complex tasks to be
completed quickly and cooperatively, also across multiple sites.
The application server connecting the client and database relieves
the client’s computer and manages the business logic with its elements
and logical relationships to each other. “With EB, different
HANNOVER MESSE
Production hall with pre-treatment
facilities at Rippert works with a perfectly
designed information system
46 WORLD OF INDUSTRIES

COMPONENTS AND SOFTWARE
Industrial Automation
Events Worldwide
Leading Trade Fair Network for Factory and Process Automation,
Systems Solutions and Industrial Software
Germany Hannover 24 - 28 Apr 2017
23 - 27 Apr 2018
China Beijing 10 - 12 May 2017
Shenzhen 28 - 30 Jun 2017
Shanghai 7 - 11 Nov 2017
Canada Toronto 25 - 28 Sep 2017
Italy Milan 4 - 6 Oct 2017
USA Chicago 6 - 9 Nov 2017
10 - 15 Sep 2018
Turkey Istanbul 15 - 18 Mar 2018
www.hannovermesse.de/worldwide

HANNOVER MESSE
designations of a component in various documents are as much a
thing of the past as time-consuming comparisons of load and field
device listings that were created at the start of a project,” reported
Quante.
“It’s worth rethinking”
Function-oriented assembly formation is now
an important focus for the engineering process
because it creates reusable standards which
significantly minimize errors and coordination
work. The assemblies are formed from individual
functions with underlying circuit components or
circuit diagram pages. According to the administrator
Möller, the structural creation of functions
requires another work method, but it’s worth
rethinking. He explained: “Functional orientation
saves a significant amount of time and divides the
sub-systems very clearly to boot.”
Clean break with the introduction of the new
system
“We have made a complete clean break with the introduction of
the new system. This means that we still use the previous tool for
old projects, but design all new projects with Engineering Base,”
explained Thomas Quante. In doing so, Rippert derives the new
standards from existing projects. However, the circuit components
and functional assemblies are still always checked again before
storing these standards in EB’s database. Thus users can always
rely on a high quality standard also. Rippert implemented the conversion
gradually for small groups of employees. “The switch was
not all plain sailing because the new system signifies a completely
different approach, but we have recognized EB’s potential and are
coming ever closer to our goal of seamless consistency with it,”
reported Thomas Möller.
Data consistency at all times
Currently, the engineers are working on the EB link to the also
new ERP system. The aim is to be able to respond swiftly and
comprehensively to necessary adjustments and ensure data
consistency at all times. Additional attributes were developed
for material types to adapt the EB device master data to the ERP
database. In this manner, the search structure remains clear in
both systems.
Rippert’s I&C Design department will now gradually adjust the
new system to its own specific requirements. Knowing the possibilities
of Engineering Base, the I&C Design experts want to make the
most of it. “EB’s flexibility is open to further requests and requirements
on our part and is thus also future-proof in the longer term.
Its consistency is already exceptional now,” concluded Thomas
Quante.
Photographs: Rippert Anlagentechnik, Germany
www.aucotec.com
Power range in the cabinet for four booths; project structure in
Engineering Base (EB)
About Aucotec
Aucotec AG has over 30 years of experience in developing
engineering software for the entire life cycle of machines,
plants and mobile systems. The solutions range from flow
diagrams via control and electrical engineering for largescale
plants to modular harness design in the automotive
industry. Aucotec software is in use all over the world. In
addition to its headquarters in Hanover, Aucotec operates
six further sites in Germany as well as subsidiaries
in China, South Korea, France the United Kingdom, Italy,
Austria, Poland, Sweden and the US.
48 WORLD OF INDUSTRIES

PRODUCT NEWS
Modular platform of automation
panel family
One of the global leader of industrial automation, B&R,
is expanding its automation panel family with a new series
of widescreen formats from 7” WVGA to 24” Full HD.
Automation Panel 1000 devices offer easy and flexible
mounting options. The slender design is available with
a single-touch or multitouch
screen. Adding a PC
unit turns an Automation
Panel into a full-fledged
Panel PC with scalable
processing power. The core
component is the panel
itself, which is available in
widescreen variants ranging
from 7” WVGA to 24” Full HD. Adding a modular SDL/DVI
receiver makes it an operator terminal. When using SDL3
digital signal transmission technology, it is even possible
to bridge more than 100 m between terminal and PC.
Standard Ethernet cables are used. Panel PCs offer scalable
computing power from Intel Atom up to Core i7.
www.br-automation.com
Tablet PC for mobile
industrial applications
The Simatic ITP1000 industrial
tablet PC is currently one of the
fastest tablet PCs on the market.
It has a projective-capacitive
10.1-inch Multitouch display,
the latest Intel Core i5 Skylake
processor technology, and the Trusted Platform Module.
Designed for industrial use, the tablet PC is especially suitable
for service, production, measuring and testing, as well as for
operator control and monitoring and supports Windows 7 and
Windows 10. With many different interfaces and well-thoughtout
product features, the Simatic ITP1000 is versatile, can be
used everywhere, and can be integrated in both new and
existing plant concepts. To handle challenging tasks, a
high-performance chip set with the latest Intel Skylake CPU
technology is used. The DDR4 RAM can be upgraded up to
16 GByte, and a 256 or 512-GByte SSD can also be added to
the device. Even customized automation tasks can be handled
flexibly with the practical industrial functions – such as RFID,
a bar code reader, camera, and six freely programmable
function buttons.
www.siemens.com
chainflex® works ...
Servo cable
26 Test
million strokes
tested 4404
Measuring system cable
66 Test
million strokes
tested 3479
Moving energy made easy with the world's
number 1 for moving cables:
● Largest selection; up to 7 price levels
● From stock, from 1meter, without
cutting fees
● Largest test lab in the industry
● Available as an assembled e-chainsystem ®
● Calculate lifetime online
www.igus.eu/chainflextest
Free Samples: igus ® GmbH Tel. +49-2203-9649-800 info@igus.eu
plastics for longer life ®
The terms "igus, chainflex, e-chainsystem, plastics for longer life" are legally protected trademarks in the Federal Republic of Germany and, where applicable, in some foreign countries.
Visit us: Hannover Messe – Hall 17 Booth H04
Igus.indd 1 14.03.2017 15:08:09
WORLD OF INDUSTRIES 49

Ethernet-IO-modules allow an efficient
plant design
The new Ethernet IO modules from Pepperl+Fuchs support all common
Ethernet protocols, such as Profinet, Ethernet IP and EtherCAT. The
L-encoded M12 plug, compliant with the power-connection concept
newly defined by the PNO, supplies the connected units with
currents of up to 16 A with no additional installation needs. The
modules can be used independently of the control panel and permit
autonomous applications. They clear the way for distributed signal
transfer within the meaning of
Industrie 4.0. The multiprotocol
feature permits standardization
in the machine where different
module types were previously
required. Change between
protocols by simply using a
rotary selector switch. The IP
address for Ethernet IP can also
be directly set. The integrated
web server allows for complete
parameterization in addition to
addressing, as well as the
retrieval of status and diagnostic
information
via PC.
www.pepperl-fuchs.com
background: fotolia
GigE machine vision camera
– compact and powerful
IDS presents the second generation of the GigE
uEye CP machine vision camera. The CMOS
camera has been completely redeveloped and
designed without compromise for classic
machine vision applications. Measuring just
29 x 29 x 29 mm, it is much more compact than
the preceding model but offers even better
performance. Its enhanced features include
CMOS sensors from Sony, ON Semiconductor,
e2v and CMOSIS, as well as full GigE speed,
single-cable operation up to a length of 100
meters via Power-over-Ethernet (PoE), and
screw-on connectors. In addition, the GigE
camera will also be available with support for
the GigE Vision standard or with the proven
IDS Software Suite. The camera series includes
models with 0.5 to 6.4 megapixel resolution
and with monochrome or color sensors.
www.ids-imaging.de
Advanced thermal imaging cameras
HANNOVER MESSE
The new Exx-Series of advanced thermal imaging cameras has been
designed for electrical, mechanical, and building applications: the Flir E75,
E85, and E95. The series features intelligent interchangeable lenses, laserassisted
autofocus modes and area measurement functionality, improvements
to Flir’s MSX imaging technology, and a larger, more vibrant 4-inch touchscreen.
The company developed a new range of compact intelligent,
interchangeable lenses that the camera automatically recognizes and
calibrates, eliminating the need for manual calibration. In conjunction with
Flir Tools, the E75, E85, and E95 are the first Exx cameras to offer UltraMax,
an embedded, super-resolution process that improves effective resolution
by four times - up to 645,888 pixels - and thermal sensitivity by up to 50 %.
A simplified user interface delivers faster, more intuitive operation, and
coupled with enhanced Wi-Fi, Bluetooth and Meterlink connectivity,
archiving and report generation has never been easier.
www.flir.com
50 WORLD OF INDUSTRIES

COMPRESSED AIR NEWS
Compressed Air and Vacuum Technology

Compressed Air for the Smart Factory
The Hannover Trade Fair addresses Industry 4.0 again
this year under the motto “Integrated Industry –
Creating Value.“ This hot topic serves as a unifying
idea for the various leading trade fairs. ComVac is no
exception in this regard, as the Smart Factory would be
inconceivable without sophisticated compressed air
and vacuum technology. Sonia Wedell-Castellano,
Global Director ComVac, Deutsche Messe AG, gives
a forecast of what awaits visitors at the trade fair.
The lead theme of HANNOVER MESSE 2017 is “Integrated
Industry – Creating Value”. What exactly does it mean?
Industry 4.0 is once again the focal point at HANNOVER MESSE.
We are at an important point in time, because the technologies for
digitalizing industrial production are ripe. Now it is time for decision
makers in the manufacturing and energy sectors to identify
the long-term advantages of digitalization for their companies.
“Integrated Industry - Creating Value” represents digitalization’s
potential to create new concepts, new business models and new
markets.
Can you name some additional trends in Hannover?
We have a broad range of current, exciting topics related to Industry
4.0. For example, machine learning and predictive maintenance
process huge amounts of data to create a distinct benefit.
Additional topics include Integrated Energy, cobots, digital twin
and smart materials. Of course, energy efficiency remains an important
issue and is a top theme at ComVac.
How may exhibitors do you expect at ComVac this year?
ComVac is quite strong this year, which is great news for us and
underscores the importance of this branch for the future of manufacturing.
In December we recognized that Hall 26 would not be
sufficient, so we now have an additional 2,500 square meters in
Hall 27. This represents display-area growth of 14 percent. More
than 240 companies will exhibit.
Where does the growth come from – Germany or other
countries?
Seventy-five percent of the exhibiting companies at Comvac come
from outside of Germany. A number of these foreign companies
have increased their display area this year – first and foremost
China, Italy and Turkey. Combined these three countries account
for more than one third of ComVac’s total display area.
Which trends await visitors this year at ComVac?
ComVac covers the complete range of compressed air and vacuum
technology, from generation and processing to pumps and
measuring instruments to financing and management. Industrie
4.0 is also an important theme. For example, sensors and software
enable machines and work pieces to communicate with each
other, resulting in continuous monitoring that improves productivity
and production security. On the compressed air side, companies
show how heat recovery, control technology and predictive
maintenance can improve energy efficiency. Companies from the
vacuum technology branch emphasize customer service and sustainability
with speed-controlled, oil-free pumps.
Are there synergy effects between ComVac and other sectors at
Hannover Messe?
Yes, and these apply to all sectors of the fair. Whether we are talking
about automation, pneumatics or environmental systems,
without well-engineered compressed air and vacuum technology
there is no factory of the future. You simply cannot develop energy
efficient, sustainable production processes without these fundamental
crossover technologies. The connection is especially
strong between ComVac and the trade fairs Energy and MDA–
Motion, Drive & Automation. MDA exhibitors in particular are
customers of ComVac exhibitors. We also see synergies outside of
HANNOVER MESSE and are bringing compressed air and vacuum
technology companies to other markets.
You also organize ComVac events outside of Germany. What does
the upcoming calendar look like?
We offer our exhibitors the chance to join us in important international
markets with the high level of service they are accustomed
to from Deutsche Messe. In September 2017 we are launching
ComVac Canada in Toronto. Then we have ComVac Asia in Shanghai
at the end of October 2017. In September 2018, ComVac North
America runs parallel to IMTS in Chicago.
www.hannovermesse.com
Sonia Wedell-Castellano, Global Director ComVac, Deutsche Messe AG
52 WORLD OF INDUSTRIES

ComVac. How can we combine
innovation and expertise?
You’ll find out at ComVac:
■ Innovative compressed air and vacuum technology
■ Saving energy through improved plant technology
■ New directions in compressed air contracting
24 – 28 April 2017 ▪ Hannover ▪ Germany
hannovermesse.com
f+h Intralogistics 3/2015 53

Full-service package for complete
peace of mind
Compressed air is a vital energy source for industrial
applications. Without it, production grinds to a halt.
Predictive maintenance is important for spotting
potential problems at an early stage. This helps to
reduce or entirely eliminate unexpected downtime
and the resulting production backlogs. The result:
improved productivity, product quality and planning
security, and lower maintenance and service costs.
Author: Daniela Koehler, Press Officer, Kaeser Kompressoren SE
Repairing machines only when they break down: that’s how
things used to be done, even with compressed air systems. Today,
modern control technologies such as the Sigma Air Manager
4.0 (SAM 4.0), combined with intelligent data analysis, make it
possible to plan ahead when scheduling the maintenance of the
compressed air supply system. With digital networking and the
networking of machines with each other and with a service centre,
operators and manufacturers can track and analyse the status of
machine components on a continuous basis in order to predict optimal
maintenance times. This “predictive maintenance” concept
helps to detect impending faults, speed up processes and prevent
production downtimes.
Predictive maintenance is nothing new for Kaeser. For more than
30 years the company has offered operator models under which
customers purchase only the compressed air volumes that they
actually use. Kaeser retains ownership of the compressed air station
(contracting model) and takes care of everything else. To minimise
costs and maximise availability, Kaeser has been developing
and implementing machine-integrated master control systems
and teleservice solutions for many years. But it is only now, with the
54 WORLD OF INDUSTRIES

02 Real-time data monitoring is performed in the service centre
availability of modern databases and enormous improvements in
sensor technology, that real-time monitoring and predictive maintenance
have become a reality.
Tailor-made solutions
Customer needs vary widely. Kaeser has a diverse range of service
packages geared to specific requirements. One model, the Sigma
Air Utility, is based on the existing contracting models, which leave
nothing for the customer to take care of. Kaeser assumes full responsibility.
Similar to the electricity or water supply, customers
pay only for the compressed air that they use. This leaves them with
more liquid assets on hand for their core business activities.
Another model, Sigma Smart Air, is designed for customers who
own their compressed air stations. As regards service and availability,
however, they are just as care-free as those who opt for a contracting
solution – because Kaeser handles everything. According
to Kaeser’s estimates and the initial experiences, this model can
save up to 30 percent in service costs for customers.
Whether the compressed air station is owned by the customer or
Kaeser, the basic requirement for using predictive maintenance is
the Sigma Air Manager 4.0. This core control technology was developed
by Kaeser – as were the analysis tools behind it. The master
control system itself is the core element of a compressed air station
and is essential for utilising everything Industry 4.0 has to offer.
It functions as a central brain for the controlling tasks and data
streaming to the data (service) centre, which performs continual
monitoring and analysis. When potential faults are detected, a
process is initiated to ensure the problem never reaches the point
where components stop functioning. Along with fault analysis, the
control system determines when maintenance is actually needed,
as opposed to following a fixed schedule. This switch to needsbased
maintenance also saves costs.
01 The Sigma Air Manager 4.0 (SAM 4.0) master controller
functions as a management system for the compressed air
components and as a central node for secure data exchanges
Infrastructure, expertise and intelligent services
are essential
A system operator planning to introduce predictive maintenance
will need an excellent compressed air system infrastructure like
that provided by the Sigma Network. Real-time monitoring is possible
only if the system components are equipped with sensors that
enable the master control system to monitor activity, retrieve data,
and transfer it instantly. Naturally the vast quantities of raw, unfiltered
data are of little use on their own. Appropriate analysis processes
must be developed to extract useful information and predict
events. This requires human input – just like the steps that follow.
The global service network needs to be just as extensive and effective
as the data network to ensure a prompt and cost-effective response
when action is needed. The right combination of infrastructure,
expertise and intelligent services is essential for exploiting the
full benefits of predictive maintenance.
www.kaeser.com
The cornerstone: knowledge and
experience
Essential for the development of such predictive maintenance
concepts is the extensive knowledge, accumulated
over many years, on the processes, interrelationships,
vulnerabilities and challenges involved in producing and
using compressed air. It is this knowledge on the part of
Kaeser’s specialists – combined with the latest technologies
– that makes it possible to rapidly analyse and evaluate
the status of a station and to promptly initiate any
steps that may be needed.
WORLD OF INDUSTRIES 55

COMPRESSED AIR NEWS
Product News
One screw compressor for all
applications
Renner Compressors describes the RSF 127 D as a screw
compressor with an extensive control range and an extremely
high level of efficiency. It has a nearly loss-free direct drive
and supports power classes 75, 90 and 110 kW at pressure
levels of 7.5, 10, 13 and 15 bar. The RSF version features speed
control with 87, 97 and 127 kW available and a steplessly
adjustable pressure range from 6 to 15 bar. In combination
with the model RSF 90 D for basic supply, the RSF 127 D is
responsible for control
tasks, working especially
efficiently in the main
control range.
Because there is no
transmission, the efficiency
of the drive is nearly 100 %.
The efficiency-optimized
compressor stages and IE 3
electric motors ensure
optimum energy efficiency.
The radial fans, with a static
residual thrust up to 130 Pa,
are likewise economical. They serve as the connection to an
exhaust duct system. In this way additional “energy devouring”
support fans can generally be eliminated.
The speed controlled screw compressors are equipped with a
RENNERtronic Plus control unit as a standard feature.
Despite the space-saving design, the machine is very
maintenance-friendly. The compressor is especially economical
to maintain. This is due to the low storage and reserve
costs resulting from multiple use of service parts within the
series. With its small footprint, it is able to pass through most
door openings without being disassembled. The system can
also be installed close to a wall where space is limited – ideal
for container installation.
ComVac: Hall 26, Stand B68
www.renner-kompressoren.de
A new efficiency level for compressed
air supply
Energy efficiency plays a key role today in deciding which
technology to use to provide an industrial compressed air
supply. Almig is setting a new standard in efficiency here with
its 2-stage compression principle. A specific level of unrivaled
power is achieved by two compression stages joined together.
In this way the recently introduced G-Drive T series of Almig
provides a very high volume flow with lower motor power consumption
compared to equivalent market-standard one-stage
compressors. Lower speeds and a lower stage-internal
pressure differential not only increase efficiency but also
lengthen service life while enhancing the reliability of the
compression unit.
The G-Drive T200 compressor from Almig at the Hannover
trade fair offers all these advantages and also features a small
installation space thanks to its carefully planned design. In
terms of Industry 4.0, the compressor control unit meets all
requirements for
participating in company-internal
communication
and also for being
externally monitored via
Cloud services.
ComVac: Hall 26, Stand B55
www.almig.com
background: fotolia
56 WORLD OF INDUSTRIES

COMPRESSED AIR NEWS
New energy-efficient cold air dryers
SPX Flow intends to set a new milestone in energy efficiency with
the Flex cold air dryer series from Hankison. The high-performance
unit uses Phase Change Material (PCM) to achieve major
energy savings. The system pays for itself in one to two years. The
cold air dryer series makes use of the latest advances in heat
transfer technology as well as an innovative approach for
effectively removing
liquids from compressed
air. The system is
equipped with the 3-in-1
heat exchanger and the
PCM encloses the cooling
and compressed air
circuits. Because of this,
the Phase Change
Material remains colder
for a longer time and the
coolant compressor does not need to run as often as in conventional
energy saving designs. Because the dryers can be adapted
to the compressed air requirement at any time, they can be
dimensioned for the maximum compressed air requirement of
the system without any appreciable additional energy loss.
Hannover Messe: Hall 15, Stand G43
www.spxflow.com
Information transparency 4.0 for
compressed air units
Aerzen’s communication-capable control unit, the
AERtronic, makes it possible for users to integrate
compressed air units into their production and
manufacturing interfaces. The WebView module can
also be conveniently added to the control unit so that
operating and service data can be accessed from
anywhere in the
world at any time.
Warnings and
fault messages of
blowers or
compressors are
forwarded to the
relevant points
immediately by
email. For
diagnostics via remote access with an Internet-capable,
mobile terminal device (smart device) or for
maintenance of a central process control room,
Aerzen customers can use WebView, the integrated
AERtronic solution, to access operating data and
service information related to their process air units
with an html5-capable web browser – with no need
for any additional software or apps. This gives them a
quick breakdown of the most important measured
values and parameters related to operating and
maintenance intervals. WebView is designed so that
existing systems with AERtronic can be upgraded
cost-effectively at any time.
ComVac: Hall 26, Stand E12
www.aerzen.com
High compressed air quality and productivity thanks to integrated
drying and filter systems
The Parker Zander business unit of Parker Hannifin is presenting the new integrated drying and
filter systems CDAS (Clean Dry Air System) and OFAS (Oil Free Air System). Both CDAS and OFAS
meet the requirements of ISO 7183 and ISO 8573-1 for compressed air purity. OFAS also complies
with purity class 0 for total oil content (applies to both oil-lubricated and oil-free compressors).
This classification ensures optimum air quality, even for critical applications, at a fraction of the
cost of an oil-free compressor. The innovative drying and filter systems offer long-term high
performance capacity over a longer time. Both systems use the special Snowstorm filling technology,
which maximizes packaging density and prevents channels from forming. It also ensures a
stable dewpoint, contributes to a low differential pressure and minimizes energy consumption.
The CDAS and OFAS systems also feature impressively low maintenance times, simplified exchange
of replacement parts, maximum operating time and extended maintenance intervals. The
latest energy consumption technologies combined with advanced flow rate management and
special filter solutions ensure a consistently lower differential pressure for significantly lower
energy consumption and low operating costs.
ComVac: Hall 26, Stand B78
www.parker.com
WORLD OF INDUSTRIES 57

COMPRESSED AIR NEWS
Product News
Vacuum pumps for every application
Energy-efficient solutions for
compressed air preparation
Beko Technologies GmbH will be presenting energy-efficient
solutions related to compressed air preparation at ComVac
2017. The manufacturer and provider of components and
systems for preparation and management of compressed air
and compressed gas is highlighting its management competence
for individual projects and its service along with various
systems and products at its trade fair stand. Norbert Strack,
Technical Managing Director at Beko Technologies, notes:
“As a manufacturer we are able to offer our customers
competent and comprehensive
consulting. Each
sector of industry has its
own requirements for
compressed air. We
therefore develop
custom-made system
solutions for the entire
process of preparing
compressed air from compressor to end application. In this
way we can offer customers the optimum technology for
exactly the compressed air quality they need for an application
in whatever industry – from simple process compressed
air to dry, oil-free and sterile compressed air of the highest
quality.”
The new products introduced by Beko Technologies at this
year’s trade show include the Drypoint M eco control membrane
dryer. It features for the first time an electronically
controlled drying system that can be used to set a fixed
pressure dew point between +10 and -26°C or a fixed distance
between the temperature of the compressed air and the
pressure dew point of the outlet.
ComVac: Hall 26, Stand C31
Atlas Copco is exhibiting its wide portfolio of vacuum pumps,
some completely new, at ComVac. The Group presents itself as
a complete provider. After acquiring Edwards in 2014, as well
as the vacuum division of the Oerlikon Group (Leybold), Atlas
Copco founded its own Group division for vacuum technology.
The exhibit will cover efficient vacuum solutions for all
conceivable industrial applications, from speed controlled
screw vacuum pumps to rotary vane and multi-claw pumps
and also including
liquid ring pumps.
The series GHS
3800–5400 VSD+
speed-controlled
vacuum pumps are a
highlight at the trade
fair stand. They are
suitable for efficient
vacuum supply at up to
4800 m³/h. Previously the most powerful model in the series
had achieved a maximum of 1810 m³/h. With energy savings
of up to 50 % compared to conventional rotary vane vacuum
pumps plus their maintenance-friendly design, the pumps pay
for themselves very quickly, notes Christoph Angenendt,
Communications Manager for Industrial Vacuum at Atlas
Copco. The screw vacuum pumps are suitable for applications
with high vacuum requirements, for example in the glass
industry, on packaging lines or for drying processes. As part of
a central supply concept, vacuum generation can be precisely
adapted to the customer’s need with the new pumps. This is
because the vacuum pumps, which feature an intelligent
electronic control system, work extremely efficiently at a
variable speed (VSD+, Variable Speed Drive). Atlas Copco
provides the vacuum pumps as complete systems in a
housing, wired and ready for connection.
ComVac: Hall 26, Stand B32
www.atlascopco.com
www.beko-technologies.com
Imprint
Compressed Air News is published in cooperation with ComVac,
the leading trade fair for compressed air and vacuum technology.
Vereinigte Fachverlage GmbH, Lise-Meitner-Straße 2, D-55129 Mainz /
P.O.Box 100465, 55135 Mainz, phone: 0049/6131/992-0, fax: 0049/6131/992-100
Managing Director: Dr. Olaf Theisen
Publishing Director: Dr. Michael Werner, Tel: 0049/6131/992-401
Editorial: Dipl.-Geogr. Martina Laun, Phone: 0049/6131/992-233
(Responsible according to the press law)
Design: Sonja Schirmer
58 WORLD OF INDUSTRIES

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SUMMERof 2017
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FAULHABER Encoders
Sensitive positioning
is the key
NEW
WE CREATE MOTION
FAULHABER encoder series IER3/IERS3
The new series expands the FAULHABER portfolio with two high-precision optical
encoders. The models are characterised by high signal quality with minimum
weight and compact design. With up to 10,000 pulses per revolution, they also
offer the best resolution in their class. Due to the very high position accuracy and
repeatability, they are perfectly suited for all demanding positioning applications.
www.faulhaber.com/IER3/en
Hannover, 24. – 28.04.2017
Hall 15 · Stand H29