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Beumer Group invests all its

expertise in new high-performance sorter

in cooperation with

Purely Electrical.

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Is Germany a winner

after all?

Dear readers,

A few weeks may have passed since the World Cup in Russia and

although the German team got kicked out far too early, the event

certainly benefitted the German economy thanks to a surge of additional


According to details provided by the German/Russian chamber of

foreign trade, around fifty companies were involved in modernizing

the infrastructure, assisting with preparations, and maintaining the

premises where the events were staged for the World Cup. The chamber

of foreign trade estimates that the contract value is around EUR 3

billion. Large companies, like Siemens and Bosch, were also involved

and provided safety equipment, as well as air conditioning and heating

units. The Bosch team, for example, installed a video monitoring

system at one of the World Cup venues.

However, even once all of the orders relating to the 2018 World Cup

have been completed, numerous economic experts are certain that the

modernization of hotels and apartments will continue. The World Cup

attracted a lot of tourists from home and abroad. To ensure that

Moscow remains an attractive destination for domestic and foreign

investments, as well as company relocations, the local government has

already been investing in a renovation program since 2017. However, it

remains to be seen to what extent German

companies will benefit from this.

German and Russian companies will have an

excellent opportunity to discuss future cooperations

at Cemat Russia. A spin-off of

Cemat in Hanover, the annual trade fair for

conveying equipment, warehouse

technology, and logistics has become well

established on the Russian market. Cemat

Russia is also an excellent platform for

Russia to extend its potential in the

transport and logistics sector.



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Igus-Englisch-MH.indd 1 21.08.2018 10:46:37



Turck and Banner found Joint Venture

in Malaysia

Turck and Banner Engineering have founded an additional joint

venture in Southeast Asia (SEA). After the regional headquarters in

Singapore, Turck Banner Malaysia is the second joint venture in the

region. Both partners agreed to cover

specific markets in joint ventures

as part of their internationalization

strategy. On

March, 2018, the

business premises of

the new company

were officially

opened in Petaling

Jaya. The opening

ceremony was

introduced by

Managing director

Darren Chan.

Turck and Banner

Engineering have

successfully worked

together in Europe for

many years with joint

ventures in England, France and

Italy. Turck is the regional sales partner

for Banner products in many other regions. Picture: Ceremonial

cutting of the ribbon (from left): Chuck Choi, Patrick Maguire, Frank

Rohn, Darren Chan, Bob Schlicksup, Matthias Turck.


Large order for Interroll’s Modular

Conveyor Platform from Korea

Interroll announced that it has received a large order

from a Korean E-Commerce company, worth in the

lower double-digit million CHF range for a large-scale

delivery of Interroll’s Modular Conveyor Platform

(MCP) as well as its Spiral Lifts. Interroll will deliver

and install a record number of conveyor modules

covering a total length of 12 km as well as eight Spiral

Lifts destined for the customer’s distribution center

located in South Korea. Interroll is fully committed to

enable the customer’s go-live within an ambitious

timeline by strengthening

infrastructure capacities to

cope with the upcoming

peaks during the

Korean mid-autumn

festival and Christmas

season. Completion

of all installations

is scheduled

within 2018.


Major lithium-ion order: 19 Jungheinrich

ETV 216i reach trucks for Seglo Logistics


The Mexican logistics service provider Seglo Logistics, a

subsidiary of the Schnellecke Group with headquarters

in Wolfsburg, Germany, has ordered 19 reach

trucks, the new type ETV 216i from Jungheinrich.

This truck model is with a permanently installed

lithium-ion battery as a standard feature. The

order is part of a major contract covering a total

of 118 lithium-ion trucks from Jungheinrich for

Seglo Logistics. In addition to the reach trucks, the

order includes 42 counterbalanced fork lift trucks

types EFG 430 and EFG 220; 50 tow tractors type

EZS 350; and 6 horizontal order pickers type ECE

225. The Jungheinrich trucks will be used in a new

automobile plant close to the central Mexican city of

San Luis Potosi.



Optimism in

sight for the

Russian economy


Macro-economic and monetary stability, improvement

in manufacturing, rising wages and pensions

combined with rising oil and commodity prices provide

a positive boost to recovering Russian economy. As a

result this improves the foreign capital investment

scenario particularly in sectors like machinery, and

transportation and logistics equipment.


ussia is the largest country in the world, with a surface of over

17 million sq. kilometers and a population of 145 million. The

country has undergone drastic changes since the collapse of the

soviet union. Economic reforms in the 1990s privatized most of the

industry sectors, except energy, transportation, banking, and

defense-related industries. Russia is one of the world’s leading producers

of oil and natural gas, and is also a top exporter of metals

such as steel and primary aluminum. Crude oil, petroleum products

and natural gas comprise roughly 58 % of Russia’s total exports,

iron and steel represent 4 % and gems and precious metals account

for about 2.5 %. This makes Russia heavily dependent on global

commodity prices and also vulnerable to the boom and bust cycles

of the commodity market. The economy, which had averaged 7 %

growth during the 1998-2008 period as oil prices rose rapidly, has

been witnessing diminishing growth rates since then due to the

exhaustion of Russia’s commodity-based growth model. Russia was

among the hardest-hit economies by the 2008-09 global economic

crisis. The economic contraction was the sharpest since the 1990s,

but no long-term damage was caused due to the government’s proactive

and timely response to protect the key sectors of the economy

from the after effects of the crisis. As a result, Russia’s economy

Author: Sushen Doshi, International Correspondent, World of Industries

began to grow again and increased roughly by 4 % from 2010-12,

before slowing down to less than 1.5 % in 2013 and 0.6 % in 2014.

A combination of falling oil prices, international sanctions, and

structural limitations pushed Russia into a deep recession in 2015,

with GDP falling by close by 3.7 %. The downturn continued through

2016, but bounced back with an increase of 1.5 % in 2017 as global

demand picked up. The global growth reached a stronger than

expected 3 % in 2017. It continued its growth momentum from 2017

into early 2018 and is expected to peak at 3.1 %. Supported by improvement

in investment, manufacturing, monetary situation

along with rising commodity prices, Russia’s economy recovered

from a recession in 2017. Robust growth in advanced economies

and commodity-importing emerging markets has also contributed

to a rise in Russia’s economic situation.

In terms of manufacturing, Russia registered a marginal growth

of 0.1 % in 2017 as compared to 2016, as industries such as automobiles,

commercial and other transport vehicles, chemicals, coke

and oil products contributed the most and a drop in the production

of computers, electronic and optic devices contributed negatively

to manufacturing growth. Lower government spending in areas of

defense also impacted negatively on the growth. Exports grew by

5.1 %, in 2017 compared to 3.3 % in 2016, this exports growth in

goods was mainly fueled by growing exports of non-oil goods and

robust external demand. Services sector also demonstrated robust

growth in exports at 14.4 %, driven by an increase in exports of

transport services, construction, information and communication


Russia’s internal domestic demand also bounced back by 3.6 % in

2017, and became the main engine of growth. Increasing domestic

demand, investment, growing real wages and pensions and declining

unemployment, supported by a stronger ruble, contributed

nearly 1.8 % to GDP growth in 2017. Fixed capital investment in

mineral resource extraction (oil and gas), in transportation via

pipelines and sports mainly due to the 2018 FIFA World Cup, were

the main areas of growth in fixed capital investment. While fixed

capital investment started the recovery in some manufacturing sectors

like food products (close to 10 %), textile (close to 40 %), phar-


maceuticals (close to 15 %), electrical equipment

(around 30 %), mechanical machinery

and components (around 15 %), some sectors

like metallurgy and metal goods saw a

contraction in fixed capital investment

which was the biggest drag on manufacturing

investment dynamics.

Growth prospects

from 2018-2020

Russia’s growth prospects for 2018 – 2020

remain modest, with growth forecasted

to be between 1.5 and 1.8 %. However, in

the short-term, these forecasts may

change due to highly volatile oil prices.

Relatively high oil prices, continued momentum

in the global economic growth

and macro stabilization would support growth.

Yet, the growth forecast for Russia for 2018 has been slightly

decreased to 1.5 % due to carry-over effect from a weak second

half of 2017 and lower than expected growth in the first

quarter of 2018, aggravated by some uncertainty arising from


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the latest sanctions. Growth projections for 2019 and 2020 stand at

1.8 %. This forecast is subject to both favorable and unfavorable

risks. Favorable risk factors come primarily from higher than expected

oil prices. Unfavorable risk factors include escalation of

trade tensions and restrictions among major economies, which

could derail the recovery in global trade and negatively impact confidence

and investment worldwide. Other external unfavorable risk

factors include a further expansion of trade sanctions, unfavorable

currency exchange rate and rising inflation.

Overview of Russia’s logistics sector

Russia’s continent-straddling size is both a blessing and a curse.

Despite existing transport links, Russia ranks 99 out of 160 countries

in terms of logistics performance. The World Bank’s Logistics

Performance Index ranks Russia far lower than other comparable

economies such as Germany (1st) and the UK (8th). Current low

logistics performance, however, does not close off investment

avenues. Rather, it points towards some golden opportunities. Russia

is in need of updated technologies, methodologies and attitudes

when it comes to transportation sector. Below are some reasons

why Russia’s transport and logistics market is a fertile ground

for foreign companies to invest in.

Well established logistics network – but there is room for expansion:

With over 86,000 kilometers in rail tracks, a road network over

1.4 million kilometers long, plus countless air and seaports, Russia

is a well-established intermodal network hub. That said, there is still

major room for improvement and expansion. The estimated market

potential stands at $ 150 billion in a report from research firm PricewaterhouseCoopers.

Fresh warehousing stock is in demand, updated

cargo handling facilities at ports, new airports, rail hubs and

logistics centers are needed to match government ambitions.

Foreign investment in transport & logistics is being sought: Due

to a lack of competitiveness in domestic operators, foreign logistics

businesses are already being courted for investment – often in the

form of tie-ups, joint ventures or operational co-operation. Huge

sums are being injected into transport and logistics from overseas

investors. For example Dubai’s DP World, global port infrastructure

and management specialists inked a $ 2 billion deal to enhance

Russia’s port infrastructure networks. Other foreign firms, such as

DHL or Finnish company Itella Russia, are already well established

in the Russian market. Technological advantages, efficient operations

and experience, puts international brands at a significant advantage.

Russia is greatly in need of integrated and cost-effective

transport and logistics solutions, so international operators can

score some big wins in Russia.

E-commerce is on the rise: With more than 75 million internet users,

Russia’s e-commerce sector has been growing despite the otherwise

economic hardships. Online retail grew by more than 6 % in

2015 during the peak of the Russian recession, and is now worth

more than $ 23 billion. So what does this mean for transport and

logistics? Simply put, Russia requires a higher number of fulfillment

centers, increased third-party and courier services and extra warehousing

real estate. Warehousing alone is estimated to need $ 30

billion of extra investment to keep pace. E-commerce is gaining further

prominence in Russia’s retail makeup – and extra logistical services

are needed to match growing online sales numbers.

Weak third party logistics: Underdeveloped and lack of competitiveness

from Russia’s domestic 3pl providers is hampering the sector.

Foreign companies such as DHL and TNT Express already dominate

the market. Foreign firms are able to do so due to their

significant technological advantages, operational efficiency and

access to financing. Logistics technology manufacturers can supply

Russian 3pl operators with the tech needed to claw back a larger

market share. Fulfillment, cargo tracking and intelligent inventory

solutions are in high demand.

With opportunities abound across the length and breadth of the

country, investors and companies should certainly look to the world’s

largest nation as their next market for investment or expansion.

Photographs: Lead Photo Fotolia, processing VFV Layout


Visit us!

CeMAT Russia, Moscow, Russia

September 19 – 21, 2018






We know the challenges of handling a broad variety of items. With our

new BG Sorter family, we have once again redefined innovative and

highly efficient sortation. Our systems are tailor-made to meet your

business‘ specific needs while still providing the expected ease of

operation and maintenance. Leave the business-critical sortation of

items in reliable hands with high throughputs and capacities that meet

the demands of tomorrow‘s material handling world.

For further information visit beumergroup.com.

BLG remains confident about

Russia’s potential

BLG Logistics has been active on the Russian market

since 2008. Around ten years ago, the logistics service

provider opened its first branch in St. Petersburg. Two

years later, BLG entered into a strategic partnership

with the Sea Port of St. Petersburg to take on port

handling activities there. Initially, the logistics expert

was responsible for marketing the automobile areas as

well as for quality inspection.

Good development in Bronka

In 2017, some six years after starting up in St. Petersburg, BLG

Logistics relocated its operative port activities from the city port of

St. Petersburg to the newly built port of Bronka. St. Petersburg’s new

deep-water port opened in January 2016. Regular line services

connect Bronka with the main Northern-range ports, including the

Auto-Terminal Bremerhaven run by BLG.

At the beginning of 2017, BLG Logistics Automobile SPb and LLC

Fenix, owner and operator of the Russian port of Bronka, signed a

long-term cooperation contract for automobile handling via Bronka.

It means BLG Logistics is now responsible there for port handling as



n 2011, BLG Logistics added transport services to its portfolio.

The next year saw the Russian automobile market boom, with

some 3 million new registrations. However, uncertain political

conditions in the subsequent years followed by sanctions imposed

by Western countries and the collapse of the oil price led to a devaluation

of the ruble, high inflation, and declining real income.

The central bank reacted with two-figure interest rates, which

tightened credit for companies and consumers. These

developments have caused the consumer-driven automobile

market to crash by more than 50 percent since 2013. In 2016, the

market generated just 1.4 million vehicle registrations. This also

affected BLG Logistics. Now, since the beginning of last year, the

Russian automobile market has been picking up again.

We want to successively expand

our service portfolio in Bronka

Uwe Seliger, Managing Director of

BLG Automobile Logistics, Eastern

Europe & Russia Business Unit

well as storage of vehicles. With direct access to the bypass road as

well as six berths for ocean-going ships plus direct connection to the

rail network, Bronka offers ideal conditions for import and export of

vehicles and other ro-ro cargo. Together with Fenix, BLG started its

new business initially on a 12-hectare area with 25 truck loading and


unloading bays. Uwe Seliger, Managing Director of BLG Automobile Logistics GmbH &

Co.KG, Eastern Europe & Russia Business Unit, says: “The port offers us excellent

infrastructure with direct access to the Russian Federation’s road and rail network.”

Covering the entire transport chain for finished vehicles

BLG Logistics is also well placed in the transport field in Russia. Drawing on European

quality standards and a state-of-the-art IT system, the logistics expert has attracted big

names in the German and Korean automotive industry as major anchor customers for

transport operations.

Additionally, in April 2018, BLG took on the entire transport from Germany of a model

from a German automotive company manufactured in the US. The logistics expert ‘s

activities here start as soon as the vehicles arrive in Bremerhaven. BLG was awarded a doorto-door

contract from there. This includes sea transport from northern Germany to Bronka

as well as distribution to the dealers in St. Petersburg and Moscow. This is the first time the

customer is importing vehicles via sea to Russia. For BLG Logistics, it is a further step toward

establishing Bronka as an entry port for the German automotive industry. Uwe Seliger

explains: “Our medium-term goal is to also ship vehicles made in Germany for the Russian

market to Bronka via Bremerhaven rather than overland, as we do now.”

BLG Logistics remains committed to covering the entire transport chain for complete

vehicles in Russia. The company aims to establish a network similar to that in Western

Europe. The plan is that BLG will take over the full chain from the factory or import port

right through to the dealer. Due to the sheer size of the country, BLG considers rail and

inland waterways to be the best transport forms for Russia.

Photographs: BLG Logistics



Turkish Machinery.indd 1 28.08.2018 13:35:37

CeMAT Russia: showcasing Russia’s potential

in the transportation and logistics sector

Russia’s transport and logistics sector is a

lucrative prospect for foreign companies. The

international trade fair CeMAT being held in

Moscow, offers countless opportunities across the

length and breadth of the country. Visitors and

exhibiting companies should take advantage of

this event to expand into the Russian and

neighboring market.

With a surface area larger than that of Pluto, Russia

is truly vast. The world’s largest country’s

geographic constraints make it absolutely essential

to have an extensive transport and logistics network.

In order to service its 145 million citizens with

goods and services, the air, sea, road and rail logistics

are in high demand. Moving goods into and

around Russia is a herculean task. This requires a

strong logistics sector – including functional transport

links and well equipped logistics hubs. Russia’s

transport strategy 2030, laid down by the ministry

of transport back in 2012, specifies the growing

need for development in the logistics and warehousing

sector around the country. With the efforts

put in by the Russian government it looks like the

country is on course towards expanding the availability

of world-class logistical hubs and integration

of modern technology into the logistics sector.

Since the beginning of April, 2016, that transport &

logistics markets in Russia are on the rise after a

difficult 2014 and 2015, Western sanctions and the

oil crisis had played havoc on Russia’s transport

firms but now things are starting to look positive

again. Since 2016, millions of Euros have been

spent and assigned for construction of new and

strategic facilities. With number of logistics hubs

increasing throughout Russia, the demand for related

technologies such as picking and fulfillment,

cargo tracking, and other sector-specific

equipment, machinery, and tech is also on the

rise. With all the big logistic projects in the pipeline

and overall growth prospects in mind, CeMAT Russia,

country’s leading international trade show for logistics

and supply chain becomes a ‘must go’ event for all

the industry stake holders.

This 3 day event is an ideal business-to-business platform to meet

and engage with the who’s who of Russian logistics industry, right

from international logistics experts to industry professionals

and highly qualified decision-makers of small as well as large

corporations. For machinery manufacturers and exhibitors,

CeMAT Russia provides a unique opportunity to create

new networks, cultivate new relationships with potential

customers and also to catch up with the latest

developments and requirements of existing customers.

CeMAT Russia welcomes industry

players of all sorts, from small and medium-sized

enterprises to large corporations

and market leaders from

Russia and from Europe and

elsewhere. Whether it is

about offering sus-

CeMAT Russia 2018


The 9th edition of CeMAT Russia – the international exhibition for

materials handling, warehousing equipment and logistics is set be

held from 19th to 21st September 2018 at Moscow’s Crocus Expo.

Author: Sushen Doshi, International correspondent for World of Industries


tainable solutions in order picking and packaging technology,

functional safety in material handling, performance enhancing

automation systems or project management, CeMAT Russia

has on showcase all the latest technologies and services in all

areas of end user-oriented applications. The event is organized

by two of the world’s exhibition industry leaders –

Deutsche Messe RUS from Germany and ITE Group of

Russia. The exhibitions and conferences organized by the

ITE Group in Russia are supported by various industry

associations and the government of Russia. Combining

Deutsche Messe RUS and ITE’s local market and industry

knowledge along with international experience

enables the organizers to host a business event which

corresponds to global standards.

With all the big logistic projects in the pipeline and

overall growth prospects in mind, CeMAT Russia provides

exhibitors and visitors a platform to network,

showcase their latest products on the market, and

expand their services throughout Russia. This is the

place to be to take the pulse of Moscow’s, and Russia’s,

logistics sector.

Like every year, the show in Moscow will feature

a business forum which will involve presentations

and discussions on various important issues and

trends that are coming up in the industry. The

forum “Efficient management of company intralogistics” is the

main business event of the logistics community. Over the years, the

forum has turned into an efficient communication business-platform

for discussion of recent advances, exchange of ideas and exposure

to the best practice in the field of intralogistics and creating

of warehouses of future. In 2017, the forum discussions included:

n Key trends in logistics and intralogistics 2017-2018: uber, Big data,

drones, IoT, cloud technologies,

n Session on successful development of logistics strategy of leading


n Workshop focusing on increasing the efficiency of warehouse

operations without heavy investments

n A case-study session on successful utilization of information and

digital technologies, video analytics and warehouse management

system at warehouses

n A round table conference of supply chain professionals, logistics


n A discussion on warehouse automation, digitalization and integration

Future of intralogistics

Just like production and manufacturing, the future of transportation

and warehouse logistics is digital and networked. Automated

guided vehicles and systems are quickly becoming a key part of

01 The scalable solutions for the

e-commerce sector include shuttle systems


02 Weasel is the AGV system used for the flexible in-house

transport of goods such as containers, boxes, and rack goods

03 Externally it can hardly be distinguished

from the well-known attachment: the 2T160B

fork positioner with electronic drive and

patented control system


today’s warehouses and production facilities worldwide. New

methods of navigation and increasingly sophisticated sensor technology

ensure efficiency and process automation in production

and warehouse logistics worldwide. What benefit do they offer to

users? What technical innovations and enhancements are there?

All these questions will be answered by the research experts and

manufacturers in Moscow at CeMAT Russia.

Product categories at Moscow’s event

At CeMAT Russia, you can find the latest trends and technologies

that provide solutions for faster loading and unloading, improved

ergonomic performance and the future of hoisting and material

handling. The Move & Lift section of the trade fair has on display

industrial trucks, forklifts and its accessories, vertical lifting

equipment and platforms, scissor lifts, escalators, cranes, hoists,

mechanical handling equipment, monorails, remotely operated

transportation systems, shelf storage & retrieval equipment, power

and drive technology components, hydraulics, pneumatics and conveyor

systems, complete supply chain management solutions, complete

robotic handling systems and port related logistics equipment.

Businesses today need solutions for handling growing quantities

of goods. The Store & Load section of the trade fair features automated

systems designed to increase productivity, and reach maximum

capacity. Visitors can find automated guided vehicles, conveyor

systems that require extremely low drive energy, apps

for storage planning, storage shelf systems, factory and

workshop equipments, pallets, bins and containers, industrial

doors & gates, cleaning facilities for warehouses, loading

bridges and ramps, transfer bridges, loading systems for

bulk goods and containers, and complete logistics service


Logistics sector like any other, is adapting to the emerging market

realities. The Manage & Service section of the trade fair will give you

an excellent overview of all the logistics services now available for

managing today’s challenges. This includes transport financing

models, logistics planning, traffic control systems, integrated traffic

systems, real estate & sites for logistics operations.

Logistics IT is the technology zone dedicated to professional

logistics software and systems. The focus here is on innovative IT

solutions for production logistics, commercial logistics, cloud computing

and mobile logistics applications in the warehouse. This

section of CeMAT at Russia features e-logistics services, intralogistics

systems & software, computer & control systems, control technology

& sensors, identification technology, Auto ID/RFID etc.

The way, in which today’s organizations are concentrating their

production and logistics networks, it is creating a larger impact on

the evolution of order-picking and packaging technology. At CeMAT

Russia, the Pick & Pack exhibition area focuses on latest packaging

technology for warehouses, packaging and order picking systems,

labelling and identification systems, measuring and dispensing

units, and various kinds of packaging materials.

Photographs: Lead Photo Fotolia, processing VFV Layout, 01 Vanderlande,

02 SSI Schaefer, 03 Kaup



Dematic creates

Robotics Center

of excellence

Dematic, a leading global

supplier of integrated

automated technology,

software and services to

optimize the supply chain,

today announces the

formation of the Robotics

Center of Excellence

business unit, dedicated to

the development and

engineering of robotic

automation. The new

business unit is responsible

for the application and

implementation of robotic

solutions that make order

fulfillment operations more

efficient, productive and

responsive to today’s

on-demand omni-channel

distribution environment.

Toyota launches the new Traigo80

heavy-duty electric forklift

The heavy-duty 80-Volt counterbalanced truck is a true

all-rounder. The new Traigo80 range replaces the current

Traigo HT range and consists of 6, 7, and 8-tonnes models,

of which the latter is now also available with 900 mm load

centre. The powerful motors offer strong climbing ability and

high travel speed, making the forklift suitable for demanding

applications normally reserved for engine-powered forklifts. The truck can also manoeuvre in

compact spaces where necessary thanks to the sharp rear steering angle. The well laid-out

dashboard allows the driver to work intuitively and experience low vibrations and noise thanks

to the full floating driver’s compartment.


The Dematic Robotics

Center of Excellence

provides a wide variety of

automated solutions built

around process improvements,

robotic technology,

vision and software. These

solutions are applied in all

functional areas of the

warehouse from receiving to

shipping. Typical solutions

include de-layering,

de-palletizing, bin replenishment,


piece picking, kitting,

crossbelt and pouch sorter

induct, palletizing and

trailer loading. Solutions are

designed to handle pieces,

cases, totes, layers and



BLG.indd 1 20.08.2018 10:32:47


Beumer Group invests all its expertise

in new high-performance sorter


The BG Sorter from Beumer Group is optimally

prepared to meet the challenges of high-performance

sorting. The new sorter family offers the appropriate

version for each type of item. Tilt tray and cross-belt

sorters can be used in customer systems. Thanks to

permanent communication with the carriers, the

system features exact and controlled sortation with

maximum flexibility. Contactless energy and data

transmission reduces maintenance costs as well as

wear and tear.

The BG Sorter CB (cross belt) offers a reliable solution for sorting

any kind of items, such as parcels or bagged goods. The socalled

“full cross belt design” means that the maximum belt width

is ensured. The customers’ benefit: More usable belt surface is

available with the same sorter size. This permits handling a wide

mix of goods easily and safely. The risk of products lying between

the belts is reduced. The E-Tray version (tilt tray) also offers many

advantages. An improved tilt tray design prevents items from getting

stuck between the trays, which helps to avoid collisions and


Wireless real-time communication

“Our new construction series is based on proven technologies with

key components like the sorter frame made of steel or the contactless

energy supply system instead of the usual contact lines,” explains

Stephan Heessels, global Director of Beumer Group’s Logistic

Systems division. This enables users to reduce machine

maintenance costs as well as wear and tear. In addition, the dust

generated when using contact lines is avoided. Permanent wireless

communication on W-Lan basis enables real-time data transmission

– compared with infrared communication where data are

transmitted only when an infrared sensor is passed. The BG Sorter

features communication times reduced to milliseconds so that discharge

profiles can be adapted in real time. W-Lan communication

permits careful handling of a wide variety of products: Users can

add, select and change discharge profiles at any time without the

need to adapt the hardware. Moreover, discharge is very precise

with different discharge speeds.


Beumer Group attached great value to low maintenance and repair

costs when developing the BG Sorter. Status monitoring and extended

diagnostics tools enable employees to detect possible errors

at an early stage. This has a positive effect on product life-cycle

costs. The sorter can be easily accessed for maintenance and repair.

Its design is compact and permits efficient use of the space above

and below the system.

Innovative kinematics of carriages

A completely innovative carriage featuring two points of articulation

and carrying and guide wheels which are tightly fastened to the

axles has been developed for the carriage assembly of the BG Sorter.

This patented solution offers two advantages: On the one hand, it

enables clearly reduced curve radii compared with conventional

carriage geometries. On the other hand, the polygon effect in curves

is minimized, which results in less oscillations in the system.

The BG Sorter is equipped with carrying wheels that have been

specially developed for it and are larger than those used in comparable

systems. They minimize rolling resistance, which directly results

in lower energy consumption and also ensures reduced noise

emission as well as increased running smoothness.

01 Beumer Group’s BG Sorter combines experience and advantages of

the proven tilt-tray and cross-belt sorter families

Energy-efficient drive

The construction series is available either with the proven Opti­

Drive, which is based on servo drives, or the contactless linear synchronous

motor (LSM). Both drive systems reduce energy consumption

and CO 2

emissions. OptiDrive is a patented highly

efficient frictional drive solution, which offers an economical alternative

to the asynchronous linear motor drives often used in highperformance

sorters. A special feature is that the contact pressure of

the drive wheel is automatically set depending on the required driving

power – even for braking. This boosts efficiency to up to 85 percent

and enhances the service life of the drive wheels. The advantage

of the LSM, which is energy-efficient as well, is that it eliminates

contact between moving parts, providing minimal levels of wear

and tear without compromising speed, capacity and reliability.

BG Sorter CB: cross belt design increases capacity

and safety

The cross-belt sorter BG Sorter CB achieves a high throughput at a

speed of up to three meters per second. The carrying capacity is 50

kilograms per cross belt. “Depending on the throughput and product

mix, we can configure the system with one cross belt per carriage

or with two or three cross belts,” explains Stephan Heessels.

We support our customers in

achieving long-term growth

Stephan Heessels, global Director of Beumer

Group’s Logistic Systems division

“This enables us to sort a wide variety of products with sizes of up to

1,500 x 1,000 mm.” The configuration with several cross belts, especially

with varying product sizes, clearly increases the system capacity

if compared with conventional sorters with only one cross

belt per carriage.

The full cross belt design provides an appropriate response to the

increasing share of items that lack dimensional stability. Thanks to

02 The so-called “closed deck” closes the gap between individual trays,

preventing items from getting stuck between the trays

the maximum belt width, these are safely positioned, transported

and accurately discharged.

The new induction unit places items on the cross belts with maximum

accuracy. The position of the items on the system is checked

after induction and corrected, if necessary, ensuring that the products

are always perfectly positioned.

BG Sorter ET: Intermediate cover prevents failures

The BG Sorter ET is a tilt tray sorter, which can transport items with

a weight of up to 60 kilograms. “Jamming of items between the trays

is among the most frequent reasons for unplanned downtimes of

this sorter type,” says Stephan Heessels. “We have introduced a new

tray design to avoid this.” The so-called “closed deck” closes the gap

between individual trays, preventing items from getting stuck between

the trays. This function reduces downtimes and avoids possible

damage to the sorter or the goods. Users can handle items of

different sizes with more flexibility.

“Our BG Sorter combines future-oriented features, which set new

standards in precise and cost-effective handling of as large a product

range as possible,” says Stephan Heessels. “Providing our customers

with this scalable system, we facilitate their future growth

and help them achieve long-term returns on investment.”

Photographs: Beumer Group



Combined transport and

handling system

Production-related process sequences and spatial

constraints were the main focus of the requirements

set out by the Arnold Group regarding the design of a

conveying system for glass tubes. The tubes coming

directly from production at a temperature of approx.

100°C were to be accepted by the conveying

technology, transported, and transferred to the

corresponding further processing stations. Although

this design sounds pretty straightforward, the

engineers at AMI Förder- und Lagertechnik had to

develop a technically sophisticated indexing conveyor

system that was specifically tailored to the operator’s


The requirement

The requirement for a customer from the glass tube production sector

was to implement a fully-automated conveying system that was

able to execute the handling and transport functions for the tubes

– with a diameter of 25 mm and lengths ranging between 90 and

150 mm – coming directly from production at a temperature of approx.

100°C and ultimately combining all of this into an efficient

material flow. Within a eight-second cycle, four correctly sorted, i.e.

90 mm long, glass tubes should be transported, picked up by a suction

gripper, transferred to a workpiece carrier system with 24 units,

and supplied to the machine plant for further processing by the

conveying technology.

As the Arnold Group had already collaborated with AMI Förderund

Lagertechnik on other projects and because it appreciated the

company’s ability to meet individual requirements, as well as its

specialist knowledge and reliability, the request for a quote and ultimately

the contract to develop, construct, produce, and finally

implement the indexing conveyor system was awarded to the company

from Luckenbach, Germany.



he Arnold Group supplies a broad range of burners, tools, and

standard machines for demanding specialist glass companies

in the thermal and mechanical glass processing sector. However,

the company’s portfolio also includes complex process solutions,

for example, for solar thermal glass tube production processes, the

highly accurate resizing of fused quartz glass tubes, the highly automated

production of laboratory and light glass, and other special

applications for thermal glass processing. The customer directory

includes companies from the photovoltaics, glass and fused

quartz glass processing, fiber optics, and automotive manufacturing


The framework conditions

Certain framework conditions had to be observed in addition to the

technical requirements and the request to integrate the conveyor

system within the downstream processes following actual production.

“Due to the existing on-site infrastructure comprising machines,

systems, safety equipment, and a control cabinet, as well as

the limited floor space required us to be quite creative when it came

to the structural design and implementation,” explains Rolf Quint,

design engineer at AMI. Ultimately, the indexing conveyor system

had to meet process-related requirements and also had to be integrated

within the systems used for subsequent processing. According

to Quint, the workpiece carrier (incl. protruding components)


used to hold the glass tubes was not allowed to exceed a certain

width, for example.

The solution and design details

Once the persons responsible at the Arnold Group had defined the

framework conditions and requirements, the AMI project team was

given the go-ahead to develop a suitable conveying system.

The construction was based around a belt conveyor with a special

toothed belt that guaranteed the accurate acceptance of the glass

tubes on to the individual workpiece carriers and exact transfer to

the relevant further processing station. With a distance of approx.

six meters between the drive axle and steering rod, a split of 24 was

selected to bridge the gap between the acceptance and transfer

points on the two processing systems. This also enabled the required

eight-second cycle to be implemented.

Due to the existing machines and systems, a workpiece carrier

system with a width of 260 mm was designed, whereby each unit

can hold four glass tubes and can be manually adjusted to tubes

with a length of 90 to 150 mm, as requested by the customer. If an

adjustment is required, this can simply be implemented by the

operator via a knurled head screw located on the side of the workpiece


A high-temperature resistant polyamide plastic that even retains

its shape at continuous working temperatures of up to 155°C was

selected for the device attached to the individual workpiece carriers

for accepting the glass tubes.

A relevant guide rail is indispensable for ensuring that both the lateral

and height positioning of the glass tubes on the workpiece carriers

is correct when they are accepted from production and transferred

for further processing. Although the toothed belt is equipped

with its own lateral guide rail on the conveyor system, the lateral and

height positioning of the workpiece carriers must be able to be positioned

accurately for accepting and transferring glass tubes. To ensure

this, the AMI design engineers developed an internal guide rail

system via which the workpiece carriers can be aligned laterally and

in height using two adjustable guide elements on both sides of the

indexing conveyor. This design solution ensures that the length settings

on the workpiece carriers are not affected by interference contours

caused by supports, for example, and that a safety barrier of less

than the available width of 260 mm could be implemented.

A bevel gear with a flange-mounted servo motor and absolute

value transmitter supported by an inductive proximity switch at the

acceptance position have been implemented to ensure that the cycle

of the toothed belt and workpiece carriers is accurate. A light barrier

and reflector at the relevant acceptance and transfer stations are

also used to check whether the holding fixture on the relevant workpiece

carrier is empty before being loaded and following removal.

Special handling features

01 Quint: “By developing the indexing conveyor system, we have

once again demonstrated that with our specialist knowledge we can

implement specific operator requirements.”

02 The knurled head screw on the workpiece carrier is used to

adjust it to the length of the tube being accepted

03 The onboard suction gripper unit ensures that the glass

tubes are accepted and transferred

AMI developed and produced a handling system made up of an aluminum

base frame construction to be used for the transfer function

to the relevant further processing system. A solid aluminum base

plate is provided to secure the linear pneumatic drive, including the

guide rail, mechanical stop, and vibration damper. The guide block

of the linear drive is designed to support the vertically guided cylinder,

on which the four spring-loaded suction grippers – one per

glass tube – are attached. All of the pneumatic valves are positioned

in close proximity to the relevant drive. This ensures that any delays

caused by excessive hose lengths are avoided.

The onboard vacuum ejectors for the handling system are positioned

in direct proximity to the suction grippers for similar reasons.

The advantages are clear to see: Short hose lengths, improved

response characteristics, and fewer hoses in the energy chain (only

two air supply lines, instead of one air supply and four vacuum

lines). The pneumatic hoses, valve cables, and drive signal transmitters

are routed via an onboard energy chain – its large turning

radius guarantees the long service life of the hoses and cables.

Within the energy chain itself, the hoses and cables are routed separately

using partitioning strips.

Transfer of the glass tubes by the suction grippers to the holding

fixture on the workpiece carriers is monitored by a combined light

barrier/reflector. This ensures that tubes are only transferred when

the holding fixture is free.


With all of the constructional details and overall design, the design

engineers at AMI have developed an indexing conveyor system for

glass tubes that can be integrated into an existing production plant

including its sub-processes and machines, and that meets the objective

of achieving an efficient material flow. Thanks to its low maintenance

design, the conveyor system will also demonstrate its efficiency

when it comes to maintenance and servicing – the bearings are

lubricated for life, for example. Additionally, all of the main elements

are made of low-friction plastics and only need to be checked at regular

intervals for possible damage. This also applies to the workpiece

carriers, where checks are limited to looking for possible deformations

caused by excessive temperatures that may have occurred.

The operator is more than satisfied with the indexing conveyor

system and this project has once again illustrated that collaborating

with the responsible persons at the Arnold Group was a key factor

to its success, explains Manfred Langen Jr., an employee in the Sales

Department at AMI Förder- und Lagertechnik GmbH.

Photos: AMI



Liebherr launches

first purely

electrical port crane

The new LPS 420 E is the latest extension

of the Liebherr mobile harbor crane

product range. The newly designed

machine is a purely electric driven portal

crane. All crane movements like luffing,

hoisting, slewing and travelling are done

by electric motors.

As the LPS 420 E is a member of the LHM series, it is also characterized

by high modularity. Therefore, it is a universal allrounder

and a key asset for handling every type of cargo, from containers

to bulk, general cargo and heavy lifts up to 124 t. The forward

looking machine is designed for ports and terminals with an electrical

infrastructure. Equipped with two winches, each with a powerful

190 kW electric motor, the LPS 420 E provides a maximum load capacity

of up to 124 t. Therefore, the portal crane can be perfectly

used for heavy break bulk as well as project and general cargo.

Bulk Handling


The LPS 420 E raises the bar in terms of electrical driven bulk handling

performance. With a turnover of up to 1,200 tons per hour, the

new Liebherr electric crane exceeds the average turnover of comparable

electric driven cranes in the market. With a maximum outreach

of up to 48 m, ships with a size of up to Panamax class can be

served. This makes the crane the ideal electrical driven solution for

bulk handling – local emission-free.

The main components of the E-drive are liquid cooled and the

heat is dissipated by heat exchangers. The fully closed liquid cooling

system in combination with the heat exchanger are installed on top

of the slewing platform. According to this, no overpressure unit is

necessary to prevent dust coming inside the machinery house,

which is a big benefit for cranes working in a dusty environment.

Container Handling

Productivity is a decisive factor in modern container handling.

The LPS 420 E is an ideal solution for terminals where every container

counts. With up to 30 cycles per hour, the LPS 420 E is the

perfect solution when it comes to container handling performance.

Ship sizes up to post-Panamax class are ideally servable

for the LPS 420 E.

The operator of the new LPS 420 E can rely on very dynamic electric

motors. Furthermore, the low moment of inertia ensures a fast

response of the motor for precise drive characteristics. Due to the

high motor speed spread no gear shifting between normal and

heavy load is required. This allows for uninterruptible power

transmission from maximum load to maximum speed. Another

well welcome side effect is that the noise emission of the planetary

gear box is low.

Latest Technology

The LPS 420 E is especially optimized for terminals with a power

supply ranging from 380 V to 460 V. Thanks to the Liebherr activefront-end

frequency converter deviations in the voltage supply can

be compensated easily for safe and stable operation. Due to the

critical conditions, like limited space and harsh environmental conditions,

a liquid-cooled and highly efficient multi-drive frequency

converter system was implemented. The frequency converters are

Liebherr built components, which have proven themselves in Liebherr

ship-to-shore gantry cranes and material handlers. As an additional

benefit, Liebherr energy storage units can be used to reduce

the peak-load in the crane main power supply and to take

advantage of regenerative energy within the system. The compact

unit ensures a high power storage capacity, which enables the

accumulation and supply of 200 kW of power within 15 seconds.

Photograph: Liebherr












→ hannovermesse.de/worldwide

Global Fairs. Global Business.

High performance polymer

bearings for beverage filling and

packaging systems


Bottling and packaging machinery manufacturers

have a wide variety of possible applications for

bearing systems made of high-performance polymers.

Companies like Küppersbusch GmbH near Essen in

Germany have been using plain bearings from the igus

modular construction system for more than 20 years.

Smoothies, bio-juices, concentrates, spirits and liquors made in

Germany: The variety of beverages for consumers today is much

greater than in the last few decades. usually, it is the smaller

companies that set important trends and, at least in the beginning,

produce smaller quantities. When they want to invest in a partially

or fully automated filling system, they often turn to industry experts

like ‘Küppersbusch GmbH’ in Velbert. Located just 70 kms away

from Cologne, the company develops and manufactures customerspecific

bottling and packaging machinery for the beverage


Established in 1972, the family owned enterprise specializes in

this clientele and its special requirements. Jochen Küppersbusch,

managing partner and the second generation entrepreneur to run

the company: “In the 1970s, when there were many regional corn

distilleries, we mainly developed and built filling systems for spirits

and liquors. Today, this only accounts for around 10 % of our business.

We are now a more diverse company and see ourselves as a

niche supplier for small producers and fillers of liquid and paste-

like products. We are also profiting from the trend towards smaller

containers and special containers.”

First hand application know-how

through contract filling

A typical feature of Küppersbusch’s procedure is that there are no

pre-fabricated solutions or type series. Klaus Voigt, project engineer

in the company explains: “The customer tells us their requirements

and then we develop a solution.” Since it is mostly about small to medium

volumes and users want flexibility, their solution often consists

of semi-automatic, linear filling, labeling and capping machines.

During the project planning, the developers can fall back on

extensive application know-how and experience at Küppersbusch.

On a separate floor of the company building, the company uses its

own production facilities for the contract filling of a wide variety of

products. Jochen Küppersbusch: “That’s why we know the practical

requirements of our customers from our own experience.”

High performance polymer bearings from igus –

in use for more than 20 years

Küppersbusch looks back on decades long relationship and cooperation

with the motion plastics specialist from Cologne, igus.

Klaus Voigt remembers having visited the company in Bergisch

Gladbach, which is where it was located at the time. This was before

1994, the year in which igus moved to Porz-Lind near Cologne, the

company’s present location.

The designers at Küppersbusch use various type series and versions

from the igus bearings product range, and with good reason.



01 Semi-automatic

filling, capping and labelling

machine with drylin lead

screws for height and format



02 For height and format

adjustments, Küppersbusch

often uses drylin lead screws

with flange nuts

Klaus Voigt explains: “It is important to us that both the rotary and

the linear bearings can be cleaned well and achieve a long service

life. For hygiene reasons, they must not require any external lubricants,

and depending on the application, this means parts in contact

with product, the materials must be FDA-compliant.” All of

these properties apply to igus plain bearings made of high-performance

polymer with incorporated lubricant.

Rotary and linear bearing technology

Using the example of a filling plant for spirits, which is currently undergoing

its final test runs in Velbert before delivery, it is easy to see

how many and which different plain bearings from the igus modular

system are used here:

For diverse height-adjustment mechanisms, trapezoidal threads

from the drylin product range combined with flange nuts made of

high-performance polymer are used. The format adjustments are

made via drylin R flange bearings. Clip bearings have been built

onto the bracket of an electric motor in order to ensure easy


On another (vertical) linear axis, Küppersbusch uses a combination

of drylin R flange bearings with aluminium adapters in which

anodized aluminum shafts move. Klaus Voigt: “We have been using

this solution for approximately eight years. It is visually perfect,

does not need any lubrication and is almost wear-free.”

A variety of iglidur materials

In the choice of the iglidur material, the designers benefit from the

steadily growing variety. Klaus Voigt: “For many years we have

used the FDA-compliant solution iglidur A180. Now we mostly use

the new FDA variants iglidur A181 (blue) and the FDA-compliant

high-temperature bearing iglidur A500.” A relatively new igus

product is used in the current system at the outlet of the rotary

table for feeding the bottles. The guidance equipment for the

bottles was originally made of stainless steel. In order to dampen

the noise of bottles hitting metal, igus tribo-tape made of iglidur

B160 material is now being used. This liner is resistant to cleaning

agents and is characterized by a very good sliding / friction

coefficient compared to glass.

Bearings from igus in valve and pump applications

Küppersbusch also relies on high-performance polymer bearings

from the igus modular system at the valves and pumps of the filling

and dosing stations. At the filling stations, the bottles are raised via

drylin T-rail guides and connected to the filler. At the centering

bridges of the filling tubes, the company installs iglidur flange

bearings, which are not only FDA-compliant and chemically resistant,

but also have an extremely long service life. Klaus Voigt tells

from his experience: “These bearings are heavily stressed. We have

a filling machine that has done 40 million cycles and is still operating

with the first shaft and the first bushing.” Users of the Küppersbusch

bottling plants profit from the fact that they can get by with a

minimum of service. Their equipments are known to the customers

for this.

Photographs: igus GmbH



ackground: fotolia

Mitsubishi Electric’s new safety PLC

conforming to top most standards

Across industry sectors, many production applications

demand critical systems to be operational in case of a

failure to the primary CPU unit. Catering to this

demand, Mitsubishi Electric’s modular PLC series

‘Melsec iQ-R’ is now available as a fully redundant pair

of controllers for high performance and extra reliability.

It offers a complete duplicate PLC rack with all modules,

which the primary set will switch-over to

instantaneously. It also integrates various features into

the PLC for monitoring safety. The programming

platform, GX Works3 integrates both process and

safety-control programming in one environment. This

enables the execution of integrated process- and

safety-control programs with a single CPU module,

eliminating the time and cost associated with

purchasing and installing a separate safety controller.

Mitsubishi has added another layer of protection to the

basic architecture of the iQ-R, which provides process

integrity and dependability. It includes a SIL2-process

CPU module and a separate SIL2-function module as a

set, sitting alongside the power supply module. This

ensures continuous operation by switching to standby

operation if an error occurs in the control system.

Aluminum acts like steel, with Nord’s

innovative surface treatment

Nord’s ‘nsdtupH’ surface treatment is an outstanding

anti-corrosion treatment for gear units, smooth

motors, frequency inverters and motor starters in

aluminium cast

housings. It’s

special method

makes the

surface corrosion-resistant


harder; in this way, aluminium behaves like stainless steel with

regard to corrosion protection. It is not a coating, but a surface

treatment that creates a protective layer which is permanently

bonded to the substrate material. Any damages that occur remain

locally restricted and do not propagate. The surface is easy to

clean and largely resistant to acids and alkalis. The ‘nsdtupH’

drive units are a robust and durable alternative to painted geared

motors or stainless steel versions. Nord drives with nsdtupH

comply with FDA Title 21 CFR 175.300 and for this reason are

suitable for food application. The nsdtupH surface treatment is

advantageous for all drives used under extreme environmental

conditions and for hygienically critical applications including the

food, beverage and pharmaceuticals industry.



R+W is expanding its servo disc pack couplings offering

by adding the SCL range


Servo drives are used for high precision and dynamic motion,

especially in automation equipment, packaging machinery and

industrial robotics. Shaft couplings for these applications must

be correspondingly inertia-reduced, must provide misalignment

compensation, and operate with a high degree of precision.

The company, R+W has decades of experience in this area

with its precision bellows couplings, and will now be expanding

its offering by adding its new SCL range; consisting of a

zero-backlash disc pack coupling with light weight aluminum

clamping hubs – designed for lower torques. The servo disc pack

coupling is suitable for dynamic drive tasks involving frequent

stop-start and reversing operations, where the focus is on

absolute positioning accuracy. Their

hubs are made of aluminum, thus

have low weight and low moment of

inertia. The disc packs themselves are

made of high-strength stainless steel

and feature a high degree of power density. No micromovements

are generated in the discpack connection, which

translates to higher torsional stiffness. The shaft-hub connection

is only available in a friction-locked format with a clamping

hub, split clamping hub or conical clamping hub.



Ebm-papst expands with another

facility in China

Servo convertors equipped with module

systems deliver high performance

The drive and automation specialist Baumüller is introducing

new axis units for its module system b-maXX 5000. The new units

are suitable for a performance range with a peak performance of

up to 240 kW. The entire range of b-maXX 5000 devices cover a

nominal power range of 1 to 100 kW and thus prove to be a

suitable solution for various

applications in machine and

plant construction. The

converter series b-maXX 5000

includes feed-in and

regenerative units as well as

drive units, which can be

quickly and easily combined

by an integrated drive connect

system. For the machine

builder and operator this

means less installation effort and short start-up and service

times. The controllers are available in the air, water and cold plate

cooling types and score with minimal assembly space thanks to

high performance density. With plug-in modules the devices can

be equipped with safety functions according to IEC 61800-5-2.

The machine builder can choose from 4 different modules to

adapt the safety functions to his specific application. The plug-in

modules enable a fast and flexible reaction to new requirements.

With a ground-breaking ceremony, ebm-papst, global

player in the fans and motors segment, started the

construction of its new plant in Xi’an, the capital of

Shaanxi province in China. From summer 2019, fan

solutions for the Asian market will be manufactured here

in the 27,000 sq. meters facility. A new manufacturing

facility in China speaks volumes about the rising demand

in the Asian market. With this new facility, the company is

inching towards achieving its internationalization strategy

and targeting emerging markets like Indonesia, Vietnam,

Thailand apart from China. The decision for the new

location near the city of Xi’an, with its 12 million

inhabitants, is reinforced by the high availability of

qualified specialists and excellent transport and logistical

connections. The company is being represented in China

since 1996 and currently employs around 1,800 staff at the

Chinese sites. The headquarters, along with a

development center, is located in Waigaoqiao, Shanghai,

and a production plant in Nanhui, Shanghai and two more

locations are in Hong Kong and Qingdao. The total

investment sum of the new building is estimated at

around € 30 million.



More power !


ROBA ® -guidestop rail brakes

– more braking force

– more holding force

– more safety


your reliable partner

Mayr_Englisch.indd 1 31.07.2018 11:37:49


Capacitive thread sensors:

innovative technology from


background: fotolia

Smart servo axis for effective and

flexible production processes

Lenze, the specialist in machine automation has come up with a

scalable drive solution for production and intra-logistics systems.

The combination of an i950 servo inverter, an m850 synchronous

motor and a g700 planetary gearbox is easy to handle and

facilitates cost-effective production, even for batch size 1. At the

heart of the solution is the smart i950 servo inverter. Its greater

computing power and the integrated EtherCAT-Port make it

possible to control multiple

axes synchronously at high

speed, enabling it to

complete complex tasks.

The second component is

the m850 synchronous

motor. It stands out

because of the favorable

ratio between the mass

inertia of load and motor,

which results in very quiet

running. Despite the high

mass inertia, it is dynamic

enough to handle medium to high loads. The drive is available in

3 sizes, each in 3 different power classes that extend from 2.0 kW

to 9.2 kW. The g700 planetary gearbox is adapted for these motor

characteristics and meets the requirements of mediumperformance

applications in terms of rigidity and high dynamics.


Micro-Epsilon has introduced capacitive sensors with

a thread, these are not intended for clamping but are

screwed into a thread. This opens up numerous

applications possibilities especially for measurement

tasks where the standard sensors cannot be clamped,

non-contact displacement, distance and position

measurements can be easily carried out using the new

threaded sensors. They are specially designed for

machine building applications where the sensors must

be mounted at a defined distance e.g. on walls, in bore

holes or even very

deep drill holes.

Due to the

integrated plug-in

connection, they

are easy to install.


capacitive sensors

are equipped with

a permanently integrated cable that gets twisted when

screwing the cable in. However, the sensors from

Micro-Epsilon are screwed in first and then connected

with the cable via the integrated plug-in connection.

They stand out due to their long-term stability, reliability

and temperature stability. Furthermore, they offer

extremely high reliability and high precision

measurements down to nanometer range. Its innovative

technology, makes them useful even in harsh industrial




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Differential pressure transmitter

with railway certification

The JUMO MIDAS DP10 differential pressure transmitter with

a silicon sensor is used to detect the differential pressure in

fluid and gaseous as well as low-aggressive media. The

measurement range covers 0 to 40 mbar up to 0 to 16 bar

differential pressure. The highly vibration-resistant differential

pressure transmitter has been certified for use in the

railway industry in accordance with the latest versions of the

standards under DIN EN 50155, DIN EN 50121, and DIN EN

45545. Within the railway industry the JUMO MIDAS DP10

can be used in areas such as pressure monitoring for brake

circuits or level measurement in service water, wastewater,

and quench water tanks. JUMO MIDAS DP10 is also suitable

for monitoring differential pressure to measure current in

ventilation systems or for controlling the degree of contamination

in filters.

Sensor monitors filtration systems

in wind turbines

Efficient use of wind turbines requires full

condition monitoring. This is where

keeping hydraulic fluids and lubricants

clean with qualified filtration systems is

key. The filters not only remove the solids

which increase wear but at the same time

also serve as a sensor, since in a tribological

sense these particles are nothing than

the result of the system-related ‘wear

margin’. So in mechanical systems the

filters ‘measure’ the inevitable wear of

friction partners.

Since depending on the conditions in and under which the

parts are used, this process is not necessarily even and in can

even spike greatly due to spontaneous incidents, the filters

require continuous monitoring. Bühler Technologies

presents a new sensor for this challenging monitoring task.



Compact, flexible and easy to install

bearingless encoders are trending in

elevator technology

The use of non-contact magnetic measuring systems like the

bearing-less encoders is a rising trend in the elevator

technology. The bearingless measuring systems are especially

suitable for external rotor motors. Kübler, one of the leading

specialists in the field of position and motion sensors offers

such measuring systems, made of an incremental sensor and

a magnetic ring. This measuring system offers clear

advantages: high resolution, reduced space requirements,

suitable for narrow mounting spaces, flexible and easy to

install. With its compact installation depth of only 10 mm, the

Limes LI50 with magnetic ring can be installed quickly and

easily in tightest mounting spaces. Oblong holes ensure easy

adjusting of the measuring system. A wide mounting

tolerance between the sensor head and the magnetic ring

ensures trouble-free installation. Just like its encoders, the

bearingless measuring system is particularly robust and



Tel.: Tel.: +49 (0)4743/2769 27690 · · www.astro-motoren.de

Zu Land, On land, im Wasser, at sea, under unterwater, Wasser, in in theder airLuft andund in space im Weltall -

Small Elektrokleinmotoren electric motors according bis 200 Watt to customer nach Kundenwunsch requirements.


ASTRO Motoren GmbH & Co. KG

Debstedt · · Große Beek Beek 7 · 727607 · D-27607 Geestland Geestland · Germany

Tel.: (0)47 +49 43 (0)/ 4743 27 69 · 27690 · astro@astro-motoren.de



ASTRO.indd 1 08.02.2018 10:35:55

Witness the culture of automation

in South China’s industrial sector

As one of the largest and busiest industrial trade fairs

in Asia, Industrial Automation Show - Shanghai, offers

an excellent opportunity for visitors and exhibiting

companies to interact and understand the trends of

Asia’s automation market. These face to face

interactions allow visitors to see what companies have

to offer and for automation companies to better

understand the requirements of their clients.

Organized by Germany’s leading trade fair organizers, Deutsche

Messe AG along with Hannover Milano Fairs Shanghai Ltd.,

the Industrial Automation Show (IAS) Shanghai will be hosted

from September 19th-23rd, 2018 at the National Exhibition and

Convention Center in Shanghai. Just like every year, the prestigious

fair grounds with a display area of more than 70,000 sqm will

attract exhibitors and visitors from all over Asia and South China,

in particular. In 2017, this five-day show attracted over 160,000

trade visitors from home and abroad, reporting a rise of nearly 6.5

% more visits as compared to 2016. These numbers show the strong

market position this event holds amongst all of Asia’s industrial

automation trade fairs, and the 6.5 % rise in number of visitors

proves the increasing popularity of this international trade fair.

Apart from increasing interest from South China, more and more

exhibitors and visitors from countries like Japan, South Korea,

Germany, Italy, America, Switzerland, France, Austria, Britain,

Israel, Singapore, India and China Taiwan are participating, as the

reach and significance of this event is gaining more importance. In

2017, the proportion of overseas exhibitors was nearly 60 %. One of

the prime reasons for show’s popularity, is the large number and

quality of exhibitors from all segments of the industry that display

their top products and systems. Along with IAS, the venue also cohosts

the Metalworking and CNC Machine Tool Show (MWCS),

these two specialized themed shows bring in more than over 600

exhibitor companies respectively. The exhibitor list consists of

reputed industry names and global market leaders like Siemens,

Bosch, Phoenix Contact, Mitsubishi Electric, Omron, Delta, Turck,

Festo, Beckhoff, National Instruments, B&R, Lenze, Sanyo, Rittal,

Balluff, Wago, Pepperl+Fuchs, IFM, Sick, Harting, Baumer, Pilz,

Hiwin, Keyence, Parker, Nord and many more. Just like in the past,

even this year, these enterprises are expected to make a dazzling

presence with their best-selling products and cutting-edge

technologies that put a spotlight on smart manufacturing, highend

equipment and innovative technologies, which are the key

areas of “Made in China 2025”.

Based on Industry 4.0 principles, the smart manufacturing

concepts and applications are the main direction of China’s

transformation and upgrading of the manufacturing sector. The

spirit of the 19th Communist Party of China (CPC) National

Congress focuses on smart manufacturing and the integration of

information technology and industrialization, in order to revitalize

the nation’s real economy. In line with these guidelines, IAS

Shanghai 2018, provides a unique platform for global and domestic

enterprises to expand their market presence by showcasing the

latest technological achievements, and thus boosting the

development of manufacturing industry. As the largest and the

most influential industrial automation show in Asia, IAS Shanghai

2018 has a strong lineup of core technologies of smart manufacturing,

presenting a vast display of comprehensive solutions for industrial

automation, production and process automation, electrical system,

Industrial IT, and digitalization of manufacturing industry.

Product Category at IAS Shanghai

The trade show is categorized into various display sectors into

production and process automation, electrical system, robotics and

industrial automation IT & software. The production and process

automation category has on display products and systems from the

assembly & handling technology, linear positioning systems,

Author: Sushen Doshi,

International correspondent

for World of Industries


control systems, PLC, scada, industrial PCs, embedded systems,

data capturing and identification systems, industrial image

processing systems, sensors and actuators, communication,

networks and field bus systems, measuring and test systems, laser

technology and compressed air generation systems etc. The

electrical systems category consists of electrical and mechanical

power transmission systems like transformers, accumulators and

UPS, electric switchgear and equipment for electrical control

systems, electric and electronic test and measuring equipment,

electric motors & frequency inverters, motor drives, cables &

cabling accessories, electronic and opto-electronic components,

gears and mechanical drive systems as well. The upgradation of any

industry is incomplete without integration of IT and software

systems. To cater to this demand IAS Shanghai offers a vast array of

industrial automation IT and software products like production

and manufacturing software, basic systems and development tools

for industry, internet, intranet and extranet solutions, IT hardware

for industry, professional services and consultancies that showcase

comprehensive IT services to maximize the benefits of software


Robotics at IAS Shanghai 2018

One of the most in-demand sectors is robotics, with China

investing aggressively in this arena. For four consecutive years,

China has been the world’s largest industrial robot market. In 2016,

China had a total sales volume of almost 90,000 units – representing

30 % of the global market. According to the International Federation

of Robotics (IFR), China has had the most industrial robots in

operation globally since 2016. By 2020, China is expected to

produce 150,000 industrial robot units and have more than 900,000

industrial robots in operation. However, despite China having the

most industrial robots in the world, its robot density is below the

global average, with only 68 units per 10,000 workers in 2016.

China’s robotics industry is clearly large, but still has significant

room for development. The Chinese government has recognized

this and has tried to address it in it’s ‘Made in China 2025’ policy.

Over the next decade, there is no downside to this sector as the

penetration of robots in China’s manufacturing set up is set to

increase tremendously. At IAS Shanghai, the robotics display area

will showcase the latest industrial robots, servo control, humanmachine

interaction techniques, robot vision and intelligent

speech, robot simulation system, service robots, machinery,

appliances & components for robotic products.

Shanghai: an industrial power in itself

Another reason why IAS Shanghai is one of the favorite events

amongst automation industry professionals is the host city:

Shanghai. It is one of the fastest growing cities in the world, a global

trading and financial center, a major transport hub and one of the

busiest container port in the world, with more than 37 million TEU

in container volume annually. Even the Shanghai stock exchange

has emerged as one of the world’s largest by market capitalization.

Since 1992 the city has recorded double-digit growth almost every

year except during the global recession of 2008-09. In 2017,

Shanghai’s total GDP grew to $ 475 billion. Apart from service

industries like finance, retail and real estate, Shanghai also boasts a

strong manufacturing sector which accounts for more than 35 % of

the total output respectively. Steel, shipbuilding, automobile

manufacturing, food and pharmaceuticals, software and

automation are important industry sectors. Shanghai’s advantage

lies in its size and industrial diversity, the competitiveness of several

manufacturing subsectors, and the emergence of business services.

At the same time, Shanghai’s expanding technological capabilities

are being nurtured by a deepening pool of qualified human capital,

increasing R&D, FDI in high-tech activities, and the openness of the

city to the rest of the world. The dynamic megapolis is driven by a

growing middle class, which is feeding a demand for innovation.

With its advanced services, large supplier base, easy access to

skilled and highly skilled technicians and engineers, Shanghai is

rightly positioned as China’s premier business city.

Apart from the business context, Shanghai is also a major tourist

destination, as it attracts a wide range of tourists due to its vibrant

culture, natural beauty, and modern infrastructure. A wide range of

trade fair venues, conference facilities along with its wellestablished

transport system make Shanghai a great destination for

an event of the scale of IAS Shanghai.

Photographs: Lead Photo Fotolia


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Oliver Winzenried in conversation with

Nicole Steinicke at IAMD Show Beijing


Security for the connected industry


The Industrial Internet of Things, Made in China 2025,

Cyber-Physical Systems – many new terms have been

coined to describe something that will influence the

way we work. What does the IoT mean for mechanical

engineers or the manufacturers of controllers or other

devices? We have spoken to Oliver Winzenried, CEO of

Wibu-Systems, about the risks and opportunities that

lie ahead and the solutions we have available.

In car factories, driverless transporters bring semi-finished goods

from production line to production line, where robots choose the

tools they need from their kits to process them. Robots will be sent

to fight fires in places too dangerous for humans; robots will provide

care, and nurture and grow plants. The list of applications that

are suited for the Internet of Things is already long, and it is growing

every day. The IoT systems of the future will rely on public networks,

but public networks are not safe environments. Hackers are always

looking for backdoors or exploits to use in their criminal endeavors.

Author: Nicole Steinicke, Editor, World of Industries

Attackers’ attempts to tamper with data can cause and are already

causing untold damage. The IoT has many unprotected flanks,

which means that every component needs to have its own appropriate

safeguards. This requires fully secure and reliable channels

over which components in factories can communicate with each


Strategy for success: Wibu-Systems’ concept for

protection, licensing, and security

Wibu-Systems, a privately held company founded by engineers

Oliver Winzenried and Marcellus Buchheit in 1989, is an innovative

technology leader in the global software license lifecycle management

market. Wibu-Systems offers CodeMeter, a complete package

for protection, licensing, and security that fulfills all relevant standards

and requirements. CodeMeter is its core product, available

either as a dongle (CmDongle), device-bound license (CmAct-

License), or cloud license (CmCloudLicense). CodeMeter’s components

are integrated into software and back-office systems to guarantee

a streamlined process. Nicole Steinicke, Editor-in-chief, met

Oliver Winzenried at the exhibition IAMD Beijing, China and spoke

to him about the future of protection, licensing, and security for the

Internet of Things.


01 CodeMeter offers secure protection and effective license

control for software and digital documents


How is your China business developing, especially with regard to

the mechanical and industrial engineering sector?

Our China business is growing very well. Industrial automation is

a driver for the integration of protection, licensing, and security

capabilities. Last year, we saw a 40% increase in revenues in China.

There is increasing demand for industrial automation technology,

and industrial automation systems are more and more relying on

software to deliver their functions. This requires security-by-design

as well as geo-versatile and user-centric business models.

Digitalization and Industrie 4.0 are hot topics nowadays. Which

research projects have you joined that focus on these topics?

02 Oliver Winzenried, founder

and CEO of Wibu-Systems,

Karlsruhe, Germany

In the Industrial Internet of things (IIoT), security-by-design needs

to be the benchmark for all components. This places particular

priority on industrial grade design, the footprint of hardware and

software, development support, and cross-brand cooperation as

well as complete protection from the very first software layer. IoTcapable

protections need to be physically and functionally scalable.

Wibu-Systems offers CodeMeter, a complete package for protection,

licensing, and security. The consistent and interoperable solution

is fully scalable to match any job and application. But how can

companies equip themselves for the connected future ahead?

Oliver Winzenried discusses the requirements and challenges

and shows how companies can look forward to lasting success

in the new world of the Internet of Things.

What did you exhibit at this year’s IAMD Beijing?

At IAMD Beijing we presented the new firmware features for CmA-

SIC and all CmDongles, the new CmStick/B and /BMC, and some

additional features in CodeMeter License Central, Protection Suite,

and CmEmbedded. Our new CmStick/B and /BMC come in a onepiece-metal

casing, designed for greater shifts in temperature and

humidity, and are equipped with an integrated security controller.

Intelligent device manufacturers can protect the integrity of their

technical IP against piracy, reverse engineering, and tampering,

all while monetizing their digital assets.

IUNO, the German national reference project for IT security in

Industrie 4.0, is meant to identify the threats and risks for smart

factories and develop protective measures that manufacturers can

implement. With our interdisciplinary R&D project, our purpose

is to provide sustainable designs and methods that meet the special

requirements of IT security in terms of the operation, scalability,

robustness, and efficiency recommended for Industrie 4.0 processes.

In this regard, we are active in two use cases: A prototype

of a secure technology data marketplace, e.g. for 3D printing data,

and the integration of secure hardware elements in OPC UA

enabled RFID readers to protect M2M communications. The two

demonstrations are the result of our cooperation with Balluff, a

world-leading maker of sensor technology, and TRUMPF, a global

technology leader in machine tools and lasers. We are active in

several other Pan-European projects and continuing to strengthen

our relations with China by being a contributing member of the

Alliance Industrial Internet and cooperating with the Tongji

University in Shanghai.

Security leaks and cyber-attacks are raising the question about

the awareness of the security situation in industry. What is your

recommendation for manufacturers?

Awareness is definitely increasing. Nevertheless, the additional

cost for security mechanisms and their more complex operation

and setup are slowing down implementation. Companies should

consider the best practices and start by aiming for 80% improvement

with a 20% immediate effort. Doing nothing and waiting for an

incident is too risky. To find out more about sustainable solutions,

please watch my video at https://youtu.be/jLHd8zrDcxU.

You are talking about “4D Integration” with Wibu-Systems’

solutions. What is behind this term?

Four-dimensional integration is the core foundation of CodeMeter

to provide maximum interoperability. License containers: Our

CmDongles with and without additional flash memory in many

form factors, including industry-grade CmASIC, CmActLicenses,

CmCloud, support for TPM and TEE like Intel SGX or ARM Trustzone.

Devices: Support for small microcontrollers with CmMicro-

Embedded, embedded systems, PLCs, PCs, servers to the cloud.

Platforms: Wide OS and architecture support, e.g. for VxWorks,

QNX, RTOS, Linux, Android, ... and X86, PPC, ARM processors.

And last, but not least, business process integration with CodeMeter

License Central connected to ERP (SAP), CRM (Salesforce), and

e-commerce (Digital River) solutions.


Photographs: ornaments fotolia, others Wibu-Systems



digital twin


to your



Learn more: SAP’s view on

network of digital twins:



In order to create new business models and boost

innovation; digital twins must evolve to connect,

interact, and communicate with each other –

expanding the entire value chain by creating a

network. This article demonstrates the impact of

digital twins as a first step towards making processes

more intelligent, collaborative, and automated.

Digital transformation offers significant opportunity, but it can

also be a challenge for manufacturers as machines are becoming

more complex and need to support flexible production.

Digital twins can be leveraged to boost multi-discipline collaboration

over the complete product lifecycle from innovation to operation.

Digital twins are not a new concept for specific purposes like

engineering, manufacturing or operations; but they stood alone and

did not deliver on the promise of seamless collaboration – until now.

SAP believes that in order for digital twins to have the desired impact

they need to deliver value in four distinct areas: be an exact

digital representation of and have a high fidelity connection to the

physical object, support multiple processes (R&D, manufacturing,

service) with just one version of the digital twin, allow multiple

stakeholders and partners to collaborate on one version of the digital

twin, and to allow semantic relations between digital twins of

assets from different suppliers in the customer context.

A new era of networks and product design

Digital twins are more than a virtual lookalike of a physical product.

Spread across the entire product and asset lifecycle, digital twins

are used in engineering, manufacturing, operations and service.

With the product lifecycle shrinking, ever-increasing streams of

connected data and more complex production; organizations need

to work across silos and ensure decision access for all disciplines.

What if digital twins could communicate with one another, creating

a network between themselves? The real-world product and its

digital twin can bridge the physical and digital worlds at all points

along the value chain, opening the door to new innovation and

multiplying the possibilities of what can be achieved. Drawing on

actual usage data of connected products and assets, digital twins

are the basis for new product-as-a-service business models: Using

machine learning, live insights can be gained from the constant

stream of real-time usage and performance data to continually

automate, learn and improve processes throughout the value chain

and across all business areas.

Digital Twins improve collaboration and provide


Creating a network of digital twins makes it easy to share data with

internal colleagues, external supply chain partners and even customers.

Its its partners and it’s customers can collaboratively improve

processes and more.

Sharing digital-twin data with multiple internal departments ensures

everyone is on the same page. The R&D, finance, marketing

and sales teams – groups that typically work in silos – can collaborate

to ensure a new product is properly designed, accurately priced,

sufficiently promoted and commercially viable. Supply chain partners

benefit from a network of digital twins with enhanced visibility.

If an asset malfunctions, the maintenance provider knows it needs

to mobilize a team to fix the equipment. If an organization manufactures

a product ahead of schedule, the logistics provider knows it

can pick up the goods and deliver them early. Finally, digital twin

networks help glean invaluable insights from customers. By monitoring

how customers interact with goods, organizations can remove

underused features from future product iterations or develop

new products that highlight popular features.

Enabling an open, collaborative environment through a network of

digital twins offers the chance to transform engineering, operations

and everything in between. In turn, this allows enterprises to bring

digital representations of multiple products, equipment and assets

together into one technical and business context, and to become

more intelligent.

Photographs: SAP


SAP supports the network of digital

twins from idea to manufacturing to

service and back in the innovation cycle.

Georg Kube, Global Vice President, Industrial

Machinery & Components Industry Business Unit, SAP


High-quality spices

with process control

The processing and marketing of agricultural products like herbs

and spices is very sophisticated. For this reason a market leader has

invested heavily in modern technologies and restructured their

production processes in accordance with high standards. This

includes a modern Scada system, a new plant controller as well as

converters and motor starters.


Juan José Albarracín (JJA) in Spain is among the market leaders in

the production and marketing of high-quality spices such as paprika

and pepper blends. Founded in 1854, the company is also the

oldest of its kind. To future-proof the quality of its products moving

forward and to simplify the operation of its plants, JJA relies on extensive

solutions from the Siemens product portfolio. These not

only help the producer to improve the performance of its milling

plants, but also increase plant availability and simplify control of

the drives. The Siemens solution also permits simple adjustment to

future requirements.

Optimization of the production

Until the new solutions were introduced, the products were still

processed using largely manual processes. This meant that only

limited or no use of product data could be made to optimize

production sequences, and also made the process of troubleshooting

and localizing faults very complicated. The extensive modernization

of its operations using Siemens components such as a modern

Scada system, a new plant controller as well as converters and motor

starters – all engineered in the TIA (Totally Integrated Automation)

Portal – has allowed JJA to move ist production into line with the

latest state of the art.

Perfectly control of the spice mill drives

The Simatic S7-1500 is used as the central controller. The company

uses the runtime software WinCC Runtime Professional to operate

and observe its processes. Simatic IPC547E hardware is also used to

enable simple, intuitive process visualization. JJA also relies on

Sinamics G120C built-in units and Sirius 3RW soft starters to control

01 Process

visualization with

Simatic WinCC


02 Simatic S7-

1500 in practical


the spice mill drives. Operation and visualization of the overall

plant take place using Simatic Industrial Flat Panels with touch

functionality. The Siemens solution was rapidly and successfully

integrated into the existing infrastructure, and allows simple plant

operation coupled with the assurance of high product quality.

Detailed visualization of the production sequences

The production data can now be integrated into the existing ERP

(Enterprise Resource Planning) system, improving both traceability

and documentation. The selected configuration is additionally

designed to permit troublefree expansion of the plant at a later date.

Detailed visualization of the production sequences enables

particularly intuitive plant operation, while the simple localization

of faults has meant a significant improvement to plant availability.

Photographs: Siemens





generation of

positioning systems


Large reading window and codes guarantee

SIL 3/PLe-compliant safety applications, or in other

words adherence to the most stringent safety

guidelines and optimum protection for human and

machine at all times. Achieving this level of safety

previously entailed a great deal of time and money,

but these problems will no longer affect future users

of a new positioning systems.


n 2011, Pepperl+Fuchs celebrated the first launch of its PCV (Position

Coded Vision) sensor, combining a 2-D camera as a reader

with a Data Matrix code tape for absolute positioning. The reader

extracts the information in the Data Matrix code, identifies the current

location, and then calculates the exact position in relation to

the center of the camera. The system is innovative in that it offers

the highest possible level of data security by always reading several

codes at the same time.

In 2014, the newly developed PGV (Position Guided Vision)

system – a navigation solution for automated guided vehicles (AGV)

– was released using the same technology. The method of using a

2-D code to tackle the task of positioning remains unique, and offers

major benefits over solutions using 1-D codes. For example, the

user can evaluate the Y axis as well as the X axis and use this data for

positioning purposes.

Both of these systems have undergone continuous optimization

and development over the past few years. The second generation of

the PCV successor model - the new PXV system - was presented late

last year. Yet despite the continuous efforts to enhance these positioning

devices, operators frequently reported a need for additional

safety solutions for absolute positioning and safe navigation.

Machines and plants which can be controlled by electrical or elec-

Author: Armin Hornberger, Head of Product Management for Industrial

Vision Components, Pepperl+Fuchs GmbH in Mannheim, Germany

tronic systems and sensors present a hazard to the humans working

with them. In order to protect these individuals, stringent statutory

requirements must be met. They are set out in the Machinery Directive,

and are intended to ensure that all the machines and plants

placed on the market are safe. With the safePGV and the safePXV

systems, Pepperl+Fuchs has developed a new generation of positioning

systems which achieves the required SIL 3/PLe compliance

for the first time – all with a single sensor.

What is so ground-breaking about this

safety solution?

To start with, SIL 3/PLe-compliant safe absolute positioning has

been virtually unachievable for plant operators to date owing to the

substantial amounts of time and money involved. Redundant

systems with different sensors or different technologies needed to

be constructed. It was furthermore necessary for the safe control

system to carry out plausibility checks of the data, and the overall

development process needed to be monitored by TÜV and ultimately


A single positioning system with just one sensor achieves all of

this in the new safePGV and safePXV systems from Pepperl+Fuchs.

The new safety technology is based on the particularly reliable combination

of a 2-D reader and the Data Matrix code, which has been

popular for many years. The new system however introduces a special

tape with two superimposed red and blue Data Matrix codes.

The 2-D reader is equipped with two different colored LED rings -

also red and blue. The two-color codes, in combination with twocolor

illumination, form the basis for this unique security solution.

Each individual code contains position and safety information

which is made visible by red or blue LED illumination and can

therefore be read by the camera.

Direct and safe data transfer to safety PLC

The real brain of these positioning systems can be found in the innovative

new firmware. It controls the different LED colors with an

algorithm rated as safe. Each code is then independently checked

for plausibility in the safety section of the sensor. The mathematically

random flash sequence must match the actual position. Since

the different LEDs are controlled via the safety section, the camera



n Safe absolute positioning

according to SIL 3/PL e with

only one single sensor

n Multiple-redundant

technology combines safe

firmware, 2-D read head,

and two-color Data Matrix

code band

01 The 2-D camera can be easily

parameterized with Profinet-GSDML

file via the safety PLC

Absolute positioning system

detects the data matrix codes

regardless of radius size

n Direct and safe data

transfer to safety PLC

via Profinet Profisafe


any additional

function block


evaluation system does not know the illumination color currently

being used for recording. It therefore only compares the data actually

recorded for the code against the expected value.

This means that checks are constantly being carried out to ensure

that the software in the camera is still functioning properly.

The system firmware only transmits all the data to the safe control

system via Profisafe once it has carried out plausibility checks

within the sensor itself. The safe X position can then be directly

processed by the safe control system without additional checks

and used for process control. The result is a unique and absolutely

reliable sensor technology which continuously performs selfchecks.

The system also meets the stringent SIL 3/PLe safety requirements

for the first time, with a high level of efficiency - and

just a single sensor.

Suitable for many versatile fields of application

Based on a multi-redundant

technology, safePXV and

safePGV enable safe absolute

positioning according to

SIL 3/PL e with one single

sensor for the first time.

Armin Hornberger

The new safePXV system is ideally suited for linear safe absolute

positioning in electric overhead conveyors, stacker cranes in the

field of warehousing and material handling, rotary tables in mechanical

engineering, elevator construction, and wind turbines in

the field of renewable energies. As well as safety and reliability,

ease of handling was also of enormous importance when developing

the system. The mounting procedure could not be quicker or

easier. The code tape is already supplied in the appropriate length

and simply needs to be adhered in place. Following approximate

alignment of the reader, additional parameterization can be carried

out directly via the safety control system using the Profinet-

GSDML file.

The new safePGV system has been optimized for navigation with

automated guided vehicles (AGV) in the field of warehousing and

material handling, supply, and production. The solution goes far

beyond simple positioning in this respect. In addition to the safe X

position, the sensor supplies all values required for reliable vehicle

control. In automotive manufacturing, for example, a minimum distance

can be guaranteed between vehicles at all times, protecting all

the employees working in that area. As well as the safe data, the plant

operator can also access angles and Y positions easily and flexibly.

This means that track deviations can be corrected easily at any time.

The new positioning system is therefore the ideal solution for all

navigation tasks, as well as being a safe investment in the future.

A crane system with a crucial safety advantage

The new safety technology makes it possible to increase levels of occupational

safety for employees working on crane systems efficiently

and without significant effort. The safePXV system can be used to

achieve the absolutely reliable definition of a safety zone in which

the goods can be lowered without any hazard. In the case of gantry

cranes in large halls, for example, the new safety technology must be

affixed to the side rails. The sensors then reliably report their precise

position to the safe control system using the Data Matrix code tape.

Since both sides of the crane system are fitted with the safePXV system,

synchronization can be ensured. The trolley and the axis on

which it moves are also fitted with a sensor and the Data Matrix code

tape, with a view to guaranteeing the exact position of the load within

the crane system and safe absolute positioning.

The new technology can also significantly increase safety during

unloading and reloading of containers in port facilities. Portal

cranes are frequently used in these situations to load the cargo onto

trucks. Safe absolute positioning is a crucial factor in placing the

container accurately and avoiding damage to vehicles and hazards

to workers. The new safePXV system can also be fitted onto crane

systems of this kind with very little effort, ensuring that safe X and Y

positions are determined from the system’s two directions and

transmitted to the safe control system.

Photographs: Pepperl+Fuchs



Making machine

vision robust


What makes a machine vision system robust?

Robustness in this context is more than just reliability.

It is a reliability that is maintained within the natural

variations of the environment in which the system is

being used.

number of factors come into play here, including influences

A from the surrounding environment, object variations and

machine vision component effects. Choosing the optimum components

for a machine vision system is therefore a challenging task

and benefits from the knowledge and experience offered by

machine vision systems integrators and specialist suppliers. There

is a very large difference between a solution that works in a demonstration

lab environment and one that deals with all the variations

that an industrial environment will expose the system to.

Machine vision requirements

Machine vision systems consist of several component parts,

including illumination, lenses, camera, image acquisition and data

transfer, and image processing and measurement software. The

capabilities offered by machine vision have grown exponentially as

technology continues to deliver improved performance in all areas.

Author: Mark Williamson, Stemmer Imaging, Puchheim, Germany

The overall complexity of the system is determined by the specific

application requirements. Choosing the optimum components for

a robust vision system should be based not only on their ability to

achieve the required measurement (appropriate resolution, frame

rate, measurement algorithms etc.) but also on external machine

and environmental influences and conditions. Especially in an

industrial environment, these can include part variations, handling,

positioning, the process interface, vibrations, ambient light, temperature,

dust, water, oil and electromagnetic radiation. For extremely

hostile environmental conditions, it may be necessary to utilise

specialist housings to protect machine vision components. A common

example would be the use of camera housings in hygienic

environments that require washdown capability. However, there are

many applications where various environmental conditions can be

accommodated using the most appropriate ‘off the shelf’ components.

The environmental challenge for components

The challenges posed by external factors can have implications both

in terms of potential damage to the machine vision components

themselves, and the effects that they might have on the actual measurements.

This is perfectly illustrated in considering a vision system

that has to cope with temperature variations. Many modern cameras

are built to work in temperatures as low as -5 ˚C or as high as 65 ˚C

without damage. However, increased temperatures can lead to more

noise in the image from the camera sensor, but this can be countered

by ensuring that sufficient illumination is used to improve S/N.

It is also important to recognise that temperature could affect the

object being measured. For example, temperature effects can cause

expansion or contraction particularly in metal components, leading

to variations in their actual linear and volumetric dimensions.


Many cameras are available in housings rated to IP65/67 which

effectively protects against dust, dirt, water splashes or vapours

In 3D measurement systems the change in geometry of the 3D

sensor will generate errors, unless the sensor’s calibration has

temperature compensation included. Many other environmental

conditions can be addressed by choosing the optimum components.

For example vibration & shock – many modern cameras are

designed with high resistance to vibration and shock. Robot or

track-grade cables are available for applications where the camera

moves. Lockable connectors prevent them being dislodged by

vibration. Ruggedised PCs and embedded computers offer good

mechanical stability. Fixed focus lenses in metal mounts with

lockable screws provide shock and vibration protection. Filters can

provide simple protection of the lens surface.

Or what about dust, dirt and water? Many cameras are available in

housings rated to IP65/67 which effectively protects against dust, dirt

and water splashes. Dust, dirt, liquids or vapours can stick to the LED

or the surfaces of the lens system, reducing the light reaching the

sensor. This can be overcome by increasing the camera gain, by software

processing of the image or by adjusting the output of the LED.

These and other factors affect the quality of the images produced

by the sensor which is critical since these images are used for the

actual measurements.

Making measurements

Machine vision measurements are handled according to the system

configuration. Smart cameras have image acquisition, processing

and analysis capabilities embedded within them. Compact embedded

vision systems designed for demanding machine vision and

automation applications requiring multiple cameras provide image

acquisition, processing and analysis capabilities within the processing

unit. PC-based systems will have the software on the PC.

The accuracy and repeatability of results depends on the particular

software algorithms used and their sub-pixel accuracy.

High quality software products and libraries often provide more

robust software tools than cheaper or open source systems, but

often differences can only be evaluated by direct comparison and

with varying inspection environments. Today’s vision systems can

even tolerate a limited degree of variation in product size and

shape, and can recognise classes of natural product with their

inevitable variations within them. Even with the most robust vision

system, however, external influences can lead to poor measurement

results. For example, vibrations can lead to blurry images,

while variable part feeding could lead to variable image perspectives.

Motion blur can arise when using too long an exposure time

to image moving objects.

What you see is not what you get

One pitfall for the untrained machine vision user is the significant

difference between the human eye and the image acquisition

system. Eyes automatically adjust to deal with apparent significant

dynamic range while a fixed camera is unable to see significantly

bright and dark areas at the same time. Sunlight through a roof light

or a shadow of a tall machine operator can change a camera’s

images image where the human eye would compensate without

you even knowing.

Planning and specifying a machine vision system

Planning, specifying and implementing a machine vision system

that is fit for purpose should involve more than simply choosing the

most robust machine vision components. One way is to make use of

the VDI/VDE/VDMA 2632 series of standards for machine vision,

published by the VDI/VDE Society Measurement and Automatic

Control, developed in conjunction with VDMA Machine Vision in

Germany. Following the VDI/VDE/VDMA 2632-2 process not only

allows the determination of an optimised solution but ensures that

if proposals are sought from several suppliers, they all follow the

same terms and definitions and use a consistent terminology. This

allows exact ‘like for like’ comparisons to be made.

To raise awareness of how the VDI/VDE 2632-2 standard can help

to smooth the successful integration of machine vision into production

equipment, Stemmer Imaging holds a number of training

courses, in association with the European Imaging Academy. These

are ideal for end users looking to embark on a machine vision

project, as attendees will learn what questions to ask suppliers, how

to evaluate proposals and understand the completeness of any proposal.

In this way, users can be confident that they will get a truly

robust vision system.

Photographs: 01 Courtesy Gefra, 02 Stemmer Imaging,

ornaments fotolia


Machine vision systems

consist of several component

parts, including illumination,

lenses, camera, image acquisition and

data transfer, and image processing

and measurement software. All of

them have to be planned and

specified based on the

application requirements.

Mark Williamson


Guided Operator Solutions enhance

quality control process


The need to maximise quality, productivity and

efficiency on production lines and in manual assembly

cells is a challenge faced by much of manufacturing

industry. It has been met at Mitsubishi Electric Air

Conditioning Europe by employing Guided Operator

Solutions from sister company Mitsubishi Electric,

Factory Automation.

Based in Livingston, Scotland, Mitsubishi Electric Air Conditioning

Europe wanted to enhance quality control processes by reducing

the opportunity for picking mistakes in its production cells

where several different products are assembled. In addition, there

was a desire to increase productivity by helping workers to quickly

adapt to new assembly processes.

The answer came from Mitsubishi Electric, Factory Automation

with its Guided Operator Solutions, a versatile solution that uses a

PLC to control parts picking sequences using lights, doors, terminals

and touch sensors. This is coupled with high definition HMI

screens that guide operators through live assembly tasks.

The HMI screens have been used to replace a system of complex

product cards that were previously used for work instructions. As

part of the integrated Guided Operator Solutions, the screens allow

for dynamic instructions and prompts to be added to a pick sequence

that ensures the correct part is selected.

High degree of automation to avoid mistakes

Production section manager, Mitsubishi Electric Air Conditioning

Plant, Audrey Smith explained: “We operate semi-automated assembly

cells, each of which offers the facility to assemble a number

Compared to the original process,

we have seen a huge enhancement

in the quality control process,

picking accuracy, assembly speed

and consistency.

Audrey Smith, Production Section

Manager at Mitsubishi Electric Air

Conditioning Plant

of different products. Due to the fact that we make several products

in one work space there is a high potential for operator error. To

combat this, operators have to have a high level of training in order

to work on the assembly line.” The high level of training required in


the past also added to the overall cost of production, and so was an

obvious target for improvement.

Piotr Siwek, Product Marketing Manager EMEA, Factory Automation,

Mitsubishi Electric Europe B.V., added: “The complexity

of the products was clearly a challenge for the operators and was

resulting in picking mistakes. This often resulted in re-work of

products, which significantly reduced the efficiency of the assembly

process. Furthermore the process to identify which components

were required in different air conditioning systems was also

time consuming.” This challenge was solved by implementing

Mitsubishi Electric, Factory Automation Guided Operator Solutions.

“Guided Operator Solutions were first installed in a cell assembling

modules for heating and cooling units,” says Smith. “Initially it

was used only on the first two stages of the assembly operation, so

that we could assess the benefits and see if it was worth moving

forwards with.”

Advantages of a pick-to-light system

For the trial installation a pick-to-light system with visual indicators

on the parts bins was combined with light curtains or touch switches

for pick confirmation. Mechanised doors that opened in sequence

were also used to create a physical barrier to prevent wrong

part selection. The effectiveness of each combination was compared

and the results combined with user preferences in order to

gauge overall effectiveness for different component bins and process


The variety of operator guidance devices ensured that a wide

range of picking scenarios could be accommodated and tested.

Each assembly station was then equipped with the most effective

solution, improving quality, while also making the operator more

productive and the production line more efficient.

01 Each assembly station was then equipped with the most effective

solution, improving quality, while also making the operator more productive

and the production line more efficient

Sequential visual indication

The installation built for the air conditioning plant was commissioned

around Mitsubishi Electric MELSEC Q series modular PLCs

and GOT2000 HMI operator terminals, all connected over a dedicated


“From an operator’s point of view, rather than complex paper

based assembly instructions, the HMI now presents a set of clearly

defined work instructions. It gives the operator a sequential visual

indication of the parts to be picked for building each assembly, and

their quantities,” explains Smith. “Although the work instructions

for the assembly of these products are complex and detailed, the

installation has had an immediate impact on the assembly cells.

Picking has not only become inherently more reliable and errorfree,

but also much faster. Quality and overall productivity have

both shown a marked improvement.”

Importantly, the application has also addressed the operator

training challenge at the plant. The terminals now guide operators

to the correct parts and the GOT HMI shows clear images of the

product to be assembled. This has reduced the resource required

for training, whilst actually improving the time taken to learn each


Seamlessly integration with the other components

Another key benefit for the air conditioning plant was the excellent

integration of the hardware. The PLC and the HMI seamlessly integrated

with the other components in the system, while providing

the potential to link to wider automation systems at the plant.

02 The complexity of the products presented a challenge for the

operators when it came to learning which products were needed in the

assembly of different air conditioning systems

This will enable new product specifications to be sent directly to the

production cells and an inventory report to be sent back for logistical

planning. Further, connectivity to other guided assembly cells

throughout the production facility in the future could also allow for

workflow information to be passed downstream.


“The success of the trial on the first two stages of the assembly process

has been dramatic,” Smith concludes. “Compared to the original

process, we have seen a huge enhancement in the quality control

process, picking accuracy, assembly speed and consistency. We

are now looking at implementing similar systems on all six stages of

the assembly line, plus the parts loading process. We are passionate

about making improvements and the benefits of this technology are

now really showing their worth.”

Photographs: Mitsubishi Europe Electric B.V.




Chinese Partner on site

The demand for sensors and measurement technology

is also expanding in a variety of different sectors in

China. One company that has already been offering

its expertise in the industrial process measurement

technology sector since 2006 is Ziron Shanghai Ltd.

As a partner company of the well-established German

specialist – Zirox Sensoren & Elektronik GmbH – Ziron

is helping Chinese customers with the procurement of

measurement technology, and the supply of calibration,

repair and maintenance services. The equipment and

measurement systems, that have been specially

developed to meet the requirements of Chinese

customers, are being used in power plant technology

systems, by manufacturers and operators of reflow

soldering furnaces and operators of CO2 recovery

systems in breweries. Ziron has also developed an

economic reflow soldering device – the ECO 2000.

Its core element is the proven Zirox measurement

cell, although the device itself is produced in Shanghai.

For more information please contact: Xianglong Zhai,

phone: ++21 62 54 69 05, E-mail: ziron@126.com.


New e-chain concept with dynamic pins

Whether high-tech or low-tech applications, igus is constantly

researching new energy chain solutions to meet the special requirements

of industrial applications for flexibility, reliability and low costs. For this

reason, the motion plastics specialist developed the lokchain, a new

concept consisting of an e-chain with

automatically extending pins and a

compact guide trough for the dynamic

guidance of energy chains. This allows

hanging, vertical or side-mounted use of

the system with or without lateral

acceleration. Even long travels with a

moving lower run are possible by fixing

the lokchain in the upper run trough. The

system can also be used in vertical

circular applications. For example, the

lokchain is an obvious choice for use in

the compact space of rotating C-arm

X-ray scanners.


Practical safety

solutions for

industrial automation

The AZM300 solenoid interlock

from Schmersal is characterized by

various mounting options. This

interlock can be used flexibly as the

new cross-shaped locking system

enables a universal approach from

three directions. As a result, one

and the same model can be equally

used for doors hinged on the left or on the right and for sliding

doors as well. Apart from this, the AZM300 has a hygienic concept,

which is a decisive advantage regarding the use of these components

in machines for the food industry.


JAI introduces high-speed 4K

prism color line scan camera

JAI has introduced

a new 3-CMOS

prism color line

scan camera in its

Sweep+ Series

camera family.

The new SW-4000T-

MCL features three

custom CMOS line

sensors with 4K (4096 pixels) resolution,

mounted on a high-grade optical prism assembly

that precisely splits the incoming light into red,

green, and blue wavebands. The new camera

provides 24-bit non-interpolated RGB output

at up to 67.7 kHz (67,700 lines per second).

To support its high-speed operation, the

SW-4000T-MCL features three custom CMOS

imagers with 7.5-micron square pixels, offering

high responsivity for the short exposure times

needed at maximum line rates.



Wind power brakes for pitch

and yaw drives

Wind power plants around the globe are equipped

with electromagnetic brakes by mayr power

transmission. As the leading international

manufacturer for wind power brakes, the

renowned family-run company from the Allgäu

region provides the ROBA-stop-M brakes as

safety brakes especially developed and tested

for yaw and pitch drives. “All brake components

are reliably dimensioned and produced only from

high-quality, tested and proven materials”, explains Andreas

Merz, Product Manager at mayr power transmission. “Our brakes have

been dimensioned to reliably achieve the specified braking torque

under all operating conditions which might occur, regardless of e.g. the

air humidity or the ambient temperature, depending on the region.”


Precise picking and feeding in

warehouse logistics

For the first time, Weidmüller presents its Pick-to-

Light and Put-to-Light solutions for picking and

assembly tasks in industry and intralogistics.

Robust and EMC-resilient electronic compartment

displays (DPD) are installed above the individual

PSIRT website helps achieve a high level

of security

Phoenix Contact is one of the first companies to have established

an international Product Security Incident Response Team (PSIRT).

On the website http://www.phoenixcontact.com/psirt customers,

scientists, authorities, and all those involved in the field of access

security can report potential security vulnerabilities. Acknowledgment

of receipt will be provided

within two working days.

Following extensive testing

and the provision of

patches, details of the

security vulnerability will

be published on the PSIRT

website. The PSIRT

website lists all security

vulnerabilities that have

been identified thus far for

Phoenix Contact products

and the website is

continuously updated.


storage locations in the pick and put areas, and

are connected with the production information

system of the plant via a junction box and the

integrated u-remote remote I/O system. When the

compartment displays light up, the picker is

guided through a sequence of steps requiring

confirmation within a precisely defined work

process. This avoids errors and raises productivity

by more than 50 %.











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