2017-1

01/2017
MOTION, DRIVE & AUTOMATION
Schaeffler boots its
standard bearing business
www.engineering-news.net
in cooperation with
Fluidtechnik
Antriebstechnik

MDA Events Worldwide
Join the No. 1 Trade Fair Network for Motion, Drive & Automation
Turkey Istanbul 16 - 19 Mar 2017
Germany Hannover 24 - 28 Apr 2017
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
India Mumbai 22 - 24 Feb 2018
www.hannovermesse.de/worldwide

EDITORIAL
The world has
turned upside down
Dear readers,
the world seems to have turned upside down in these times: In Syria a
bitter civil war has been raging for years. Since 2003 Islamic State,acting as
a terrorist Sunni militia, has not only been active in Iraq and Syria, but has
also spread fear and terror worldwide with terrorist attacks. In Turkey
President Erdogan is gaining more and more power, visibly pushing the
country in the direction of a dictatorship. In Europe, Great Britain has
pitted itself sharply against the European Union with Brexit and by so
doing is stoking the flames for the nascent right-wing populist parties,
which seem to be winning seats in more and more parliaments. And then
there are the two great potentates, Putin and Trump. One casually
annexes Crimea while the other – barely in office – is quickly following up
his threats with actions in matters of protectionist trade and investment
policies. And in general he is behaving like a bull in a china shop – without
regard to existing agreements and treaties.
But getting back to the USA: There is a climate of great uncertainty in
industry, quickly leading to a reluctance to invest. Thus even before
Trump took office, from January to October 2016, exports from Germany,
one of the major trading partners of the USA, declined by 3.4 %. In the
period from August to October, machine exports even fell by 5.8 %. Other
countries face similar problems. The course of further developments is
unclear. It will depend greatly on how the new president implements what
he has announced in actual policy and also whether Congress will simply
wave through all the changes. Thilo Brodtmann, General Manager of the
German Engineering Federation (VDMA, Verband Deutscher Maschinenund
Anlagenbau e.V.), notes confidently, “Isolating the American economy
with tariffs and walls would inevitably hurt not only its trading
partners, but also the United States itself.” After all, US companies are also
tied into global added-value chains and rely on foreign business markets.
How the individual conflicts will be resolved is very difficult to predict. But
we will experience how worldwide industry is responding in the coming
months at some important trade fairs in the near future: The leading trade
fair for the next generation of production starts in March in Istanbul with
WIN Eurasia, while the Hannover trade fair will attract the world to
Germany again in April to the largest event for mechanical engineering in
the world. The most important innovations related to drives and automation
technology will be on display here. This
edition already has a small foretaste of what
you can expect. Here too the world has turned
upside down – not politically, but with technological
innovations.
Wishing you enjoyable reading,
Dirk Schaar
Editorial Director
Meike Sauer
Deutsche Messe AG
MOTION, DRIVES & AUTOMATION
Editorial director:
Dipl.-Ing. (FH) Dirk Schaar
Email: d.schaar@vfmz.de
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Email: m.pfister@vfmz.de
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Email: info@jordipublipress.de
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Email: verlagsbuero-mezger@vfmz.de
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Fachverband Fluidtechnik im VDMA
Fluid Power Association of India
Moskauer Deutsche Zeitung
Internet:
www.en.engineering-news.net
8 th year (2017)

TABLE OF CONTENT
EDITORIAL
WORLDWIDE NEWS
TURKEY: OPPORTUNITIES DESPITE
TURBULENCE
WIN EURASIA: BRINGING
INTEGRATED SOLUTIONS FOR
TURKEY’S NEW GENERATION
MANUFACTURING
DIRKS CHOICE
SCHAEFFLER STRENGTHENS ITS
BEARINGS BUSINESS WITH A NEW
PRODUCTION FACILITY
BRAKE TECHNOLOGY 4.0: SAFETY
BRAKES FIT FOR ALL CHALLENGES
NEW GENERATION THERMOPLASTIC
POLYURETHANE
PRODUCT NEWS
SUCCESS IN THE HIMALAYAS
PRODUCT NEWS
MDA SHOWCASES DIGITALIZATION
WITH PREDICTIVE MAINTENANCE
APPLICATIONS
MOTION, DRIVES & AUTOMATION
WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/2017

TABLE OF CONTENT
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Find out more at www.FAG-GenerationC.com

Worldwide News
Japan’s Yaskawa expanding strategically
in Europe
Japanese technology group Yaskawa is focusing to intensify
its presence in Europe, with the aim of becoming one of the
leading manufacturers of industrial robots in strategic target
markets. The company plans to expand its production
capacities and open a new robot manufacturing plant and a
new European robotics development centre in Slovenia.
Creating 200 additional jobs in the process. The first Yaskawa
Austrian company NKE completes 20
successful years in the bearings industry
NKE, the bearing manufacturer based in the Austrian city of Steyr
is celebrating its 20 th anniversary. The company, by Heimo Ebner
and Harald Zerobin, produces bearings for all industrial applications,
with engineering, product development, production,
logistics, sales and marketing being centralised at its Steyr
headquarters. The company operates its sales through 12 international
offices and 240 distribution outlets in 60 countries. In its first
10 years, NKE saw rapid growth, with its turnover increasing on
average by more than 20 % a year. To keep up with the growth, the
company invested more than 15 million Euros to build its new
premises in Stadtgut Steyr business park in 2009. This investment
helped NKE double its production capacity. In 2016, the Spanish
company ‘Fersa Bearings’ acquired 49 % interest in NKE. The
resulting group of companies now boasts 3 production sites, 5
distribution centres, and 3 R&D locations. After guiding the
company for 20 years, both its two founders Heimo Ebner and
Harald Zerobin passed the company’s management on to Thomas
Witzler in July 2016. With their expertise and experience they
continue to actively deal with NKE’s vision and strategic planning
for the coming decades.
robots from all-European production are expected to roll in
2018. The factory should satisfy about 80 % of the European
demand for robots. Total investments are estimated to be in
the order of 25 million euros. As one of the top global players
in the industrial robot sector with more than 350,000 units
sold, Yaskawa is pursuing an ambitious expansion strategy in
Europe. The new production and development capacities will
permit faster customized robotic solutions in Europe. This
will also strengthen the cooperation with OEMs in these
markets. Yaskawa is expanding its European activities
through investments in the existing robot business as well as
electric drive technology, industrial control technology and
‘Green Energy’.
www.yaskawa.eu.com
Caption: NKE founders Heimo Ebner (left) and Harald Zerobin
(right) with General Manager Thomas Witzler (centre)
www.nke.at/en/home
NEWS AND MARKETS
Mayr power transmission expands its existing facility
Since the ground-breaking ceremony in mid 2016, much has
happened on the construction site of the new facility at Mayr
power transmission in Mauerstetten. Currently, trapezoidal
sheets are being installed on the roof. Therefore, the roofing
ceremony for the new facility took place back in November in
the presence of numerous representatives from the companies
involved in the construction. Owing to smooth construction
process, it has been possible to cover the site according to plan
before the winter. Over the winter months, the interior
construction will take place, so that it will be possible to move
into the new hall by approximately mid-2017. The new
production and assembly hall has a length of 105 m and a
width of 45 m, occupying a total floor area of 4 500 m 2 . The
assembly, dispatch and a warehouse close to the assembly will
be located in the new facility. Around 600 m² office area,
appropriate meeting and engineering rooms have been
planned in the building. Mayr Power transmission is investing
heavily in its Mauerstetten location with this new site along
with the new communications centre simultaneously being
built on the premises.
www.mayr.com
WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/2017

KTR Kupplungstechnik GmbH changes its
name to KTR Systems GmbH
Founded in 1959, the KTR group
comprises of 23 subsidiary companies
and 90 sales partners worldwide
along with 7 production sites in
Germany, Poland, USA, Brazil, India
and China. KTR Kupplungstechnik
GmbH, the family-owned company
located in Rheine has strongly expanded over the past
decade in the sectors of drive technology, brake systems,
hydraulic components and cooling systems. Furthermore
the company has intensified its international activities in the
fields of production, logistics and sales substantially. The
product portfolio includes mechanical couplings, torque
measuring shafts, clamping sets and universal joints,
hydraulic and electromechanical brake systems, cooling
systems for industrial applications in mechanical and plant
engineering. Being the legal successor, KTR Systems GmbH
will automatically and fully take on all rights and obligations
from KTR Kupplungstechnik GmbH. Rheine will remain the
company’s headquarters, with only the mail address being
changed from Rodder Damm 170 into Carl-Zeiss-Straße 25,
Rheine 48432. The well-known company logo and the claim
“Made for Motion” will remain unaffected.
www.ktr.com
Nord Drivesystems expands its facility in
Pune, India
Nord Drivesystems has committed to invest 45 million Indian
Rupees (approx. EUR 600,000) to the expansion of its Indian
subsidiary. The investment was used to establish a new service
area at the Nord Drivesystems Pvt. Ltd. facility in Pune. The factory
now boasts a 13,000 m² shop floor and can turn out over 24,000
drives per year.
Since 2005, the
company has
delivered more
than 100,000 geared
motors to customers
across the
subcontinent. Short
delivery times and
fast service are
among the most
important measures
to keep
regional customers
satisfied. Staffed with a team of experienced, highly trained
technicians, the new, expanded service area is crucial to ensure
this for the future. In addition, NORD has launched an initiative for
service vehicles: they serve customers on location, quickly provide
qualified customer service, and are even equipped to offer
training.
www.nord.com
DERANTRIEB■ Reliable
■ Versatile
■ Global
NORD DRIVESYSTEMS:
■ Worldwide available
■ Subsidiaries in 36 countries
■ Agents in 52 countries
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

Turkey: opportunities
despite Turbulence
NEWS AND MARKETS
For Turkey, 2017 began on a hurtful note with the
attacks in Istanbul; the entire world expresses their
condolences and support to Turkey and its people. But
in my regards the best way to beat the narrative of the
disruptive forces is by not letting them derail the cycle
of growth and development in the region.
Turkey is a key ally to both, Europe and the United States. A longstanding
member of NATO and a candidate for membership
in the European Union, it has strong ties to the West and has long
served as a bridge to the East in a volatile, yet extremely strategic
region. The collaboration between Turkey and Germany or Europe,
in the context of technology and industry has been progressive ever
since the Ottoman Empire. Since then, a large number of technology
based corporations like Siemens and Schneider Electric have
been the first to introduce many innovative technologies in Turkey,
for example, establishing the telegraph system in mid-1800s, supplying
heavy industry products to the Ottoman Navy, laying the
electricity network in 1914 even during the first world war or bringing
the fiber optic cable on the Bosphorus bridge in 1986. With the
onset of the new millennium, Turkey’s acceptance and integration
with the new technologies has created a massive growth cycle for
the Eurasian region’s industrial development.
Turkey’s economy and role of industry
In the broad frame of economics, Turkey has definitely been a
success story in this century so far. In the last 15 years, Turkey has
shown robust macroeconomic growth with an average annual real
GDP growth rate of 4.7 %. The GDP rose from $ 230 billion in 2002
to more than triple at $ 720 billion in 2015. The country has undergone
profound transformation over the last decade to solidify its
economic foundation. It is the 16th largest economy in the world
in terms of purchasing power parity and the 6th largest economy in
Europe. In 2015, Turkey had global trade volumes totalling to more
than $ 315 billion, of which approximately 40 % was with the EU 28
countries, followed by China, Russia, USA, South Korea and Iran.
The EU is Turkey’s number one import and export partner while
Turkey ranks 7 th in the EU’s top import and 5th in export markets.
Turkey’s exports to the EU are mostly machinery, transport equipment
and engineering goods. (Statistics: European Commission,
Directorate General for Trade)
The Economist Intelligence Unit (EIU) expects an annual average
growth rate in real GDP to be around 5 % in 2017-18. The OECD
forecasts the GDP growth to pick up to around 3.25 % in 2017 and
3.75 % in 2018, driven mainly by recovering household consumption
and gradual increases in exports. Monetary policy played a
vital role in controlling and bringing down the inflation over recent
years. The rate of inflation in Turkey has stayed under 10 % since
2004 and year-end inflation was capped as 6.2 % in 2012. EIU forecasts
that the average inflation rate will further ease to 4 % by 2018.
The manufacturing industry is one of the main drivers of the
Turkish economy, accounting for roughly a quarter of the total GDP.
According to Turkstat, Turkey’s manufacturing industry has been
growing at a CAGR of 12 % since 2003, exceeding the growth levels
of the GDP and reached TL 220 billion in 2012. Turkey’s increasing
level of disposable income and the high disposable income levels of
its export partners – mostly EU countries, provide a much necessary
boost to the domestic consumption as well as exports.
Author: Sushen Doshi, International Correspondent for World of Industries
WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/2017

Turkey 2023
To establish itself as major manufacturing power, Turkey has set the
year 2023 as its target. All the government initiatives and policies
are focused with 2023 in sight. For the machinery and equipment
manufacturing sector, the goal is to achieve $ 100 billion in export,
securing a roughly 2.5 % share of the global machinery market.
Apart from creating more economic value, the country’s industry
aims to create custom-designed, high-quality, affordable and environmentally
friendly products, accelerating Turkey’s transition
from low value-added products to high value-added products and
creating joint R&D centres while increasing R&D spending. Turkey
has signed agreements with the EU ensuring an increase in R&D
expenditure up to 3 % of its total GDP until 2023. Two thirds of this
will be funded by the private sector as is stated in its agreement
with the EU. These incentives that are backed by law will secure
Turkey’s position as a R&D base by encouraging foreign investors
to set up Technology Development Zones (TDZ) in Turkey. TDZs
are organized research and business centres where academic, economic
and social structures become integrated and universities,
research institutions, and industrial foundations work together for
innovation, technology transfer; increasing productivity and reducing
production costs; increasing product quality and standards;
working on product development; supporting technological investments
and entrepreneurship. To further promote the participation
in TDZs, the government offers incentives and tax exemptions to
entrepreneurs operating in this region until 2023 from the income
made from R&D operations and software. Taxes on the wages of
R&D personnel are exempt until 2023 as well. On an average, every
year 4 new TDZs are launched in Turkey.
Demographic advantage
Turkey’s workforce is one of the youngest and largest in Europe with
the necessary education, skills and knowledge. More than 60 % of
the population is aged between 24 and 54, and 25 % population in
the age group of 0-14, which is a huge demographic and economic
advantage for Turkey. Moreover, Turkey has one of the lowest minimum
wage rates in Europe with approximately $ 600 per month in
2016. There are four mechanisms through which the demographic
benefits are delivered:
n The increased labour supply. However, the magnitude of this benefit
appears to be dependent on the ability of the economy to absorb
and employ the extra workers.
n The The increase in savings. As the number of dependents decreases
individuals can save more. This increase in national savings
rates increases the stock of capital in developing countries
already facing shortages of capital and leads to higher productivity
as the accumulated capital is invested.
n The human capital. Decreases in fertility rates result in healthier
women and fewer economic pressures at home. This also allows
parents to invest more resources per child, leading to better
health and educational outcomes.
n The increasing domestic demand brought about by the increasing
GDP per capita and the decreasing dependency ratio.
Free trade and customs agreement with EU
According to the Ministry of Economy, Turkey has free trade agreements
(FTA) with 19 countries and has started negotiations with
another 13 countries. In 1995-96 the Ankara agreement established
a customs union between Turkey and the European Union. Under
the customs union agreement, goods may travel between the two
entities without any customs restrictions. The customs union does
not cover essential economic sectors such as agriculture (to which
bilateral trade concessions apply). Turkey’s main exports to EU and
imports from EU are dominantly industrial. Since 1996, Turkey’s
GDP has increased 4-fold, making it one of the fastest growing
economies in the world. At the same time, however, the foreign
trade deficit of Turkey (between EU) has increased 2 fold. The customs
union is a large factor in both of these developments. In addition
to providing for a common external tariff for the products
covered, the customs union foresees that Turkey is in compliance
with the EU industrial standards.
Apart from FTAs, there are also 19 free trade zones within Turkey
which enable corporate, income and customs tax, VAT and other
exemptions. The Turkish investment incentive program provides
varying tax reductions between 15 to 65 % depending on investment
region, scale and social security support for 2 to 12 years.
Growth despite turbulence
The Turkish economy continues to face geopolitical headwinds
and unsettled political conditions, after having weathered a coup
attempt in July 2016 and engaged in military operations in Syria.
More recently, in the context of high geopolitical uncertainty and an
extension of the state of emergency, a rating downgrade triggered a
weakness in overall business sentiment. Turkey’s main export markets
in Europe and in the region remain subdued. A trade embargo
imposed by Russia in 2016, which is in the process of being waived,
added to the volatility of export markets. Nonetheless, exporters are
highly entrepreneurial and taking opportunity of the exchange rate
depreciation, Turkish firms have increased their share in several alternative
markets in 2016, including in some EU countries. With the
expected normalisation of external trade conditions, real exports of
goods and services are projected to recover gradually in 2017.
Photographs: Lead photo Fotoliaz
Safety 4.0
ROBA ® -topstop ® —the certified
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Mayr-Englisch.indd 1 13.01.2017 11:09:26
WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/2017

WIN Eurasia: bringing integrated solutions
for Turkey’s new generation manufacturing
The Tüyap Fair and Convention Center in Istanbul will
be a very busy place from 16 th to 19 th of March 2017,
as experts and professionals from the industrial sector
will gather to attend the trade fair, WIN Eurasia. This
international event focuses on latest technology in
areas of automation, electro-tech, hydraulics,
pneumatics and intralogistics.
Istanbul is at the centre of an economic area known as ‘Eurasia’. The
proximity to the Balkans and the rest of Europe as well as to the
emerging markets in Central Asia, the Middle East, and North Africa
creates unique business opportunities. The presence and consistent
growth of numerous global firms consolidates its position as
a dominant investment location and export platform. Turkey is the
leading investor in the Caucasian and Central Asian Republics. Due
to the strong cultural and historic ties, Turkey provides privileged
access and a perfect base to develop business with these countries.
It is an important market for global business to reach over one billion
consumers. And as the economic capital of Turkey, Istanbul is
NEWS AND MARKETS
Author: Sushen Doshi, International Correspondent, World of Industries
10 WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/2017

the natural location for an international industrial trade event like
‘WIN Eurasia Automation’. This trade fair represents a real-time, interactive
environment bringing together the supply and demand of
Turkey’s manufacturing industry.
Most influential industrial trade event in Eurasia
Motion, drive and automation are the three keywords of the trade
fair, to be held from 16th to 19th March in Istanbul, Turkey. A large
number of Turkish as well as German along with other European
and Eurasian companies will participate in the event, which is now
to become the most important and influential industrial trade event
in the region. With more and more number of European companies
taking part in this event every year, it aims to increase the knowledge
of latest trends and technology among Turkish operators who
are always keen on innovation. The trade fair also encourages the
gradual development of industrial and commercial cooperation between
European companies and local Turkish companies. The fair
will take place at the Tuyap Fair Convention and Congress Centre in
Istanbul, where the exhibitors with high level of technical expertise
from various sector will be able to show the best of technology and
innovation to the visitors and industry professionals.
As the most influential industrial trade event in the Eurasian
region, WIN Eurasia is expected to attract approximately 70,000
visitors and industry experts from all parts of Turkey. In Istanbul,
visitors shall have an advantage of being able to attend four different
trade shows, namely Otomasyon Eurasia, Electrotech Eurasia,
Hydraulic & Pneumatic Eurasia and CeMAT Eurasia. This event
provides complete solutions for manufacturing industry, focusing
mainly on mechanical engineering, electrical engineering, industrial
IT and digitalization of manufacturing. With more than 1500
exhibitors showcasing their products and intelligent technologies
within a display area of 30,000 m 2 , the show attracts exhibitors
not only from Turkey but 25 other countries, including Germany,
Italy, USA, China, UK, Taiwan, Korea, Japan, Sweden and
the Netherlands. Exhibitors have the opportunity to introduce
their innovations to visitors from Middle East, Europe, Africa, CIS
countries besides Turkey, Bulgaria, Cameroon, India, Romania
and Uzbekistan.
Of all the marketing instruments, international trade fairs and especially
WIN Eurasia, has the widest range of business functions.
It serves as an opportunity to develop and the cultivate customer
relations, it helps in identifying new local partners, distributors,
suppliers and competent personnel from the relevant industry sector
and it helps to increase the company’s market presence and
position as a whole. With so much of technological developments
taking place in Germany, particularly with increasing digitalization
and whole Industry 4.0 revolution, this event serves as a test in the
Eurasian market for new integrated and digitalized products and
hence also functions as market research instrument for innovative
companies. In order to reach the right target audience, WIN Eurasia
provides exclusive sponsorship opportunities to widen the market
and brand exposure of partner companies. This Trade fair serves to
analyze the market situation and to prepare the ground for implementing
market strategies, resulting in increasing the sales. For new
companies in particular it is important to gain an overview of competitors,
their performance, products and after-sales services. Often
a visit to an international trade fair like WIN Eurasia Automation is
all that is needed at an early stage of entering a market.
4 different trade fairs under one roof
WIN Eurasia Automation provides many solutions required for a
factory under a single roof, from cables to fluid power technologies,
drive technologies to software products, robotic arms to unmanned
forklifts. With 4 different trade fairs under one roof, at WIN Eurasia
Automation visitors will be able to see that, Istanbul is the pioneer
for the Eurasian countries in terms of advanced manufacturing,
digitalization and Industry 4.0 technology.
Otomasyon Eurasia: The importance of globalization and productivity
is an ever increasing and urgent demand in today’s world
and that can only be supplied by Industrial Automation. Otomasyon
Eurasia focuses on automation of factories, processes, operations and
industrial buildings. Exhibitors will showcase their quality products
and services, innovations, components and robotic applications of
Industry 4.0. Product category at Otomasyon Eurasia includes: Assembly
& handling systems, linear positioning systems, communication,
networks, and field bus systems, control systems, embedded systems,
Industrial building automation systems, industrial IT & software.
Electrotech Eurasia: By 2023, Turkey is planning to increase its energy
generation capacity from around 40,000 MW to nearly 100,000
MW. To stimulate the level of investment from the private sector in
energy generation capacity and distribution infrastructure, the Turkish
government is making requisite investment to the tunes of tens of billions
of dollars. These huge sums of investment testify to the enormous
scale of Turkey’s commitment to expand and future-proof its energy
sector. Companies wanting to participate in Turkey’s journey to a modern,
diversified energy industry will find the perfect platform for presenting
their technologies in Istanbul – at ‘Electrotech Eurasia’. Product
category at the trade fair includes: Cables & equipment for electric
power transmission, electric and electronic test and measuring equipment,
electric motors & frequency inverters, motor drives, electric
switchgear and equipment for electric power distribution, electronic
and opto-electronic components, gears, mechanical drive systems,
transformers, accumulators, uninterruptable power supplies and generators,
grid management and power quality monitoring systems.
Hydraulic & Pneumatic Eurasia: The hydraulic and pneumatic
systems are among one of the most essential systems for engineers,
thanks to the advantages and increasing number of product range
they offer. The Hydraulic & Pneumatic Eurasia is getting ready to
present outstanding innovations in this field for industry professionals.
In addition to this, also on display will be the Compressed
Air and Vacuum Technology, for the first time during WIN Eurasia
Automation. Product category at ‘Hydraulic & Pneumatic Eurasia’
includes: Hydraulic pumps, motors, gear pumps and gear motors,
hydraulic variable speed drive units, hydraulic and pneumatic cylinders
and actuators, control valves and pressure switches, pipes
and hoses, filters for lubrication systems, compressors and compressed
air preparation equipment.
CeMAT Eurasia: Today, increasing needs of the industrial society
lead to a huge demand for solutions in areas of transport, handling
and storage. Exhibitors from around the world present innovative
logistics systems, cranes and forklift trucks, packaging technologies,
shelving systems, logistics IT and electronic in intralogistics
sector at CeMAT Eurasia.
Photographs: Hannover Fairs Turkey Fuarcilik A.S.
www.win-automation.com
WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/2017

Innovations you
definitely shouldn’t miss
at WIN EURASIA 2017
CHOICE
SMC’s new 4-axis step
motor controller
Drive controller in
multi-axis drive system
Low-maintenance
drives for intralogistics
PRODUCT NEWS
Lower device costs, less programming
time, less wiring work and lower space
requirements – are the most important
advantages of SMC’s new 4-axis step
motor controllers JXC73 and JXC83.
These make it possible to control up to
4 electrical actuators for individual or
multiple axes simultaneously. Programming
is done on a PC using a USB
2.0 interface. The new 4-axis step motor
controllers from SMC can reach
entered target positions in 2 ways: for
linear interpolation, only the target
position and the speed of an axis are
required. From this information, the
controllers calculate all of the values of
the X, Y and Z axes that are necessary
for three-dimensional movement.
Alternatively, it is also possible to use
circular movements. If you enter the
coordinates of the target position, the
rotation direction and the centre point,
the controllers use circular interpolation
to calculate all of the X and Y
values required to run the circular path.
www.smc.eu
Under the name of SI6, Stober presents
its latest drive controller in multi-axis
drive system. With a width of only 45
mm, the SI6 has compact design and
requires extremely little space in the
control cabinet. Even more decisive
than the compactness is the omission
of redundant supply units. The entire
series of drive controllers is connected
with a central supply module. The fuses
and cabling for each individual axis are
also distributed from here. The drive
controllers are connected with each
other via quick DC-link modules and
by using double axis modules, unused
power reserves of an axis can be used
for other axes. In regards to acceleration,
the SI6 in combination with the
Stober’s synchronous servo motor,
accelerates from 0 to 3 000 rpm in
10 ms. For the safety concept, Stober
counts on the STO (”Safe Torque Off”)
function that can be controlled via
terminals as well as via Fail Safe over
EtherCAT (FSoE).
www.stober.com
Nord Drivesystems now offers standardized
drive units in 3 versions for
typical requirements in conveying
applications. The line-up of LogiDrive
systems enables a quicker selection of
the drive for a given application. IE4
synchronous motors with 1.1, 1.5, and
2.2 kW rated power are combined with
two-stage helical bevel gears for speed
ranges of 0 to 565 rpm or 0 to 482 rpm.
The transmission is continuously
variable in the range from 1 to 500.
Distributed frequency inverters for
installation on the conveyor frame near
the motor ensure accessibility. They
feature a key switch for disconnection
from the plant control system and a
direction switch for local set-up.
LogiDrives are designed for horizontal
or inclined conveyors. The motors
feature a high overload capability. The
system has all components that can be
serviced separately. This significantly
reduces maintenance costs. Nord
integrates all standard fieldbus and
Industrial Ethernet interfaces directly in
the AC drive.
www.nord.com
WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/2017

Automatic torque
limiter
In case of rough operating conditions,
the drives particularly are encapsulated
and therefore hard to access. But these
machines require reliable overload
protection. Mayr, the specialist in
power and torque transmission has
now developed a robust, disengaging
torque limiter which can withstand
Plug and play adapters
for Simatic controllers
For error-free connection of modules
to the Simatic S7- 1500 controller,
the company Phoenix Contact now
offers controller-specific front
adapters as part of the Interface
system cabling range. Due to its
plug-and-play concept, these adapters
reduce the wiring effort to just a few
steps. The adapters are easily swiveled
into the digital or analog I/O cards
and connected to the ‘Varioface’
interface modules via pre-assembled
system cables. They are available as
Servo motors for highprecision
applications
With the new DSH1 series, where “H”
stands for high precision, the drive
specialist Baumüller has created
another derivative in its servo motor
range. The latest product impresses
with a particularly low torque and thus
achieves an extremely high control
high loads and also automatically
re-engage. In case of overload, if the
torque exceeds the value set on the
clutch, a patented disengagement
mechanism of the EAS-reverse torque
limiter, separates the input and output
almost free of any residual torque with
high accuracy.
www.mayr.com
‘passive’ components with various
connection methods including knife
disconnection.
www. phoenixcontact.com
accuracy. The DSH1 high precision
servo motors were developed specifically
for applications with the high
precision e.g. in the handling and
robotics field, including welding robots
that produce components with a
precise and high-quality welding seam.
www.baumueller.de/en
Servo drive even with a
sine wave filter
B&R has made further developments to
the current control loop for its Acopos
P3 servo drives. Users can now
implement a sine wave filter without
having a negetive effect on the drive
control performance. These developments
are aimed at providng the
machines the advantages of a sine wave
filter while the Acopos P3 retains its
usual high performance. By converting
the voltage signal from a square
waveform to a largely sinusoidal one,
sine wave filters help improve energy
efficiency, reduce strain on the motor
and decrease electromagnetic noise on
the motor cable. They also smooth out
the current curve, which reduces both
acoustic noise and motor losses.
www.br-automation.com
OPC UA communication
With a new extension of the OPC UA
specification, which Beckhoff played a
prominent role in developing, the
publisher/subscriber principle is being
introduced into the established and
standardized OPC UA communication
protocol. One particular advantage is
the much simplified configuration
resulting from direct integration into the
TwinCAT 3 environment. Communication
is initiated directly from the
TwinCAT 3 runtime, creating a realtime-capable
communication channel
via OPC UA. Conventional client/server
applications are decoupled from one
another in publisher/subscriber-based
data communication and no longer
need to “know” each other.
www.beckhoff.com
Planetary gearboxes for
better performance
Neugart’s 2 latest products: a high
precision gearbox with helical gearing
and a right angled gearbox with
compact output flange, offer solutions
to the increasingly demanding
challenges the customers face.
Neugart’s ‘PSBN’ is an apt combination
of a precision planetary gearbox and
efficient bearing technology. The
WPLFE, is the right angled gearbox
with compact output flange, and is
extremely helpful when things are tight.
The WPLFE saves up to a third of the
space and has up to 5 times higher
torsional stiffness. Due to its standardized
flange interface, it is simple to
assemble.
www.neugart.com/en-us
WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/2017

FAG Generation C Deep
Groove Ball Bearings
Schaeffler strengthens its bearings
business with a new production facility
MACHINE ELEMENTS
Schaeffler expands its business for rolling bearings
with additional production capacities for FAG
Generation C deep groove ball bearings. With an aim
to make this product series even more attractive for
its customers, the company has tweaked its
manufacturing process and the logistics model, therefore
providing an even better price-performance ratio.
Schaeffler, the global integrated automotive and industrial supplier
of high precision components and systems, is now further
expanding its standard rolling bearing business. One aspect of the
new growth strategy is on the FAG Generation C deep groove ball
bearings. The company has made heavy investments in new production
and logistics capacities as well as improved product characteristics.
In the coming months, Schaeffler will put the production
lines at its location in Yinchuan (China) gradually into operation.
This will considerably increase the availability of FAG deep groove
ball bearings. Overall, Schaeffler will double its capacities in this
high volume product series of FAG deep groove ball bearings. In
addition to the new location in China, Schaeffler’s production network
comprises manufacturing plants in Caldas (Portugal), and
Savli (India), where the deep groove ball bearings have been manufactured
for several years.
Strengthening the standard rolling bearing
business
Strengthening the standard production business is an important
aspect of the ‘Core’ program, which was developed to reorganize
Schaeffler’s Industrial division. “Our investments will help us satisfy
the strong demand for standard deep groove ball bearings, especially
from China and the Asia/Pacific region, and meet the specific
requirements of this high volume business in an optimum way.
Our products live up to the highest technical requirements and, at
the same time, offer a cost-effective price-performance ratio” said
Dr. Stefan Spindler, CEO Industrial at Schaeffler. Electric motors,
household appliances, pumps and fans, power tools, and two-wheelers
are the fields of application in which FAG Generation C deep
groove ball bearings are most commonly used. In these fields, highquality
products that meet high requirements, especially in terms of
noise, friction, and sealing are required. “We looked at the product,
production, and logistics, and developed solutions that fulfill the
highest requirements on the market” said Thomas Kreis, project
manager for the deep groove ball bearing, a high volume business
at Schaeffler. “We have optimized our technically advanced product
even further, developed the newest, highly-automated production
processes, and come up with a specific logistics concept”.
Bearings with low-friction and lower
noise emissions
Ever since FAG Generation C deep groove ball bearings were successfully
introduced in 2008, their product characteristics have continu-
WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/2017

02 1. Open bearing, 2. New gap seal on both sides (2Z),
3. Lip seal on both sides (2HRS), 4. Lip seal on both sides (2ELS),
5. Non-contact seal on both sides (2BRS)
1 2 3 4 5
01 The FAG Generation C Deep Groove Ball Bearings are
characterized by particularly low frictional torque compared
to other competent competitors in the market
ously improved. In the context of technical characteristics, German
companies have always led the way and have been considered as
a benchmark. When it comes to technical characteristics of the
bearings, Schaeffler is among those benchmark-setting companies,
with its best features as minimum friction and noise. Focusing on
continuously improving its products, the company has also recently
developed two new sealing concepts. Reducing the grease loss and
offering better protection against contamination extends the grease
operating life, which makes the bearings more durable. The new
‘Z’ sealing shield with its innovative labyrinth seal helps to reduce
the egress of grease by 20 %, and prevents contamination by 30 %
in comparison with conventional designs. It optionally comes with
the patented ‘efficient lip seal’ (ELS), which provides maximum
sealing action at low friction and is particularly suitable for changing
axial loads, such as in wheel bearings in motorcycles. The increased
sealing action can be attributed to the innovative lip shape that is
perfectly matched to the ring recess, without any additional friction
loss. Furthermore, the recesses that have been shifted to the interior
of the bearing significantly improve its robustness during handling,
for example during mounting. Moreover, non-contact BRS lip seals
and HRS lip seals, which start at the inner ring, are available with
increased sealing action in the standard program.
The high-quality balls and the noise-optimized cage make the
FAG Generation C deep groove ball bearings run with significantly
less noise compared to conventional deep groove ball bearings. In
addition, the optimized osculation reduces the friction. These characteristics
can be attributed to numerous optimization adjustments
to the raceway parameters in regards to the roundness, waviness,
roughness, and restricted manufacturing tolerances. The friction
which is reduced to an optimum level also means lower energy
costs when in operation.
New production process in China
In Yinchuan, China, where Schaeffler’s new manufacturing plant is
located, the German engineers have come up with a new production
concept, which is fully geared towards the specific requirements of
the high-volume business. This comprises an outstanding level of
quality, availability, and cost-effectiveness. The highly-automated
production lines are optimally designed for these types of bearings
and any variations, so that setup operations and downtimes can be
reduced to a minimum. Schaeffler puts a special focus on cleanliness
in the production process. For this reason, various automatic washing
stations that prevent even the slightest contamination of the
products are integrated into the production process. At the same
time, highly-skilled employees and several automatic inspection
facilities ensure that the highest quality standards are met. Just like
the plants in Caldas (Portugal) and Savli (India), where deep groove
ball bearings have been produced for several years, the plant in
Yinchuan has been certified according to the highest ISO quality
standards for the industrial and automotive sectors.
Improved supply chain ensures prompt delivery
A stockholding and logistics concept that is coordinated worldwide
ensures prompt and reliable delivery to our customers from the
plants in China, Portugal, and India. For Europe, setting up a new
European distribution center (EDC) is of central importance. Operations
at the locations in Northern Europe (Sweden) and Southern
Europe (Italy) have already started. The “Central” logistics center in
Germany is currently under construction and will start supplying
customers in Central, Western, and Eastern Europe as of next year.
In total, Schaeffler has invested approximately 200 million Euros for
expanding and modernizing its logistics network in Europe.
Photographs: Schaeffler AG
www.schaeffler.com
About Schaeffler AG
Schaeffler Group is a leading integrated automotive and
industrial supplier. The company based in Herzogenaurach,
Germany, generated revenues of approximately 13.3 billion
Euros in 2016. With around 85,000 employees,
Schaeffler is one of the world’s largest family owned
companies. The technology group has approximately
170 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 – MOTION, DRIVE & AUTOMATION 1/2017

Brake technology 4.0:
safety brakes fit for all challenges
Mayr power transmission’s approach towards
integrating the industry 4.0 technology with the
braking systems delivers utmost level of operational
and functional safety, at the same time its brake
monitoring modules increase the productivity through
preventive fault detection and maintenance.
The great challenge on the road to a “smart factory” is the digitalization
of the information flow in production and the use of the
collected data, not only to establish intelligent processes, for example
in planning and manufacturing, but also for preventive maintenance.
For safety brakes, this specifically means the realisation of
comprehensive monitoring using sensors. Here, Industry 4.0 comes
up against safety regulations and standards, which already demand
the monitoring of safety brakes with sensors. In addition to the tried
and tested brake control unit Roba-SBCplus, Mayr power transmission
has now developed a new, intelligent generation of monitoring
modules with the Roba-brake-checker and Roba-torqcontrol.
Condition monitoring without sensors
MACHINE ELEMENTS
Mayr power transmission’s brake technology 4.0 with a
advanced friction system and permanent brake monitoring,
making the safety brakes fit for the challenges
of the industry 4.0
The Roba-brake-checker module monitors the tension path reserve
as well as the switching condition without sensors and detects safety-critical
changes in voltage, air gap and temperature. On reaching
the tension path reserve, the Roba-brake-checker sends a warning
signal indicating that the brake can continue to be operated for a
certain amount of time. During this time, the machine owner can
undertake targeted maintenance – in coordination with their work
process. In addition, the module also simultaneously assumes
the control of the brake and therefore replaces a rectifier. Switching
condition monitoring and brake controls are thus combined
in one device. As the Roba-brake-checker works without sensors,
no microswitches or proximity sensors have to be attached to the
exterior of the brake for switching condition monitoring, and the
safety brakes can be employed in their basic design. Furthermore,
additional cables and sealing of the switches and sensors become
obsolete. This therefore ensures full design freedom. Unlike solutions
with switches and sensors, which, due to their installation
position on the brake are exposed to impacts and vibrations, monitoring
with this module takes place from the control cabinet, i.e. in a
protected environment. It works without mechanical contacts and
is highly reliable and wear-free.
For applications, which additionally require braking torque control
as well as status monitoring, Mayr power transmissions provides
the braking torque control module Roba-torqcontrol. It shares the
features of the Roba-brake-checker and can also change the level
of the braking torque in operation by influencing the current and
voltage. As a result, devices and machines can be evenly and gently
decelerated. The Roba-torqcontrol module permits the development
of control loops and brakes movements intelligently – the
ideal basis for its application in smart, interconnected machines.
Even more safety and reliability
One indispensable prerequisite for intelligent, automated processes
with permanently monitored safety brakes is however a reliable
brake technology, as it is of primary importance that brakes work
safely and reliably, and deliver the required torque over the entire
service lifetime. As a result, Mayr power transmission consistently
takes basic safety principles into consideration for development
and manufacture, as defined amongst other things in the standard
EN 13849-2: The electromagnetic Roba-stop safety brakes work
according to a fail-safe principle, and therefore they are closed in
de-energised condition. The braking torque is generated through
the force stored in the thrust springs. When the magnetic coil is
WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/2017

01 The Roba-brake-checker
module monitors the
tension path reserve as well
as the switching condition
without sensors, and
detects changes in
safety- critical parameters
like voltage,
air gap and
temperature
02 Engineers at Mayr,
have developed a new
friction lining technology
through which
the brakes achieve
improved torque consistency
and a higher
performance density
energised, a magnetic field builds up, which attracts the armature
disk against the force of the springs and thus releases the rotor
with the friction linings. The brake is released. In addition to the
application of a fail-safe principle, all brake components are reliably
dimensioned and produced only from high-quality, known
and proven materials. The screw thrust springs used are made from
rust-proof steel and are tested for a lifetime strength of 10 million
load alternations.
Advanced friction lining technology
One key factor for the manufacture of reliable brakes is the use of
high-quality friction linings. Mayr’s highly-qualified engineers
and technicians have developed a new friction lining technology
based on extremely complex parameters. A friction lining is not
100 % homogenous, but rather comprises of many components
which react differently to external influences and environmental
conditions. Engineers at Mayr, have managed to create a new friction
lining technology through which the brakes achieve improved
torque consistency and a higher performance density. Influences
caused through environmental conditions, such as air humidity or
temperature, have successfully been reduced, and this is further
supported through the increasing use of enclosed brake designs,
which are protected against external influences. Higher braking
torques can be achieved with the new linings, this means, a smaller,
lighter brake construction size can be selected for higher braking
torques. This takes into account the general trend for machines and
their components, for example engines, to be increasingly compact
in construction, but with greater performance density.
The company observes careful quality checks: This includes quality
assurance measures during the design process and a comprehensive
final inspection. Prior to delivery, all brakes are thoroughly
tested on the test stands and function-relevant values are documented.
An electronic database in which the measurement values
are archived together with the corresponding serial numbers of the
products ensures 100 % traceability.
Controlling the brakes reliably
In particular for applications which have to provide personal protection
according to standards regarding functional safety, Mayr
brakes are perfectly supplemented with the reliable brake control
Roba-SBCplus. Together with the company Pilz, Mayr power transmission
has developed this module which can control and monitor
one or two Roba-stop safety brakes. The Roba-SBCplus module
reliably interrupts the current in the magnetic coil on switching off
the brake. For this purpose, the module operates using wear-free
electronic semi-conductors, and as a result achieves practically unlimited
switching frequency and switching reliability. In addition,
a reliable integrated plausibility check is carried out through the
evaluation of the release monitoring signals. The evaluations of
the switching conditions and the return signal therefore enable
reliable fault diagnosis. As a result, even creeping faults influencing
the switching times, such as increasing wear for example, can be
detected in good time. The reliable brake control Roba-SBCplus has
been prototype-tested by the company TÜV Süd (Southern German
Technical Inspectorate) and can be used up to the maximum
Performance Level ‘PLe’ and Safety Integrity Level (SIL) 3.
Brake technology 4.0
Brake technology 4.0 by Mayr power transmission is a concept which
begins with the smart selection of the products. In order for a user to
find the best or most reliable brake for their purpose, they require a
comprehensive selection of products with the solutions appropriate
for them. The brake technology 4.0 approach means a technologically
leading friction system which, together with safety principles,
stands for reliable braking with extremely high performance density.
Innovative monitoring solutions are firmly integrated into this
system, and as a result, Mayr’s brakes and the corresponding monitoring
modules are able to master all challenges. They ensure the
utmost operational reliability and enable preventive maintenance
in the increasingly compact, higher performance density machines.
Photographs: lead shutterstock/solarseven, 01-02 Mayr power transmission
www.mayr.com
About Mayr Power Transmission
The family-owned company, Mayr power transmission,
founded in 1897, is a leading manufacturer of safety
brakes, torque limiters and shaft couplings. These products
are primarily used for electrically-powered machines
in filling plants, machine tools, packaging and printing
machines as well as in elevators, wind power plants
and in stage technology. Approximately 600 employees
currently work in the Allgäu-based Headquarters
in Mauerstetten, Germany. Mayr power transmission
has over 1000 employees worldwide. The company is
globally established with plants in Poland and China,
sales subsidiaries in the USA, France, Great Britain, Italy,
Singapore and Switzerland and with representatives in
36 other countries.
WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/2017

New generation thermoplastic
polyurethane
Within the scope of the Kastas R&D Department
Material Development Division, raw material and
product development activities are two of the most
important factors that affect the performance of the
seal in line, with a design that makes a difference in
different applications. With the new PU8502 material,
Kastas now combines longer service life and higher
performance in pneumatic cylinders, while increasing
the usage rate of thermoplastic polyurethane in
pneumatic systems due to its increased compression
set property.
Polyurethane material is commonly used in fluid power systems
due to its advantages, such as wear resistance, tensile strength
and tear resistance, which enables durable solutions in both
hydraulic and pneumatic systems. Standard polyurethane materials
have superior mechanical properties compared with elastomers.
However, they also have disadvantages, such as low
resistance to different environmental conditions, in particular to
fireproof hydraulic fluids and air, and high compression set value
at low hardness.
One of the most important indicators affecting the performance
of the sealing element in pneumatic systems is the compression set
property. Low compression set value is critical in terms of perfor-
Life test performance
For testing PU8502 at Kastas Test Center, a product named
K59 Pneumatic Piston Seal was produced. The K59 Piston
Seal is made of special PU8502 material and provided
excellent leakage protection and performance through
a 30 000 000- cycle-test. According to results of the test
under 90 cycle/min speed (approximately 0.6 m/s) and over
8 months, it can maintain continuous movement even under
0.13 bars. Examination of seals shows that all abrasion is at
acceptable limits and seals continue to function smoothly.
mance and service life of the seal. Kastas developed a new polyurethane
material, PU8502, for increasing expectations for high
performance for the pneumatic systems and applications requiring
material usage with low hardness. PU8502 provides better compression
set values and resistance to external environmental conditions
compared to standard polyurethane materials, without compromising
its other superior mechanical properties.
Standard polyurethane materials used in pneumatic systems in
the market show high compression set values. PU8502, specially
developed for pneumatic applications, has considerable advantages
compared to standard PU materials with low compression
set values. It also provides long service life
because of its abrasion loss property
and shows high performance at high
temperatures because of its high
Vicat Softening value (153 °C).
MACHINE ELEMENTS

Comparison K50 vs. K59 Pneumatic Seals (PU8502)
K50 Pneumatic piston seal
The K50 is a single acting pneumatic piston seal designed
to have an asymmetrical profile with a shorter and thinner
dynamic lip. Additional advantages of K50 include:
n secure seating due to the longer and thicker static sealing lip
n low friction and good sealing performance due to the seal
geometry
K59 Pneumatic piston seal
K59 ensures easy installation and excellent sealing performance
in a wide range of pneumatic applications. Additional
advantages of K59 include:
n low friction and good sealing performance due to the seal
geometry
n high sealing effect with cushioning applications
0 bar 6 bar 0 bar 6 bar
01 FEA simulation image of K50 under 6 bar pressure
02 FEA simulation
image of K59 under
6 bar pressure
Sealing solutions for hydraulic breakers
Contaminated work environments, constant high speed para meters
and their complex structures make hydraulic breakers a very challenging
application in the construction field. Kastas produces the most
reliable sealing solutions for hydraulic breakers, drillers and crushers
by using the most advanced technology to meet application demands.
Diaphragms
A hydraulic system requires a diaphragm to ensure the continuity
of pressure within the accumulator for smooth operation.
Therefore, the operating performance is directly proportional
with the diaphragm work in accordance with the system used in
About Kastas
With over 500 employees, Kastas is a leading manufacturer
and supplier of sealing technologies. Kastas is
based in Turkey and produces advanced sealing elements
for fluid power and various specific applications. Through
the headquarters in Izmir, Turkey, the European Distribution
Center in Germany as well as sales and service
partners all around the world, the company serves its
customers with high quality, reliable products.
„PU8502 has high hydrolysis resistance,
low compression set value and long service life compared
to standard polyurethanes“
Nihat Öziri, Technical Manager
the accumulator. The diaphragms made out of PU8502 offer long
service life in diverse operating conditions and pressures and
even at high sliding speed. Polyurethane material offers product
advantages such as high coefficient of elongation, high durability
and flexibility. These advantages do not exist in diaphragms
made of elastomeric material. Unlike standard polyurethane,
PU8502 has the ability to provide quick response to shock pressure
changes needed on the accumulator diaphragms by offering
better hydrolysis resistance, compression set and long service life.
Therefore, Kastas offers products distinct from its competitors
through PU8502 polyurethane material.
PU8502
WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/2017

TR012015 Pneumatic sealing
elements test rig
Kastas Sealing Technologies contains
the Pneumatic Sealing Element Test Rig
(TR012015) with latest technology for
performing tests such as internal leakage
test, minimum continuous movement
pressure test, life test, guide ring/
bushing life test. As a part of its work on
the Technical Committee of ISO, Kastas
has developed the test rig in accordance
with the ISO 19973-3 standards. The
pneumatic test rigs developed in-house
are redesigned in accordance with ISO
standards.
www.kastas.com
Pneumatic sealing
element test types
n Inner leakage test: 6 bar pressure
is locked between the air
port of the cylinder and pressure
transmitter. Decrease of
pressure depends on the time,
which is monitored.
n Minimum continuous movement
pressure test: The pressure
in the hose connected
to the cylinder’s air port is
gradually increased. The pressure
that the cylinder moves is
determined as the minimum
continuous movement pressure.
MACHINE ELEMENTS
n Life test: Various types of
pneumatic cylinders are
installed to the test rig. When
the internal leakage test value
exceeds the limit set by ISO
19973, testing is finished.
Operating life of the seals is
determined according to these
values.
n Guide ring / bushing life test:
Guide rings and bushings on
the cushioning cylinders are
periodically measured. Subject
to wear over the specified limit,
samples are changed, allowing
the service life of the samples
to be determined.
WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/2017

Product News
Compact and highly dynamic small servo
motors with an integrated screw
Wittenstein cyber motor GmbH launches a new series of small
servo motors with an integrated screw for use when the machine
has to be installed in a confined space. The servo motor, spindle
drive, linear guide rail and encoder system form a closed, highly
integrated and ready-to-mount unit. The series is offered in 4 sizes,
each with 2 different screw pitches and two stroke lengths for short
or long-stroke applications. Each of the four sizes achieves
excellent acceleration values, cycle rates and machine throughputs
in a very small space. This is due to the compact design, which
results in much lower mass inertia than is possible, for instance, if
the screw is simply attached to the servo motor. The new small
servo motors with an integrated screw can be configured with
simco drive servo regulators to form high-performance small servo
axes. Multiple connection options are available for these solutions,
which can be integrated
in a higher-level
controller via Canopen,
EtherCAT,
Profinet RT/IRT or
EtherNet/IP.
www.wittenstein.de/en-en
New fan-cooled brushless servo for
increased machine productivity
Moog Industrial Group, a division of Moog Inc. has released a new
series of fan-cooled brushless servo motors. The design offers
additional torque to accelerate and decelerate the load, resulting in
30 % more torque than a naturally-cooled motor. This benefit,
coupled with low rotor inertias, enables higher power density.
Furthermore, the improvement in operating conditions increases
the motor’s robustness by extending the life of the windings. The
new motors are available in size 5 and 6 Compact Dynamic (CD
Series) and Maximum Dynamic brushless servo motors (MD
Series). In addition to the CD and MD Series, fan cooling can also
be added to existing naturally-cooled motors using a separately
mounted fan kit.
Along with the fan-cooled brushless servo
motors, the company also launched its
“Two-You” program. This program
offers Moog’s customers a highly
flexible supply chain, so they can
select among the most commonly
used compact servo drives.
www.moog.com
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WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/2017

Success
in the Himalayas
Climbing the tops of Himalayan Mountains is a thrilling experience. The elevation at Mount
Everest’s base camp is about 5,200 meters. The oxygen content is just half what it is at sea level,
making even breathing difficult. If you plan on lingering here, you should go through high-altitude
training ahead of time. Otherwise, you face a serious risk of coming down with ‘altitude sickness’.
You would expect to run into mountain climbers in this part of the world, but you’ll be surprised to
meet the employees of Krones, a leading maker of filling and packaging technology, who occasionally
spend time at these high altitudes.
MACHINE ELEMENTS
few years ago, specialists from the company headquartered in
A Neutraubling, Germany, installed a complete beverage bottling
facility in a high mountain valley not far from Llasa, Tibet’s capital.
PET bottles are manufactured there, filled with mineral water from
glacial springs, labeled and shipped throughout the world. Today,
Krones employees handle service and system maintenance.
“The stretch-blow-molding machine used to produce the PET
bottles at the facility is the highest in the world,” said Danuta Kessler-Zieroth,
Head of Press Relations at Krones AG. “The extremely
low atmospheric pressure up there is not just hard on people, it was
a challenge for our development work as well.” For example, in the
Himalayan highlands, a machine designed for pressures at sea level
cannot deliver enough pressure to completely blow-mold PET
bottles and press them into the mold. Moreover, the facility’s touchscreen
operating panels were actually designed for altitudes up to
3,000 meters. Another issue is the bottle design that Krones developed
in concert with the beverage producer. The mineral water
bottles are intended for export, so they should not be deformed
when shipped to lower-elevation regions of the world. That means
the containers must be configured to compensate for the forces
resulting from pressure differences with defined deformation.
Becoming a global company through innovation
“Our innovation potential today is evidenced by our more than
3,730 registered patents and utility models,” explains Kessler-Zieroth.
Since its foundation in 1951, Krones has developed far beyond
classic machine and facility design. “We are able to implement
projects like the one in Tibet because Krones offers the complete
process chain for beverage production from a single source. We can
build a complete turnkey factory on a green field,” she says.
This starts with the planning of the manufacturing spaces and
supply areas and extends to actual equipment production, related
processing technology and in-house logistics, all the way to IT
services spanning the entire factory. For example, the hardware and
software solutions for data processing cover the operation of the
WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/2017

equipment, diagnostics to check technologies and monitor processes,
and intralogistics with inventory management, material
flow controls, and yard management. And, of course, the maintenance
and modernization of the facilities are part of the service
package.
About Freudenberg Sealing
Technologies
Freudenberg is one the leading companies in the world in
the areas of sealing technology. The company has sales
revenues of over € 2 billion and employees more than
15,000 people. Its products and services are used in wide
range of applications in areas of automotive, civil
aviation, mechanical engineering, food and pharmaceuticals,
agriculture and construction machinery.
High quality requirements
The food industry also has its own, extremely stringent quality
requirements for production facilities and processes. For example,
the various parameters such as mixing processes, filling and packaging
must be monitored during the entire operation. Facilities and
machinery must meet strict hygienic standards and may not
discharge impurities that could reach the foodstuff at any point in
their lifetimes. “At our company, quality begins right at the machinery’s
development to guarantee maximum process reliability,” says
Kessler-Zieroth. An important cornerstone is Krones’ vertical integration,
which is unusually extensive compared to the competition.
For example, its Evoguard subsidiary was established in 2011 for the
development, design and production of valves and pumps. Details
of safe manufacturing operation are considered alongside the
requirements of hygienic design.
Close cooperation with Freudenberg
Seals are the most important aspect of any valve. Early in the design
phase, the Evoguard development team works closely with experts
from Freudenberg Sealing Technologies to identify the optimal
design in combination with the right material for the particular seal.
At the same time, Freudenberg supports Evoguard in both the layout
and design of the seals and with material-related know-how.
Freudenberg Sealing Technologies’ current product portfolio has
about 1,800 “active” rubber compounds that have been ordered at
least once a year, the largest portion of them as exclusive special
mixtures produced in-house. Evoguard also makes use of Freudenberg’s
materials expertise for damage analyses in the event of valve
and pump failures in customer operation. Freudenberg’s experts
then investigate the reason for the failure and propose solutions to
the problem.
The two companies’ successful partnership dates back to Evoguard’s
very beginnings. Its first valve product portfolio, introduced
in 2011, was equipped with radial shaft and butterfly-valve seals
from Freudenberg Sealing Technologies. “At the time, we went all
out to develop the seals so we could display our production-ready
valve lineup on schedule at trade fairs and exhibitions,” recalls Willi
Wiedenmann, Sales and Product Management at Evoguard.
Another result of this close cooperation is the use of seals made of
Fluoroprene XP instead of the usual EPDM in Evoguard valves. This
premium material is recommended for high stability, its suitability
for hot-steam sterilization and its low risk of flavor transfer from one
food product to the next. Among other products, Freudenberg Sealing
Technologies supplies Krones’ Evoguard subsidiary with shaft
seals, seat gaskets and an entire series of O-rings and butterfly-valve
seals of the highest quality.
Photographs: Freudenberg sealing technologies
www.fst.com
WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/2017

Product News
Menzel constructs slip ring motor for
hazardous area
In 2015, a Senegalese cement manufacturer had to install a motor
that provides the plant with fine coal dust to meet the plant’s primary
energy needs. While coal dust offers good caloric properties, the
particles of dust left on slip rings and brushes may cause sparks and
lead to an explosion. The motor therefore required a design that
would reliably prevent dust ingress during all operating stages. To
meet these challenging requirements, Menzel Elektromotoren, the
German manufacturer of custom motors engineered a rugged unit
with IP65 ingress protection.
Since a squirrel-cage
motor requires a high
starting current and has a
lower starting torque, a slip
ring motor was chosen. The
motor construction
featuring special terminal
boxes for the stator and
rotor, a non-magnetic cable
entry plate, and hazardous
area terminal clamps for
the auxiliary terminal boxes was then devised for the application. A
slightly larger motor housing ensures the operating temperature
does not exceed +125 °C. Thanks to these measures, the replacement
motor has received a ‘Ex II 3D Ex tc IIIB T125 °C Dc’ explosion
protection marking.
A new mechatronic drive designed for
horizontal material handling
The m350 mechatronic drive from
Lenze, is an integrated solution
consisting of gearbox, motor,
electronics and software. Yet
Lenze does not just combine the
motor and gearbox, but runs the
two elements together so that the
gear ratio slips far into the motor
housing. The situation is similar for the electronics and software,
with which the fixed motor speed can be easily adapted via the
user-friendly smartphone app with a NFC connection. So, with the
same torque, speeds of 42 to 216 rpm can be freely selected at the
gearbox output – thus considerably simplifying the design. The
m350 is available in three sizes with torques of 25, 50 and 75 Nm.
With just two levels, Basic and Advanced (including brake), no
more than six versions cover a wide spectrum in horizontal
material handling. This drive package is more energy-efficient than
all drives customarily deployed in horizontal material handling. In
addition, integrated ramp functions and brake control options
ensure that conveyed goods are transported smoothly and thus
gently without jerks. Accessories allow the drive unit to be fitted
with an additional torque support, thus customizing it to the
respective machine requirements.
www.lenze.com
PRODUCT NEWS
www.menzel-elektromotoren.com
Compact and integrated motion control
drive with Bonfiglioli’s iBMD
Bonfiglioli, the drive systems specialist with a strong international
presence, has launched its latest product, the iBMD, an integrated
drive with a broad torque range from 2.7 to 30 Nm. It has all the
features of a highly dynamic servo motor as well as those of a
modern drive controller. The iBMD can be used as a stand-alone
drive or as part of a control system. Motion control functions such
as positioning, cam profile, electronic gears and an interpolated
mode are just as intrinsic as the open communication via CANopen
and EtherCAT. Additional features include a broad range of
digital and analog I/O. Integrated in a casing, it significantly
reduces space requirements in the control cabinet and saves
cabling costs. Moreover, the drive can also be combined with the
precision planetary gears by Bonfiglioli. The functional features of
the drive in combination with the highly compact design are
especially useful for packaging, printing and labelling,
as well as for the automation of material
handling system. The dynamic and highly
precise drives are also very popular for
filling systems and machines for
manufacturing in the electronics
industry.
www.bonfiglioli.com
Next generation servo motors from
Kollmorgen
A new generation of Kollmorgen’s AKM series of servo motors is
capable of even more - with its increased power density upto 30 %.
The increased power density with an improved torque-to-speed
ratio is primarily the result of the optimized winding technology.
Kollmorgen has thereby managed to reduce the
copper losses for the windings. This provides
improved energy efficiency as
well as room for more performance
with the same installed
size. The AKM2G, new generation
of synchronous servo
motors will be launched in this
year and will initially feature 6
sizes with performance levels
between 0.3 and 10 kW. The AKM2G
motors can be fitted with different feedback systems and are
primarily provided with single-cable connection technology. As a
result of the modular structure of the range, Kollmorgen is better
able to adapt the 2nd generation motors to the requirements of a
specific application in parallel with series production. Machine
builders are thereby able to use drives that fit without compromise
– especially in combination with the servos from Kollmorgen’s
AKD2G range.
www.kollmorgen.com
WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/2017

Tooth Chain
Inverted Tooth
Chain Drives
Made in Germany
Rainer Albes, General Manager Renold Tooth Chain, is
still fascinated even today by the versatility and
added customer value of “Made in Gronau” inverted
tooth chains.
Modern machinery production requires drives that
offer a high degree of economic efficiency and
reliability. Inverted tooth chain drives have unmatched
characteristics to meet these needs. When it comes to
precise, fast, and silent drives, Renold inverted tooth
chains are the ideal choice – even for the high
demands of the automotive industry. The advantages:
long service life, simple assembly, high speeds,
extremely quiet running, and high torques.
Renold GmbH
Zur Dessel 14
31028 Gronau (Leine), Germany
Phone +49 5182 5870
toothchain@renold.com
www.renoldtoothchain.com

MDA showcases digitalization with
predictive maintenance applications
Hannover Messe, the world’s leading trade fair for
industrial technology will be staged from 24 th to 28 th
April 2017 in Hannover, Germany. With its core focus
on “Integrated Industry,” it is the world’s leading
exhibition for the digitalization of production,
maintenance and energy systems
In the world of industries, predictive maintenance is currently
a hot topic and will play a central role at the Motion Drive and
Automation forum at Hannover Messe 2017. Operators of machinery
and vehicles do not want to wait until a vital component fails,
but they also do not want to replace it ahead of time. And now they
no longer have to, because leading suppliers of power transmission
and fluid technology have developed systems that permit continuous
monitoring of key components such as roller bearings, electric
motors, gears, hydraulic pumps, and compressed fluids.
“Predictive Maintenance is an important part of networked production
and Industrie 4.0. Intelligent components use integrated
sensors to capture and evaluate data in real time. Predictive Maintenance
is a terrific strategy to effectively harness the interaction
between mechanical engineering and IT,” says Peter Synek, Deputy
Managing Director, Fluid Power Division, German Mechanical
Engineering Industry Association (VDMA). This is actually nothing
new: “condition monitoring” was already a main topic at past MDA
shows. What is new, however, is the information that can now be
extracted from condition monitoring systems. With the aid of intelligent
software, the data acquired in real time allows the operator
to carry out servicing or replace worn components at precisely the
right time – with no fixed service interval, and before the part in
question fails.
How Predictive Maintenance works in reality
Roller bearings are a good example of this. The reference variables
in this case are vibration, temperature and speed (revolutions per
minute). These are continuously monitored and analyzed so that
any irregularities can be detected and their effect on the life of the
bearing calculated. At the same time, any bearing that is running
hot can be identified by temperature monitoring. For example,
Schaeffler offers such a service for roller bearings used in wind
turbines and rail vehicles. Schaeffler’s dedicated cloud analyzes the
collected data and generates the results in plain-text format. So the
user or operator no longer needs to have any expertise in analyzing
sensor data, as is the case with condition monitoring. Instead, the
system itself performs the analysis and the condition of the bearing
can be checked from anywhere in the world via the Internet; similarly,
the remaining life of the bearing can be calculated on the basis
of the actual load spectra.
NEWS AND MARKETS
WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/2017

Demand for this kind of “micro-servicing” via data-based predictive
maintenance is currently very high, and not only in electromechanical
power transmission. Predictive maintenance systems
for hydraulic drives, for instance, can incorporate particle counters.
Parker will present such a system at MDA – not only at its own
exhibit, but also in the VDMA Forum in Hall 19. Stefan Nilgen from
Parker Hannifin tells us: “With our ‘Total System Health Management’,
we can acquire data from every part of the system, including
peripherals, then analyze it and use it to take the necessary
measures. That way, we can keep an eye on the overall productivity
as well as the total cost of ownership of complex systems such as
hydraulic installations or fluid power transmissions, and can carry
out whatever preventive maintenance might be needed. So ideally,
any corrective measures will become unnecessary, or at least foreseeable,
so that we can plan ahead and avoid the unexpected breakdowns
of the past. For the user, that translates into cost savings,
thanks to a longer service life and higher productivity.”
The predictive maintenance tool developed by Bosch Rexroth
is called OdiN, and it will also be on display at this year’s Hannover
Messe. The acronym stands for “Online Diagnostic Network”,
along with sensor technology and cloud-based applications it also
employs the methodology of machine learning to perform preventive
maintenance – with a high degree of precision. Tapio Torikka
is the man responsible for developing the system: “A human expert
monitoring the installation continuously by conventional means
will detect a fault with 43 % probability. Our system has a fault
detection rate of 99 %.”
Gaining additional momentum
Predictive maintenance has gained additional momentum as a
result of Big Data and other themes associated with Industry 4.0.
It is becoming progressively easier to collect and process relevant
data for servicing and maintenance. This trend is driven in part
by cross-sector collaboration, such as that between manufacturers
of sensors and manufacturers of power transmission systems.
Aventics and sensor specialist IFM are planning to work together
in future to monitor and analyze operating data – e.g. for pneumatic
cylinders – entirely online, and independently of machine
control functions. This is a classic predictive maintenance scenario.
Schaeffler and IBM have entered into a strategic partnership
with the aim of continuously monitoring power transmission
systems in critical applications such as wind turbines and railway
trains using machine learning to optimize performance based on
the data acquired.
Systems of this kind are discussed under the collective heading
of “predictive analytics”. Visitors to MDA forum with a special interest
in this development would be well advised to take a close look
at 7 other trade shows taking place in parallel, namely Industrial
Automation, Digital Factory, Energy, ComVac, Industrial Supply
and Research & Technology. Here, leading companies from all over
the world will be presenting their ideas and visions for Industry 4.0
and the Industrial Internet of Things, including the whole area of
preventive maintenance.
Photographs: Deutsche Messe AG
www.hannovermesse.de
Peter Synek, Deputy Managing Director, Fluid Power Division, German
Mechanical Engineering Industry Association (VDMA)
WORLD OF INDUSTRIES – MOTION, DRIVE & AUTOMATION 1/2017

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