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<strong>01</strong>/2<strong>01</strong>9<br />

www.world-of-industries.com<br />

12<br />

Driving the innovation<br />

of electric motors<br />

in cooperation with




1 – 5 April 2<strong>01</strong>9<br />

Hannover ▪ Germany<br />

hannovermesse.com<br />

#HM19<br />

Home of industrial pioneers<br />



Editorial Directors:<br />

Dirk Schaar, Email: d.schaar@vfmz.de<br />

Winfried Bauer, Email: w.bauer@vfmz.de<br />

The golden years seem<br />

to be over for now<br />

Dear readers,<br />

For many years, Turkey was known to be one of the up-and-coming<br />

economic regions. The country on the shores of the Bosporus was undoubtedly<br />

regarded as one of the future growth markets. This positive<br />

rating was certainly substantiated by the fact that the gross domestic<br />

product of Turkey really only moved in one direction over the last few<br />

decades. However, this has all changed now. Following the crash of the<br />

Turkish lira in the summer of 2<strong>01</strong>8, many experts predicted that Turkey<br />

would have a severe economic crisis – yet the national currency is gradually<br />

recovering, inflation is decreasing and the government has declared<br />

that all of its problems are over. Although skeptics in Ankara believe this to<br />

be a political flash in the pan. Many everyday consumers are having to<br />

tighten their belts. Finance minister Berat Albayrak, who is also one of the<br />

son-in-laws of President Recep Tayyip Erdogan, is trying to combat the<br />

rate of inflation by reducing the tax on furniture, household appliances,<br />

and new cars and is also appealing to Turkish companies to reduce their<br />

prices by ten percent. A significant increase to the interest rate by the<br />

central bank has also helped. According to Albayrak and Erdogan, the<br />

government has thus been able to combat the attacks on the Turkish<br />

economy. In Ankara, the difficulties the country is facing are not seen as a<br />

consequence of any of their own mistakes but as a conspiracy against<br />

Turkey. The USA has particularly been pinpointed as one of the offenders<br />

in recent months. However, the crisis is not going to simply disappear.<br />

Recent favorable developments of the inflation rate<br />

and exchange rate of the Turkish lira could give<br />

false hope.<br />

Right in the middle of this difficult situation,<br />

WIN Eurasia will be held in Istanbul between<br />

March 14 th and 17 th . More information about<br />

the trade fair is provided on pages 8 and 9.<br />

Traditionally, mechanical engineers,<br />

automation and intralogistics<br />

specialists from all around the<br />

world meet at WIN Eurasia to<br />

discuss new technologies,<br />

products, and systems. We can<br />

only hope that these discussions<br />

will have a positive impact on<br />

the Eurasia region.<br />

Winfried Bauer,<br />

Editorial Director<br />

World of Industries<br />

Editorial board:<br />

Peter Becker (Editor-in-chief),<br />

Email: p.becker@vfmz.de<br />

Nicole Steinicke (Editor-in-chief),<br />

Email: s.steinicke@vfmz.de<br />

Manfred Weber, Email: m.weber@vfmz.de<br />

Svenja Stenner, Email: s.stenner@vfmz.de<br />

Assistant editors:<br />

Svenja Stenner, Petra Weidt<br />

Design/Layout:<br />

Anna Schätzlein, Sonja Daniel, Anette Fröder,<br />

Mario Wüst<br />

Epaper designer:<br />

Katja Rüdell<br />

Managing editor:<br />

Winfried Bauer<br />

Publishing house:<br />

Vereinigte Fachverlage GmbH<br />

Lise-Meitner-Str. 2, 55129 Mainz, Germany<br />

Commercial Register No.:<br />

HRB 2270, District Court of Mainz<br />

VAT-ID:<br />

DE149063659<br />

Privacy Statement:<br />

ds-vfv.vfmz.de<br />

Managing director:<br />

Dr. Olaf Theisen<br />

Publishing director:<br />

Dr. Michael Werner, Email: m.werner@vfmz.de<br />

Correspondent India:<br />

Sushen Haresh Doshi M.Sc.<br />

Advertising sales director:<br />

Beatrice Thomas-Meyer<br />

Email: b.thomas-meyer@vfmz.de<br />

Advertising sales manager:<br />

Oliver Jennen, Email: o.jennen@vfmz.de<br />

Andreas Zepig, Email: a.zepig@vfmz.de<br />

Sales representatives<br />

Austria<br />

Heinz-Joachim Greiner<br />

Email: verlagsbuero-greiner@vfmz.de<br />

France<br />

Marc Jouanny<br />

Email: marc-jouanny@wanadoo.fr<br />

Great Britain, Ireland<br />

Roberto Tondina<br />

Email: roberto@ts-communications.co.uk<br />

Italy, Switzerland<br />

Hermann Jordi, Email: info@jordipublipress.de<br />

Sweden, Finland, Norway<br />

Malte Mezger<br />

Email: verlagsbuero-mezger@vfmz.de<br />

Taiwan<br />

Amy Liu<br />

Email: amy@hf-taiwan.tw<br />

USA, Canada, Mexico<br />

Patrick Venezia Jr<br />

Email: verlagsbuero-venezia@vfmz.de<br />

Advertising disposition:<br />

Annemarie Benthin, Email: a.benthin@vfmz.de<br />

Helge Rohmund, Email: h.rohmund@vfmz.de<br />

Nevenka Islamovic, Email: n.islamovic@vfmz.de<br />

In cooperation with:<br />

Hannover Fairs International GmbH<br />

Messegelände, 30521 Hannover, Germany<br />

Internet:<br />

www.world-of-industries.com<br />

<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/2<strong>01</strong>9 3

TABLE <strong>OF</strong> CONTENT<br />

14<br />

10<br />

20 24<br />


03 EDITORIAL<br />



FAIRS FOR 2<strong>01</strong>9<br />














<strong>OF</strong> ELECTRIC MOTORS FORWARD<br />



<strong>OF</strong>FSHORE CRANES<br />




4 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/2<strong>01</strong>9

Visit us!<br />

bauma, Munich, Germany<br />

April 08 – 14, 2<strong>01</strong>9<br />

Hall B2, stand 413<br />

Visit us!<br />

POWTECH, Nuremberg,<br />

Germany<br />

April 09 - 11, 2<strong>01</strong>9<br />

Hall 1, stand 1-627<br />







WE THINK<br />


Mined raw materials travel along extensive transport routes. Overland and pipe<br />

conveyors are an energy efficient, reliable and environmentally friendly way of<br />

transporting the commodities over long distances to the plant or storage area.<br />

We customise the curved belt conveyors to overcome any challenging topographical<br />

circumstances. This minimises the transfer points and the number of systems and<br />

reduces investment, operational and maintenance costs.<br />

For more information visit www.beumergroup.com


One of the world’s largest machine tool<br />

trade show is creating a new record<br />

Taipei International Machine Tool Show, known as Timtos, is jointly<br />

organized by TAITRA and TAMI and will be opened in Taipei on<br />

March 4-9, 2<strong>01</strong>9. 1,230 exhibitors from 26 countries to use 7,000<br />

booths, creating a new record high in the show’s history, and<br />

making it the world’s 3 rd largest machine tool trade show. In<br />

response to the development trends of global industry, Timtos will<br />

focus on “Industry 4.0 & Smart Manufacturing” and “AI<br />

Technologies”. Visitors will be able to see a number of digitalized<br />

solutions that integrate machine tools, industrial robots, sensors, IoT,<br />

machine learning and more. You too should not miss this event.<br />

www.timtos.com.tw<br />

Head Lyko Group AB invests in<br />

SSI Schaefer`s warehouse solution<br />


The Swedish company Lyko Group AB, a leading Omni<br />

channel specialist for haircare and beauty products in<br />

the Northern countries, trusts the general contractor<br />

SSI Schaefer with the realization of their new<br />

automated distribution center in Vansbro, Sweden. The<br />

turnkey project includes the high-performance shuttle<br />

system Cuby, ergonomic work stations and the logistics<br />

software Wamas. SSI Schaefer is going to realize a<br />

state-of-the-art warehouse for Lyko in a 10,000-squaremeter<br />

facility including a 5-aisle shuttle system that will<br />

provide Lyko`s customers with around 50,000 different<br />

beauty products. A bin and carton conveying system<br />

will connect the different warehouse areas efficiently.<br />

Furthermore, the Wamas logistics software from<br />

SSI Schaefer is going to coordinate the transparent<br />

warehouse processes. The system is scheduled to go<br />

live in the beginning of 2020.<br />

www.ssi-schaefer.com<br />

Australian retailer to build automated<br />

logistics centers with Witron<br />

Major Australian retail<br />

company Coles has<br />

selected Witron to deliver<br />

two new ambient<br />

distribution centers as<br />

part of a supply chain<br />

modernization<br />

program that will<br />

improve availability<br />

for customers while<br />

lowering costs. Coles<br />

and Witron have now<br />

executed definitive<br />

contracts for Witron to<br />

develop two new automated<br />

ambient distribution centers in the states<br />

of Queensland and New South Wales. The distribution centers<br />

will respectively supply a full range of ambient grocery lines to<br />

more than 240 Coles supermarkets in New South Wales and<br />

more than 170 supermarkets in Queensland. “The<br />

modernization of our supply chain will provide a safer working<br />

environment for our team members, lower supply chain costs,<br />

enhance our overall business competitiveness and make life<br />

easier for our customers”, said Coles CEO Steven Cain (right).”<br />

Witron’s CEO, Helmut Prieschenk, said the company was very<br />

pleased to be working with Coles on Witron’s first Australian<br />

project.<br />

www.witron.de/en<br />

6 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/2<strong>01</strong>9

Hannover Messe: Arno Reich<br />

named Senior Vice President<br />

Effective immediately, Arno Reich (47) has taken<br />

over management of Deutsche Messe’s portfolio of<br />

industrial, energy and logistics trade fairs, the most<br />

prominent of which is Hannover Messe. As senior<br />

vice president, his core tasks<br />

include the strategic<br />

further development of<br />

this tradeshow<br />

portfolio both in<br />

Germany and<br />

abroad, i.e.<br />

throughout Europe,<br />

Asia and North and<br />

Central America.<br />

Hubertus von<br />

Monschaw (42) has<br />

assumed the position of<br />

project manager for Integrated Automation,<br />

Motion & Drives (IAMD) and Digital Factory and<br />

Worldwide Events on 1 January 2<strong>01</strong>9. Von<br />

Monschaw has been with Deutsche Messe since<br />

2003 and was previously responsible for ICT &<br />

Business and Communications & ICT<br />

Infrastructure as well as Energy at Hannover<br />

Messe.<br />

Wibu-Systems<br />

extends its<br />

worldwide reach<br />

In the fourth quarter 2<strong>01</strong>8,<br />

Wibu-Systems celebrated the<br />

official opening of its new wholly<br />

owned daughter company, Wibu-Systems<br />

K.K., in Tokyo, Japan, together with the German-Japanese<br />

delegation and local industry luminaries. The new Far<br />

Eastern stronghold adds to the existing subsidiaries in<br />

Europe, U.S., and Asia Pacific that Wibu-Systems has created<br />

over the last 30 years.<br />

Photo (f.l.t.r.): Marcus Schuermann, Managing Director of<br />

AHK Japan, Peter Altmaier, German Federal Minister for<br />

Economic Affairs and Energy, Oliver Winzenried, CEO of<br />

Wibu-Systems AG, Yasukazu Irino, Executive Vice President<br />

of Jetro, and Tomoki Maruyama, Representative Director of<br />

Wibu-Systems K.K. (source: Manfred Knopp)<br />

www.wibu.com<br />

Double service life ...smartmonitoring.<br />

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Low-abrasionand lubrication-free iglidur ® pin/bore chainlink<br />

connection links to reduce friction. Travels of over 800 m,<br />

highspeedsofover5m/s. Optionallywith smarttechnology<br />

for predictive maintenance.<br />

www.igus.eu/P4-1<br />

plastics for longer life ®<br />

igus ® GmbH Tel. +49 2203-9649-800 info@igus.eu<br />

The terms "igus, iglidur,plastics for longer life"are legally protected trademarks in the Federal Republic of Germany and, whereapplicable, in some foreign countries.<br />

Visit us: Hannover Messe – Hall 17 Stand H04<br />

Igus.indd 1 29.<strong>01</strong>.2<strong>01</strong>9 11:48:11<br />

<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/2<strong>01</strong>9 7

The ‘must go’<br />

industrial trade fairs for 2<strong>01</strong>9<br />


Industry 4.0 is changing industries, markets… and<br />

even trade shows. In many cases, the top two<br />

leading trade fairs have combined in order to create<br />

one new annual event. Manufacturers are looking<br />

for cross-sector and cross-platform solutions, as well<br />

as digitally integrated products, in order to meet<br />

the ever-changing demand of their customers. Let’s<br />

take a look at the top industrial trade fairs of 2<strong>01</strong>9,<br />

and the latest technological trends that will be on<br />

display worldwide.<br />

Author: Sushen Doshi, International Correspondent, World of Industries<br />

WIN Eurasia: Let’s start the year in the historic and beautiful<br />

city of Istanbul with WIN Eurasia. For centuries, Eurasia has<br />

been an highly active and an important region in terms of trade and<br />

industry, and Istanbul has been at the center of all the action.<br />

Located at a key juncture of world’s most important trade routes<br />

and energy routes, Istanbul has become a thriving trading hub and<br />

an attractive base for all sorts of industries. For more than 25 years,<br />

WIN Eurasia - the international trade event involving six industrial<br />

trade shows under one roof, has been the pioneering event in terms<br />

of level of technology for the manufacturing sector. As the most<br />

influential trade event in the region, WIN Eurasia is prepared to<br />

lead the companies in ongoing industrial revolution. For visitors<br />

this event provides a 360 degree view of the Eurasian manufacturing<br />

sector by merging six trade fairs. This merger creates a synergy<br />

and brings together a wide range of technologies, products and<br />

services from the entire manufacturing domain under one roof.<br />

This international event is to be held from 14 th until the 17 th March<br />

2<strong>01</strong>9 at the Tüyap Fair and Congress Center in Istanbul, and just like<br />

previous years it is expected to attract more than 75,000 visitors and<br />

1,500 exhibitors from over 40 countries. The six trade fairs at WIN<br />

Eurasia include sectors like automation, motion and drives, industrial<br />

energy systems, electro-tech, metal working, welding, surface<br />

technology, material handling and logistics. Top areas of focus in<br />

terms of technology will be Industry 4.0 festival area, digital factory<br />

- IIoT special area, additive manufacturing, smart manufacturing<br />

line special area, the WIN 4.0 application park etc.<br />

Hannover Messe - Integrated industry -<br />

industrial intelligence<br />

After Istanbul, the world of industries will travel to Germany, where<br />

the city of Hannover will once again open its arms to welcome more<br />

8 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/2<strong>01</strong>9

than 200,000 visitors and 6 500 exhibitor companies for the Hannover<br />

Messe. Without a doubt, this has been the most popular and<br />

pioneering trade event in terms technological sophistication in the<br />

world. With strategically thought out themes, every year Hannover<br />

Messe is driving forward the digital transformation of the production<br />

and energy industries. For 2<strong>01</strong>9, the main theme is “Integrated<br />

Industry – Industrial Intelligence”, which spotlights digital networking<br />

between humans and machines in the age of artificial intelligence.<br />

It underlines the growing importance of artificial intelligence<br />

and machine learning in the production and energy<br />

industries, including areas of energy efficiency and autonomous<br />

production processes as well as challenges in terms of interfaces,<br />

protocols and security. At this event, international think tanks from<br />

the fields of AI and industry come together to jointly discuss and<br />

develop solutions for tomorrow. Like every year Hannover Messe<br />

will include trade fairs like integrated automation, motion &<br />

drives, digital factory, integrated energy, industrial supply,<br />

research & technology and ComVac - compressed air and vacuum<br />

technology show. As a part of it’s tradition, Hannover Messe<br />

shines spotlight on a chosen Partner Country. In 2<strong>01</strong>9, the<br />

partner country will be Sweden. Collaboration, innovation and<br />

digital transformation will be at the center of Sweden’s<br />

showcase. It’s main objective shall be to promote networking,<br />

trade and investment with partners from around the globe.<br />

After the home leg in Europe,<br />

its now time to fly to China<br />

The international trade fair, Integrated Automation, Motion &<br />

Drives Beijing 2<strong>01</strong>9 (IAMD Beijing) will kick off in Beijing<br />

Exhibition Centre from the 8 th to 10 th of May, 2<strong>01</strong>9. As compared<br />

to a few years earlier, the trade show has tremendously improved<br />

in terms of exhibiting technology quality and number of foreign<br />

visitors and exhibitors. More than half of exhibitors are<br />

multinational companies like Phoenix, Beckhoff, Cognex,<br />

Weidmueller, Pilz, IFM, Nord, Rollon, and Rittal. Following the<br />

trends<br />

of<br />

Industry 4.0 to integrate power transmission exhibits to<br />

automation trade fair, IAMD Beijing focuses on overall<br />

solutions of automation, electrical power transmission,<br />

fluid power transmission, control technology,<br />

mechanical transmission, parts and equipment, sensor<br />

technology, industrial automation software, interface<br />

technology and power supply solution on a total display<br />

area of nearly 20,000 m 2 .<br />

After Beijing, the IAMD brand moves to the south of<br />

China, to the city of Shenzhen. Shenzhen being an<br />

industrial and technology driven city, the IAMD trade fairs find a<br />

perfectly suitable audience here. As one of the leading<br />

manufacturing regions in China, the absorption and penetration of<br />

IAMD technologies is higher in Shenzhen. With more than 500<br />

exhibitor companies from 15 countries like Germany, South Korea,<br />

USA, Japan, Singapore, China and Italy covering a total display area<br />

of 35,000 m 2 , the fair covers sectors such as integrated intelligent<br />

manufacturing solutions for control system, PLC, SCADA, sensor<br />

and actuator, servo motor, connectors, man-machine interface,<br />

industrial communication, IoT, cloud computing, industrial Ethernet,<br />

industrial personal computer, communication, hydraulic,<br />

pneumatic, fluid transmission and components, mechanical<br />

transmission components and parts etc.<br />

Pack your bags, Shanghai is waiting for you<br />

Over the last two decades, industrial trade fairs such as PTC Asia<br />

and IAS Shanghai have been witnessing and contributing to<br />

China’s rise as an industrial and manufacturing power. Like every<br />

year, Shanghai will host the two fairs, bringing in a wave of<br />

experts, industry professionals and academicians from all over<br />

Asia. With a total display area of around 100,000 m 2 , PTC Asia<br />

leaves no stone unturned to showcase the latest<br />

developments in the industrial and manufacturing sector.<br />

In last few years, this fair has brought in close to 100,000<br />

visitors and 1 500 exhibitors from all over the world. Like<br />

every year the event is to held in Shanghai New International<br />

Expo Centre. The event kick starts in last quarter of the year<br />

mostly in November, with intelligent manufacturing and<br />

“Made in China 2025” being the focal point. As China catches<br />

up with Industry 4.0 technologies, sectors such as hydraulics,<br />

pneumatics, mechanical and electrical power transmission<br />

are getting integrated more and more with IT. At events like<br />

these, one can witness the latest innovations either in terms<br />

of technology or the business model itself. Another event to<br />

look out for in Shanghai is the Industrial Automation Show<br />

- Shanghai, which hosts 700 well known enterprises from<br />

China and abroad with a display area of more than 70,000<br />

m 2 . At this event, the exhibitors showcase products such<br />

as assembling and handling systems, linear positioning<br />

system, control system, industrial image processing<br />

system, sensor and actuator, embedded system,<br />

measurement and test systems, industrial automation<br />

data acquisition and identification system and<br />

factory’s integrated management software.<br />

Photographs: fotolia<br />

<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/2<strong>01</strong>9 9

Turkey will bounce back,<br />

as it’s industry’s fundamentals<br />

are still alive and strong<br />

Despite the recent currency crisis and macro-economic instability in the country, Turkey has a vibrant<br />

manufacturing sector which holds immense potential for growth, and is on right track, as well.<br />


A<br />

s one of the largest countries in the Eurasian region in terms of<br />

population, Turkey has a strong and a growing economy. With<br />

more than 65 % of the population within the working age of 16 to 64<br />

years, Turkey is blessed with a demographic advantage and an<br />

expanding middle class, which results in consistent domestic<br />

demand. It’s strategic geographic position as a bridge between<br />

Europe and Asia has made the country an important manufacturing<br />

and distribution hub. It is the 17 th largest economy in the world<br />

and its industrial output accounts for more than a quarter of it’s<br />

GDP. Turkey positions itself in the global value chain by leveraging<br />

its logistical advantage, lower labor costs and flexible production<br />

capabilities.<br />

In terms of global competitiveness, Turkey ranks 61 st worldwide,<br />

with relative strengths on market size, infrastructure, public health<br />

and the innovation capabilities. As compared to other emerging<br />

nations, Turkey’s performance on the innovation scale is fairly good<br />

mainly due to strong research institutions and active participation<br />

in global technology publications and forums. But the country faces<br />

many bottlenecks when it comes to converting ideas into businesses,<br />

Author: Sushen Doshi, International Correspondent for World of Industries<br />

mainly due to barriers faced by entrepreneurs in ease of doing business<br />

and embracing disruptive ideas. In terms of product and labor<br />

market, Turkey lags behind other European countries mainly due to<br />

rigidities in worker-employer relations, internal labor mobility,<br />

ease of hiring foreign labor and lack of meritocracy.<br />

Turkey’s manufacturing sector<br />

As Turkey’s economy grew with an average growth rate of nearly 5 %<br />

from 2002 to 2<strong>01</strong>6, the GDP levels increased from $ 300 billion in<br />

2003 to $ 850 billion in 2<strong>01</strong>8. Export, which was $ 75 billion in 2005,<br />

rose to more than $ 155 billion by at the end of 2<strong>01</strong>8. For Turkey,<br />

mechanical engineering and machinery sector in particular is one<br />

of the most dynamic segment of the industry and with the collective<br />

wisdom possessed by the country’s machine manufacturers, this<br />

sector shall remain one of the driving force for Turkey’s economic<br />

growth. Over the last decade, the machinery sector has more than<br />

doubled its production capacities and has now risen as one of the<br />

top exports of the country. Today, this sector accounts for nearly<br />

10 % of the country’s total export. Turkey’s machinery export, which<br />

was $ 5 billion in 2005, has reached more than $ 13.5 billion in 2<strong>01</strong>7.<br />

Turkey exports its machinery to more than 200 countries, with EU<br />

10 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/2<strong>01</strong>9

and USA being the top export destinations, accounting for more<br />

than 60 % of the total. By the year 2023, Turkish machinery aims to<br />

double their share within Turkey’s total export. The top three industry<br />

sectors driving the Turkish machinery ahead are as follows<br />

1. Automotive and Vehicles segment: $ 24 billion<br />

2. Machinery including computers: $ 14 billion<br />

3. Electrical machinery, equipment: $ 8 billion<br />

Turkey’s leading industry sub-sectors<br />

Additive manufacturing: The automotive, aerospace and defense,<br />

household appliances, jewelry, and medical/dental industries<br />

started to use additive manufacturing in Turkey in 2<strong>01</strong>4. According<br />

to 2<strong>01</strong>7 statistics, Turkey accounts for roughly 1.5 % of the global<br />

additive manufacturing market with more than 400 3D printers<br />

being used across the country in manufacturing. There is growing<br />

demand for advanced 3D printers and CAD and CAM programs;<br />

advanced printing materials, including biomaterials; and largescale<br />

additive production capabilities.<br />

Industrial Automation: According to the Industrial Automation<br />

Association of Turkey, the industrial automation market in Turkey<br />

was valued at $ 1.5 billion in 2<strong>01</strong>6, with an annual growth rate of<br />

over 20 %. It is expected to reach $ 4 billion within the next 5 years.<br />

Many international companies present in Turkey also serve the<br />

Russian, the CIS, the Middle Eastern and North African markets,<br />

with an annual regional business volume of around $ 5 billion.<br />

Data Analytics: Big Data and Data analytics solutions are mainly<br />

used in the supply chain and warehouse management systems, in<br />

predictive maintenance for real time monitoring of industrial<br />

devices. Analysts estimate that the Turkey’s IoT market size will reach<br />

a cumulative amount of $ 90 billion by 2022, including sensors,<br />

optronics, M2M software and hardware, artificial intelligence, modeling<br />

and simulations, cloud services, and cybersecurity applications.<br />

Robotics: There are more than 12,000 industrial robots in Turkey,<br />

with about half in the automotive industry. According to 2<strong>01</strong>7<br />

statistics, countries with advanced robotics in manufacturing use<br />

300 robots per 10,000 workers. This amounts to just 12 robots per<br />

10,000 workers in Turkey, which shows the potential growth opportunities<br />

for robotics in manufacturing industries.<br />

Advances and opportunities in manufacturing sector<br />

Turkish industry lies in between the 2 nd and 3 rd industrial revolution,<br />

the most mature sectors include materials (rubbers & plastics),<br />

computers, electronics and optical devices as well as the automotive<br />

sector. Advanced manufacturing technologies are<br />

increasingly being implemented across Turkey with European<br />

automotive and aviation companies leading the way. These sectors<br />

employ numerous local suppliers, and have taken swift and bold<br />

steps to adapt to the latest technical and technological requirements.<br />

In order to prepare the Turkish industry for the fourth industrial<br />

revolution, Turkey’s industry bodies and associations are taking<br />

strong actions in digitalization and automation of manufacturing.<br />

With this the country aims to move up from cheap labor to high<br />

productivity and innovation, and climb up the global value chain<br />

and ensure its future global competitiveness and boost the economy.<br />

Currently, approximately 30 % of Turkey’s manufacturing<br />

output and 35 % of its exports consist of medium- and high-tech<br />

products. With the help of advanced manufacturing technologies,<br />

the Turkish government aims to bring medium- and high-tech<br />

product manufacturing up to the EU average of more than 60 %. If<br />

Turkey fully adapts the industry 4.0 concept, it could save more<br />

than $ 15 billion every year in current manufacturing costs.<br />

Depending on the GDP growth in the coming decade, Turkey is<br />

expected to invest about $ 3-5 billion annually in the integration of<br />

industry 4.0 technologies into the manufacturing process.<br />

Tubitak (the Scientific and technological research council of<br />

Turkey) has prepared a roadmap to prepare the Turkish industry<br />

for adoption and development of Industry 4.0 concepts. It identifies<br />

three technology groups, which are digitalization, connectivity and<br />

future factories. In the digitalization segment, focus is given on<br />

developing cloud service platforms, data analytics and cyber<br />

security solutions. In terms of connectivity, attention is given on<br />

establishing an industrial IoT platform, machine-machine and<br />

machine-human software and hardware that will increase the<br />

quality and productivity during the product life cycle; and<br />

development of the innovative sensors, industrial wireless<br />

networks, and machine vision and image processing software. In<br />

the future factories segment, focus will be to develop intelligent<br />

production robots, equipment, software and management systems<br />

that can compete in the international markets in terms of technical<br />

quality and cost. A report by the Turkish informatics foundation<br />

indicates that 50 % of manufacturers in Turkey plan to invest in industry<br />

4.0 within the next three to five years, 20 % still do not have<br />

any knowledge/strategy, and the remaining 30 % plan investments<br />

in five to ten years. In a survey conducted by Tubitak in 2<strong>01</strong>8, the<br />

technologies that Turkish SMEs consider most important for their<br />

industry are automation and control systems, advanced robotics,<br />

and additive manufacturing.<br />

Despite the currency crisis and diplomatic tensions with US<br />

President Donald Trump and German Chancellor Angela Merkel,<br />

many European businesses remain committed to Turkey because<br />

they see the country’s long-term growth potential. Making any<br />

investment in Turkey seems to be a risky business at the moment.<br />

Even thou international companies are holding off investing in<br />

Turkey right now, in no-way has the willingness to invest died off. z<br />

More power !<br />

© GÜDEL<br />

ROBA ® -guidestop rail brakes<br />

– more braking force<br />

– more holding force<br />

– more safety<br />

www.mayr.com<br />

your reliable partner<br />

Mayr-Eng.indd 1 17.<strong>01</strong>.2<strong>01</strong>9 12:22:33<br />

<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/2<strong>01</strong>9 11

Driving the innovation of electric motors<br />

forward with highly efficient test bench<br />

HBM and Schabmüller GmbH, producers of electric motors for mobile machinery, have developed<br />

a new test-bench concept for a new type of drive. It offers precision and convenient equipment<br />

for cycle-accurate testing and measurement. With sensors integrated into the measurement<br />

system, they can control the tests based on acquired data. With its formula database, the motor<br />

developer can make real-time DSP calculations foe customizable measuring and testing tasks.<br />


With e-vehicles on the rise, the requirements for motor<br />

performance and efficiency are continually rising. Hence,<br />

electric motor manufacturers work continuously to develop new<br />

drives. Simultaneously, new test-bench concepts are in demand to<br />

test these new motors with the required accuracy. The challenge is<br />

to obtain reliable results while precisely controlling test processes.<br />

Schabmüller GmbH, one of the leading manufacturer of electric<br />

motors for battery-powered vehicles, also applies these<br />

requirements to its own test equipment. Together with HBM, the<br />

motor manufacturer has developed a test-bench concept that<br />

enables measured data to be acquired and evaluated in line with<br />

these requirements.<br />

Schabmüller designs electric drives for forklift trucks, hybrid<br />

trucks and buses, as well as for construction and agricultural<br />

machinery. The company relies on HBM’s extensive measurement<br />

technology in their new synchronous motor test bench, specifically<br />

the ‘Genesis HighSpeed’ data acquisition system and the<br />

‘Perception’ software program. A software program developed<br />

using National Instruments’ LabView development environment is<br />

deployed for automating and controlling the test bench. “The<br />

Genesis HighSpeed measurement system is exceptionally easy to<br />

work with and all processes run in parallel and in real time. This<br />

makes the development processes of our test bench software much<br />

easier and less complex,” explains Dr. Martin Hafner, Manager of<br />

Technology Development for Permanent Magnet Synchronous<br />

Machines at Schabmüller.<br />

A modern test bench concept for innovative<br />

electric motors<br />

As a driver of innovation, Schabmüller also offers its customers<br />

permanent magnet synchronous electric motors. This new type of<br />

drive, without any changes to the cooling concept, produces just as<br />

much power as comparable asynchronous motors while requiring<br />

considerably less space. Optimizing or revising the cooling concept<br />

enables this effect to exponentially increased. To ensure precision<br />

in testing of the new electric drives, Schabmüller worked with HBM<br />

experts to optimize the test bench’s entire measurement chain.<br />

Stefan Lauck, development engineer at Schabmüller explains,<br />

“We chose the combination of Genesis HighSpeed and Perception<br />

software, as well as the LabView development environment as they<br />

are very easy to connect with an interface. “Thanks to the Percep-<br />

12 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/2<strong>01</strong>9

<strong>01</strong> The combination of HBM’s Genesis HighSpeed data acquisition<br />

system and Perception software with the LabVIEW development<br />

environment allows precise measurements and fast analysis<br />

tion’s sensor database, we can also integrate a wide range of different<br />

sensors for current, voltage and torque into the measuring<br />

system quite easily, simply by plug-and-play, like inserting a USB<br />

device in a computer. Integrating vibration sensors as part of electrical<br />

measurement equipment is possible without any problems.<br />

That saves us time and resources in setting up the test bench.”<br />

The Schabmüller test bench is used for various measurement<br />

tasks to reliably determine the short-term or continuous power and<br />

energy conversion efficiency of synchronous machines, or to identify<br />

their service life and component reliability. Schabmüller experts<br />

measure rotational speed and torque, generate efficiency maps,<br />

and based on this measured data, determine longitudinal and<br />

transverse inductances. Additionally, Schabmüller implements<br />

service life experiments under maximum mechanical stress. Longterm<br />

thermal experiments also determine how various long-term<br />

and interval loading patterns affect the motor function.<br />

An optimum system for extremely fast real-time tests<br />

To reliably determine all measured data, the test bench’s individual<br />

components must work together perfectly. The sensors acquire<br />

measurement signals such as current, voltage, temperature and<br />

torque and send them to the data acquisition system. The Genesis<br />

HighSpeed GEN7tA data acquisition system is used on the Schabmüller<br />

test bench along with GN610B acquisition cards. The DSPs,<br />

digital signal processors on the cards, process the measured data<br />

and calculate the initial results in real-time. The calculated measurement<br />

results are forwarded to LabView for analysis – at up to<br />

1000 times per second thanks to the EtherCAT connection. In parallel,<br />

HBM’s Perception software also saves all the acquired raw data.<br />

“Measured data and real-time computing results are acquired and<br />

forwarded simultaneously and with the same time stamp. That’s an<br />

enormous advantage for analysis,” emphasizes Stefan Lauck.<br />

“We can also create our own formula database for the calculations<br />

in Perception and can be used in both, post-process as well as realtime<br />

calculations in the DSPs, without any programming of the<br />

respective computer architecture.” Perception communicates with<br />

the LabView software via a freely programmable software interface.<br />

The LabView software is responsible for controlling and automating<br />

the test-bench processes. Based on real-time computing results, it<br />

controls the load and test specimen machines’ inverters. “The<br />

measured data can be processed for cycle-synchronous individual<br />

values. Then only the relevant cycle-synchronous computing<br />

results are used for control and automation of the test processes.<br />

For example, the RMS values of current and voltage or the torque<br />

values,” says Stefan Lauck. “Since, if need be, the raw data will still<br />

02 In Schabmüller’s test bench, torque transducers measure the<br />

torque and transmit the results to HBM’s GN610B and GN1610B data<br />

acquisition cards that record the measured data with high-resolution<br />

sample rates of up to 2 MS/s<br />

03 HBM’s Perception software communicates with the LabView<br />

development environment via a freely programmable software interface<br />

be saved, we can also use it for more extensive post-process<br />

analyses.” In addition to the cycle-synchronous individual values,<br />

continuously measured data can also be linked in the Perception<br />

formula database and processed in real time. No programming<br />

knowledge is required for this either.<br />

Easy sensor integration and channel synchronization<br />

“The combination of LabView and HBM’s Perception software<br />

offers us many advantages,” says Stefan Lauck. “Genesis HighSpeed<br />

synchronously records measured data of sensors and allows for<br />

sample rates of up to 2 ms/s on up to 51 power channels. It automatically<br />

synchronizes the sample rates of the different channels<br />

and input cards. This considerably reduces users’ overhead. We<br />

were also able to make optimum use of LabView advantages, such<br />

as the TDMS data format, to rapidly save large amounts of data. This<br />

also facilitates the subsequent data analysis using a wide range of<br />

available software products.”<br />

Schabmüller’s developers received customized support from<br />

HBM’s Perception experts as they integrated the data acquisition<br />

system into the test bench. According to Stefan Lauck: “Perception<br />

is an efficient software program that acquires data reliably. Thanks<br />

to the introductory training from HBM, we quickly became proficient.<br />

And because Perception is so easy to work with, we are able to<br />

define measurement sequences for our specific purposes.”<br />

www.hbm.com<br />

<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/2<strong>01</strong>9 13

Electric drive systems<br />

for offshore cranes<br />

The most common type of drive technology on<br />

ships and offshore platforms has been the hydraulic<br />

drives. With increase in safety requirements and<br />

environmental regulations becoming more<br />

stringent, the electric drive technology has<br />

become a key area of focus. In co-operation<br />

with the German gear manufacturer O&K<br />

Antriebstechnik, offshore pedestalmounted<br />

lattice boom cranes with<br />

innovative electric drive concept<br />

were recently commissioned by<br />

Palfinger Marine.<br />

<strong>01</strong> The four drives of the<br />

cable winch within the<br />

lattice boom are arranged<br />

face to face in the steel<br />

lattice boom crane made<br />

by Palfinger Marine<br />


14 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/2<strong>01</strong>9

The overall mechanical requirements of the project have sparked<br />

the ambition of the engineers. For steel lattice boom cranes with<br />

a reach of up to 57 m and a safe working load of 60 t, the aim was to<br />

develop the most compact electric drives possible for the main<br />

winch and boom winch. The steel lattice structure of the crane<br />

boom strictly dictated the respective installation spaces, for safety<br />

reasons, nothing could protrude beyond the lattice structure. At the<br />

same time, the size of the crane also dictated the cable thicknesses<br />

and lengths, as well the dimensions of the drum. In conjunction<br />

with the necessary torques and motor outputs, it quickly became<br />

clear that the performance requirements could not be met within<br />

the available space by a simple electrical drive. The constructional<br />

task was thus to distribute the power to several motors on the one<br />

hand, while transferring the total torque to the winch drum on the<br />

other.<br />

Tight installation space requires particular layout<br />

The calculations within the given framework conditions resulted in<br />

the drive of the rope winch that operates the hook being divided<br />

into four electric motors of size IEC 280, each with a weight of<br />

approximately 1.2 t. The boom winch has two motors of size IEC 315,<br />

each with a weight of approximately 1.7 t. This determined the<br />

entrance side, but there was still a constructional task left to tackle:<br />

The effective layout and connection of the motors to the winch system.<br />

It was not only the transmission of drive power that had to be<br />

considered but also the size and weight of the motors themselves.<br />

The special asynchronous motors, at about 2 m long and with the<br />

above stated heavy weight per engine, are not insignificant. When it<br />

comes to load distribution of the drive, which occurs via electronic<br />

control, then the purely mechanical elements must also be safely<br />

arranged in a purely constructional manner.<br />

The mechanical solution from O&K Antriebstechnik consists of<br />

two components each on both sides of the drum: a motor flange<br />

and an angle system flowing into the actual winch system. For the<br />

boom winch, the angle gear is designed in such a way that a fail-safe<br />

brake is mounted opposite the engine’s power side for emergency<br />

situations. This ensures that the crane boom remains in position<br />

and cannot sag, even when there is an interruption in power, a<br />

significant safety aspect. With a high degree of efficiency, a bevel<br />

gear setup transfers the motor input torque to the winch’s planetary<br />

gear, which is located in the winch drum. The winch itself can be<br />

found at the crane tower and experiences only the rotational movements<br />

of the tower. There should be no anomalies when lubricating<br />

the angular gear. A control system ensures synchronous operation<br />

of the drives on both sides of the winch.<br />

The large cable winch drum, which has a width of around 2 m, is<br />

mounted near the tower in the boom of the crane. The four drives of<br />

the cable winch are also arranged on both sides of the winch drum,<br />

with two drives apiece directly facing each other. These motors are<br />

also mounted with a motor flange on an angular gear, which transfers<br />

the combined power of the two motors, which are joined at<br />

right angles, to the planetary gear that is integrated into the winch<br />

drum. Of particular importance here is the sophisticated lubrication<br />

system of the bevel gear setup, which ensures that the lubricant<br />

is supplied to the best possible degree, irrespective of the position<br />

of the boom. The four motors, which are also inverter-fed, work in<br />

perfect synchronization with each other.<br />

Complete electrification offers clear advantages<br />

Together with the electric rotary drives, the boom crane is thus<br />

completely electrically driven. The control system is at the cutting<br />

edge of current technology, operates and reacts quickly and ensures<br />

safety up to a significant wave height of up to 6 m, which can<br />

only be reached during stormy winds. The electrical drives are also<br />

advantageous in terms of flexibility in operation and even enable<br />

remote access to the crane, which can be implemented for fault<br />

detection and fast support, for example. In addition, standard components<br />

are used to a large extent, which enables easy maintenance<br />

and fast supply of spare parts. In all, the electric drives provide a<br />

higher level of energy efficiency, thus ensuring lower energy consumption<br />

and practically eliminating the risk of oil contamination<br />

that could occur due to a breakdown or accident involving the<br />

hydraulic system.<br />

These electric drives have proven themselves completely effective<br />

in other industries that operate in harsh environmental conditions.<br />

In construction machinery, they can provide service in their<br />

role as travel or slewing drives that is just as reliable as it is when<br />

they are used in wind turbines around the globe and under extreme<br />

weather conditions. Developed in accordance with strict EN13852-1<br />

and Norsok R002 standards, they reliably fulfill all requirements,<br />

even in offshore applications. The cranes that are equipped with<br />

electric drive technology have less wear-prone components, which<br />

therefore means they also have lower maintenance costs. Above all,<br />

however, they work much more quietly and produce noticeably less<br />

vibration. So there are many reasons for implementing this change.<br />

Know-how and experience are fundamental<br />

The specially designed drive components were implemented by<br />

engineers from German drive technology experts O&K Antriebstechnik.<br />

In close co-operation with colleagues from machinery<br />

manufacturers, they have developed and designed machine-specific<br />

solutions in a surprisingly short period of time. After a thorough<br />

range of tests that are tailored towards the requirements of a specific<br />

application, the product will go into serial production ensuring<br />

reliable supply to customers.<br />

Photographs: Palfinger Marine/Bonfiglioli<br />

02 The steel lattice structure of the crane boom strictly dictated the<br />

installation space of the winch drives in the crane of Palfinger Marine<br />

www.bonfiglioli.com/en<br />

<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/2<strong>01</strong>9 15

Bearings with black<br />

oxide finish<br />

Bearing manufacturer NKE Austria<br />

GmbH presents bearings with black<br />

oxide finish. The protective layer<br />

improves run-in and wear characteristics<br />

and protects against environmental<br />

effects. Especially in critical<br />

applications such as wind turbine<br />

gear boxes, black oxide finish is a<br />

cost-effective and technically viable<br />

means of prolonging the service life and performance of<br />

rolling bearings. The black oxide finish forms a protective layer<br />

for steel parts. In a multistage chemical process, the surface<br />

layer of the treated parts is converted into a 1 to 2 micrometer<br />

thin mixed ferrous oxide layer that causes the characteristic<br />

black appearance. Black oxide finished bearing components<br />

feature a set of special technical characteristics, especially in<br />

the case of components that move relative to each other.<br />

Multiple protective effects can be achieved if only one<br />

functional element (typically the rolling elements) is treated.<br />

For best effect, however, all functional surfaces of a rolling<br />

element bearing, including the inner and outer ring as well as<br />

the rolling elements, should be black oxide finished.<br />

www.nke.at<br />

Digital motor feedback for smart<br />

servo drive systems<br />

As a result of increasing<br />

digitalization in<br />

mechanical and plant<br />

engineering, electric<br />

drive systems are<br />

increasingly faced by<br />

the challenge of having<br />

to be integrated as<br />

smart components in future-oriented overall mechatronic<br />

concepts. The Sick range of motor feedback systems with<br />

digital Hiperface DSL interface offers the required remote<br />

intelligence and communication capability for motors<br />

and servo drive systems. The rotative sensors also meet all<br />

requirements for application-based functionality,<br />

maximum precision and dynamics as well as certified<br />

safety. The new product families EDS35 and EDM35 are<br />

the technological highlight in this range. Here, Sick<br />

presents the second sensor generation with digital<br />

Hiperface DSL one cable technology.<br />

www.sick.com<br />

Couplings for the big drive<br />

background: fotolia<br />


Axial piston variable pump: medium-to-highpressure<br />

all-rounder<br />

Construction machinery and its components must first and foremost be<br />

reliable and robust, even when under extreme application conditions.<br />

Hydraulic units are also expected to be space-saving and energyefficient.<br />

Over-sized and hence expensive high-pressure units are often<br />

used for applications with a pressure level somewhere between the<br />

classic thresholds of medium pressure (280 bar) and high pressure<br />

(350/380 bar). With its A10VOH<br />

(series 60, size 145), Rexroth has<br />

created a solution which perfectly<br />

bridges the gap in order to enable<br />

users to achieve efficient operation<br />

in this “light heavy-duty” application<br />

area.<br />

The axial piston variable pump<br />

A10VOH features a permissible<br />

nominal pressure of 320 bar in<br />

corner power operation at<br />

maximum swivel angle and rotational speed. If the swivel angle is<br />

reduced, the permissible nominal pressure increases to up to 350 bar. As<br />

such, the A10VOH is ideal for use in various applications, including<br />

steering drives, hydrostatic fan drives and working hydraulics. It is<br />

lightweight and, despite its size of 145 cm³, so compact that it requires<br />

the same installation space as the Rexroth A10VO (series 31, size 100).<br />

www.boschrexroth.com<br />

The metal bellows couplings of the KXL series<br />

from Jakob Antriebstechnik were designed for<br />

medium and large drives up to a maximum of<br />

65,000 Nm. A special design feature is the<br />

three-piece design with a flexible bellows package<br />

as an intermediate piece. This removable intermediate<br />

piece, consisting of an optimized, torsionally<br />

stiff stainless steel bellows with 2two bellows<br />

shafts per side and a variable length intermediate<br />

pipe, is frictionally connected (screws ISO 4<strong>01</strong>7 /<br />

10.9) with the two hubs. This results in a considerable<br />

ease of assembly, as e.g. can be omitted in<br />

the maintenance or service case a costly disassembly<br />

of the heavy drive or driven units. The<br />

designer has several hub variants available for the<br />

specific application. The extremely favorable<br />

moment of inertia and the rotationally symmetric<br />

design ensure good dynamic performance. The<br />

KXL couplings are particularly suitable for precise<br />

drives, such as for printing presses, cross cutters,<br />

main spindle drives, transfer axes or transmission<br />

connections.<br />

www.jakobantriebstechnik.de<br />

16 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/2<strong>01</strong>9

A filter, breaking all records<br />

The smallest non-woven element ever produced at Argo-Hytos<br />

in Kraichtal has a diameter of 25 mm and a height of 35 mm and<br />

is used in the control block of a wheel loader. The smallest filter<br />

from Argo-Hytos is just the size of a thumb, but does not<br />

compromise on<br />

functionality. A<br />

multi-layer filter<br />

fleece encloses the<br />

perforated support<br />

tube. The close<br />

cooperation<br />

between development<br />

department<br />

and prototype shop<br />

guarantees the process-reliable manufacturing of the necessary<br />

materials. Complex process steps must be mastered in a new<br />

dimension: cut to width, four-layer pleating of the materials,<br />

optimization of the pleat geometry, cutting the pleat pack to<br />

length, bonding of the longitudinal seam, dosing of smallest<br />

quantities of glue, secure fixation of all parts during curing,<br />

assembly of support tube and end cap. The miniature filter<br />

elements thus produced are then subjected to quality testing,<br />

which they have passed without complaint. In sample production,<br />

process reliability is also assessed and documented, which<br />

is important for future series production.<br />

www.argo-hytos.com<br />

Optimized insulation of motor and<br />

servo cables<br />

The development of new motors known as variable<br />

frequency drives (VFDs for short) is pointing in a clear<br />

direction: ever more compact at the same or higher power<br />

with extremely high switching accuracy of the frequency<br />

inverters. As a<br />

result, when<br />

selecting a<br />

cable in the<br />

future, the user<br />

will not only<br />

have to pay<br />

attention to the<br />

correct number<br />

of cores and cross-section combination, but also to the<br />

electrical properties of the cable. For this reason, igus has<br />

now developed a material for its latest generation of motor<br />

and servo cables that is up to the new challenges. This<br />

material withstood more than 45 million strokes in the test<br />

with a bending radius of 7.2 x d.<br />

www.igus.com<br />


Reliable. Versatile. Global.<br />

Hall 15<br />

Stand H31<br />


Strong bearings<br />

Quiet running<br />


High efficiency<br />

Global standards<br />


Field distribution system<br />

Easy implementation<br />

Getriebebau NORD GmbH & Co. KG | Fon +49 4532 289-0 | info@nord.com<br />


Laser modules provide improved<br />

efficiency for thin-film solar modules<br />

Manz AG is one of the world’s pioneers in photovoltaic<br />

engineering. In the realization of the largest order in<br />

the company’s history so far, Z-Laser laser modules<br />

play a decisive role in quality assurance and enable the<br />

production of solar modules with very high efficiency.<br />

With CIGSfab, Manz AG is the only supplier worldwide of a<br />

turnkey, fully integrated production line for the production of<br />

CIGS thin-film solar modules. “We are absolutely convinced that<br />

the future belongs to CIGS thin-film solar technology in photovoltaics,”<br />

emphasizes Bernd Sattler, Head of Vision & Metrology at<br />

Manz AG in Reutlingen.<br />

In January 2<strong>01</strong>7, the company, which was founded in 1987, won<br />

the largest order by far in the company’s history with a volume of<br />

263 million euros for this product: A joint venture of the Chinese<br />

Shanghai Electric Group Co., Ltd. and the Shenhua Group Co., Ltd.<br />

ordered a CIGSfab with a capacity of 306 MW and a CIGSlab, a<br />

research line with a capacity of 44 MW. Both factories are scheduled<br />

to start production in the summer of 2<strong>01</strong>9.<br />

50 times thinner than a human hair<br />

When checking<br />

the lines that are<br />

created in the first<br />

two structuring<br />

processes, laser<br />

modules ensure<br />

optimum<br />

illumination<br />

In a conventional crystalline solar module based on a high-purity<br />

silicon wafer, a large number of individual solar cells are soldered<br />

and mounted between a glass pane and a film. The individual<br />

wafers are up to 100 times thicker than the semiconductor layer<br />

CIGS (copper-indium-gallium-diselenide) on a thin-film module.<br />

This is vapor-deposited in a vacuum system, in just one process<br />

step, directly onto a glass pane. The use of expensive semiconductor<br />

material is correspondingly higher in crystalline technology. In<br />

addition, thin-film technology eliminates the labor-intensive and<br />

expensive multilevel process of the raw silicon, the wafer, the cell,<br />

and the module fabrication by direct application of the<br />

semiconductor to the glass substrate.<br />

The advantage according to Bernd Sattler: “The CIGS absorber<br />

layer has a thickness of only approx. 2 μm and is thus 40 to 50 times<br />

thinner than a human hair. The positive effects on the manufacturing<br />

costs due to the material savings and fewer process steps are obvious.”<br />

<strong>01</strong> In the P2 structuring machine, two laser processing<br />

heads are operated in parallel, which is why two Z-Laser<br />

illumination lasers are used on one unit<br />


18 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/2<strong>01</strong>9

02 The CIGS absorber layer has a thickness of only about 2 microns<br />

and is thus about 40 to 50 times thinner than a human hair<br />

The manufacturing process of the 600 x 1 200 mm solar modules at<br />

Manz therefore requires the highest precision. Bernd Sattler<br />

describes the essential steps as follows: “The carrier material is<br />

coated and structured in several process steps. The entire area has to<br />

be divided into smaller cells, as the whole area generates a high<br />

current. By connecting these small cells in series, the voltage can be<br />

increased from about 0.6 V per cell to, for example, about 80 V per<br />

module. “This requires three separation steps, two of which are realized<br />

with one processing laser and one with a special engraving stylus.<br />

Exact measurement for higher efficiency<br />

For the correct function of each module, it is essential that the<br />

structures for interconnecting the solar cell diodes are applied<br />

correctly. For economic reasons, it also makes sense to check these<br />

structuring lines after each of the three separation steps in order to<br />

recognize defect modules at an early stage, to take them out of the<br />

process immediately and thus not to cause unnecessary costs.<br />

The measurements that have to be made include the widths and<br />

distances of the structuring lines, the so-called dead-area as well as<br />

structuring distances. Precise measurement results have a direct<br />

influence on the quality of the solar modules produced. The<br />

so-called dead-areas are required for structuring, but do not<br />

generate electricity. For that reason, the smaller these areas can be<br />

manufactured, the higher the efficiency of the entire solar module<br />

gets. With the measured results, the structuring systems are set and<br />

the distances are kept constant to ultimately optimize the efficiency.<br />

High demands<br />

The structuring lines denoted P1 and P2 are generated by a solidstate<br />

processing laser in the infrared wavelength spectrum.<br />

Especially when applying the P2 line, the laser illumination is of<br />

particular importance: To minimize the dead-area, the position of<br />

the laser is actively controlled during the process of the second line<br />

(P2 structure) to produce this as close as possible and in parallel to<br />

the already existing P1 structure.<br />

Sattler describes how his team solved this problem: “The<br />

processing laser for the P2 process is positioned using a very fast<br />

matrix camera. It measures the P1 line with a frequency of 1 000 Hz<br />

and an accuracy of less than 5 μm ahead of the processing laser.<br />

With this tracking data the position of the laser scanner, which<br />

writes a second line parallel to the first line, is directly controlled.<br />

In addition to accuracy and frequency, the main challenge,<br />

according to Sattler, was to safely separate the laser used<br />

for the illumination from the processing laser<br />

so that the processing laser would not<br />

damage either the camera or the<br />

03 The laser modules ZQ1 are<br />

developed to facilitate the most<br />

demanding measuring methods<br />

illumination laser. “The entire integration into the optical path of<br />

the laser components could only be realized through a very close<br />

cooperation with our laser process group and the mechanical<br />

design,” says the department manager.<br />

Sattler also recalled that choosing the optimal laser lighting was<br />

not easy: “For this purpose the needed wavelength is above<br />

1 000 nm because the transmission of CIGS layer starts at that point,<br />

and the suitable CMOS camera is still sensitive enough in this<br />

wavelength area to produce a usable image.”<br />

Specialized laser modules<br />

During the design phase of the systems, Sattler and his colleagues<br />

used a proprietary prototype for lighting with a laser diode that<br />

offered the required characteristics. “When it came to series design,<br />

we looked for a partner who had more expertise in the field of laser<br />

diodes,” says Sattler.<br />

After reviewing various options, Sattler decided in favor of<br />

Freiburg based manufacturer Z-Laser: “Z-Laser’s offer was the<br />

safest and most interesting option for us. The hardware costs were a<br />

bit higher than we calculated, but we were able to compensate for<br />

this by the fact that the Z-Laser modules were very precisely<br />

manufactured and pre-adjusted. As a result, the adjustment times<br />

in the machines were significantly lower than originally planned.<br />

“At the beginning, the size also gave the Manz developers team a<br />

headache. “However, we were able to master this challenge with<br />

some good ideas in mechanical design.”<br />

Sattler mentions another important argument for working with<br />

Z-Laser: “We had specified the laser diode required for this<br />

measurement task very exactly. Our partner already had a laser<br />

module available in which this laser diode could be used with little<br />

effort. “According to Sattler, the further cooperation went very well:”<br />

Even the first prototype and also the later series models that we<br />

received from Z-Laser worked very well right away. The learning<br />

curve typically associated with new suppliers and components was<br />

much shorter than usual. Z-Laser quickly provided us with a<br />

solution to our demanding challenge. “<br />

Even when inspecting the quality of the modules after each of the<br />

three process steps, backlight laser modules ensure optimum<br />

illumination to enable perfect camera images. In a second measuring<br />

system at the final quality inspection stage, the entire substrate is<br />

scanned with a contact image sensor in order to ensure the<br />

completeness of the lines of the third structuring process and to<br />

detect any damage. “Laser modules from Z-Laser thus play a<br />

decisive role in all three surveying steps and help to optimize<br />

the production process of the thin-film solar modules,”<br />

explains Bernd Sattler. “Every CIGSfab uses several of the<br />

described systems. This is the only way we can ensure that<br />

the planned throughput is 100 % controlled and that only<br />

defect-free substrates leave the plant. “<br />

www.z-laser.com<br />

Photographs: teaser, <strong>01</strong>-02 Manz, 03 Z-Laser<br />

<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/2<strong>01</strong>9 19

Taking a look into outer space<br />


Specialist glass manufacturer Schott supplies huge<br />

mirrors for the European Extremely Large Telescope<br />

(EELT), currently the largest telescope in the world,<br />

which is under construction on the mountain of Cerro<br />

Armazones in Chile.<br />

C<br />

erro Armazones, Chile. The European Extremely Large<br />

Telescope (EELT), currently the world’s largest telescope, is at<br />

present under construction on top of the Chilean mountain of<br />

Cerro Armazones. The glass specialist Schott is one of the companies<br />

manufacturing the enormous mirrors for the telescope. The manufacturing<br />

process is based on a special ceramic glass so that the mirror<br />

can withstand the extreme local conditions. This is why Schott<br />

has chosen Siemens technology for the manufacturing process. The<br />

process control system Simatic PCS 7 ensures the temperature is<br />

measured and controlled extremely accurately during production.<br />

In addition to the main mirror with a diameter of almost<br />

40 meters, the European Extremely Large Telescope also has four<br />

other mirrors which act as reflectors. Three of these large mirrors,<br />

which measure up to four meters, are produced by Schott. The<br />

Mainz-based company uses a special ceramic glass (Zerodur) in<br />

The most being opend in<br />

the Schott cooling hall<br />

the manufacturing process as the mirror substrate. The benefit of<br />

this ceramic glass is that it has a very low coefficient of thermal<br />

expansion. This means that the material does not expand even if<br />

temperatures vary considerably. This is an important property if the<br />

EELT is to supply sharp images.<br />

Perfect temperature control for perfect mirrors<br />

In order to avoid stress cracks, the special glass is repeatedly heated<br />

and cooled over long periods of time during production. Temperature<br />

control at this point must be accurate to three decimal places<br />

which is why Schott has chosen the Simatic PCS 7 process control<br />

system and the Simatic ET 200SP distributed I/O system from its<br />

long-term partner Siemens for this project. Initially Schott<br />

“Schott chooses Siemens automation<br />

technology to produce mirrors for the<br />

world’s largest telescope.”<br />

employees and experts from Siemens tested the fundamental<br />

feasibility in the laboratory and, after successful tests, Siemens then<br />

programmed a new module specifically for this application. The<br />

solution includes many types of measurement such as stress,<br />

voltage and resistance, as well as resistance thermometers and<br />

thermal elements.<br />

Undiscovered worlds<br />

This extremely accurate measurement of temperature allows Schott<br />

to produce mirrors which can not only withstand the adverse<br />

conditions on top of this Chilean mountain, but can also contribute<br />

to taking a look at hitherto undiscovered worlds.<br />

Photographs: Schott<br />

www.siemens.com<br />

20 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/2<strong>01</strong>9

How to check presence and<br />

position simultaneously<br />

SmartRunner technology is a unique combination of light section technology and a 2-D vision<br />

sensor with integrated LEDs. This innovative combination offers completely new applications<br />

for demanding detection tasks and allows you to design efficient, future-proof processes.<br />

Robotic handling systems are often used to feed workpieces or<br />

raw materials into production and processing systems. Workpiece<br />

carriers are used to transport the materials to the plant, where<br />

the materials are then automatically removed. In conventional<br />

solutions, standard vision sensors are used to control the position<br />

of the materials being fed. This process is costly and complex since<br />

these sensors quickly reach the limits of their detection performance<br />

when working with low- contrast objects. In such cases,<br />

standard vision sensors require additional external lighting and<br />

complex configuration.<br />

Efficient operation without plant downtime<br />

An uninterrupted supply of raw materials is crucial for maintaining<br />

cost-effective operations in production plants. The materials, which<br />

can vary in color, are transported to the machine in workpiece<br />

carriers. Before the materials are picked up by the robotic system, it<br />

is necessary to check whether the materials are present (presence<br />

check) and whether the materials are in the correct position (position<br />

control). Efficient operation without plant downtime or<br />

production waste is always the top priority.<br />

Two detection tasks in a single step<br />

With the SmartRunner Matcher light section sensor from<br />

Pepperl+Fuchs, both detection tasks can be performed in a single<br />

step. The sensor is mounted above the conveyor system and checks<br />

two items simultaneously by detecting the height profiles. When<br />

these height profiles match the reference profile stored in the sensor,<br />

the switching output sends a “good” signal. Differing height<br />

profiles indicate either missing or incorrectly positioned raw material,<br />

and the sensor sends a “bad” signal. The SmartRunner Matcher<br />

thus prevents waste and plant downtime, enabling more efficient<br />

production.<br />

The benefits<br />

SmartRunner Matchers are optimized in the factory to compare<br />

height profiles, meaning they can be integrated directly into the<br />

application without any specialized expertise required. The solution<br />

is easy to configure, and there is no need to evaluate raw data.<br />

Instead, the detection result is delivered as a switching signal that<br />

can be understood by any control panel.<br />

Light section technology delivers highly precise, reliable results,<br />

regardless of the surface quality, contrast, and color of the objects<br />

being detected. Unlike conventional vision-based solutions, expensive<br />

and difficult-to-install external lighting is not required. The<br />

wide detection range of 160 mm allows multiple objects to be<br />

detected and verified. An extended version of the SmartRunner<br />

Matcher is also available, allowing up to 32 height profiles to be<br />

stored in the sensor for quick reparameterization after plant<br />

changeovers.<br />

Photographs: Pepperl+Fuchs<br />

www.pepperl-fuchs.com<br />

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www.kjellberg.de<br />

Kjell.indd 1 11.02.2<strong>01</strong>9 07:44:49<br />

<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/2<strong>01</strong>9 21

Safety light grids for hygiene-sensitive<br />

sectors<br />

The Schmersal Group has developed a new product line for<br />

safety light grids and curtains eminently suitable for use in<br />

hygiene-sensitive sectors, such as the food industry,<br />

pharmaceuticals and meat and milk<br />

processing. The new product line SLC/<br />

SLG 440 IP69K is resistant to all daily<br />

cleaning processes prevalent in such<br />

industries. Thanks to a sophisticated,<br />

detailed design, this product line<br />

achieves the protection rating IP69K and<br />

is thus protected against ingress of water<br />

during close-range high-pressure and<br />

high-temperature spray downs. The<br />

locking caps are manufactured in<br />

stainless steel (V4A) as are the cable inlet<br />

and the fastening parts. The material<br />

guarantees greater availability and a<br />

long service life for safety light curtains<br />

and grids, also allowing a compact<br />

design for encapsulated safety sensors.<br />

Other characteristics include additional functions such as<br />

double confirmation, contactor control and integrated beam<br />

blanking, which allows moving parts to be conveyed through<br />

the protection field without triggering the stop signal.<br />

www.schmersal.com<br />

Modular field bus system for<br />

on-machine installation<br />

New clamp concept for energy chains<br />

Safety plays a key role when humans and robots work hand in<br />

hand in the industry. That is why users of cobots and<br />

industrial robots are already using igus’ multi-axis round<br />

triflex R e-chains for energy and data supply. To easily attach<br />

these energy chains and increase work safety in industry, igus<br />

has now developed new plastic mounting clamps. With quick<br />

installation, these minimise the risk of injury with their<br />

rounded edge design. The triflex R range has been specifically<br />

developed for sophisticated 6-axis robots in industrial<br />

environments. By combining the flexibility of a hose with the<br />

stability of an energy chain, the round triflex R ensures<br />

reliable cable guidance in multi-axis movements. A ball/<br />

socket principle ensures high tensile strength and easy<br />

installation of the e-chain. The interior separation is freely<br />

selectable. The circular bend radius stop and the high<br />

twistability of the e-chain prevent the over-stressing of cables<br />

- this system increases the service life and operational<br />

reliability of the application. The triflex e-chains are available<br />

as a complete package with cobot designed clamps, cables<br />

and connectors immediately ready for connection.<br />

www.igus.com<br />

background: fotolia<br />


The Cube system from Murrelektronik is a modular field bus<br />

system for on-machine installation concepts. It’s engineered<br />

flexibly to be the optimal solution for any application – meeting<br />

protection class IP20 through IP69K. Cube67 features<br />

great functionality, easy connections, a robust and compact<br />

design, fully molded<br />

modules, and<br />

multi-functional<br />

inputs and outputs.<br />

The modules can be<br />

installed right next to<br />

the sensors and<br />

actuators. The<br />

one-cable-technology<br />

connects the modules<br />

to the bus node, transferring both data and power. Extensive<br />

diagnostics enable maximum transparency. The number of<br />

terminals in the control cabinet is reduced by moving field<br />

bus modules into the field, freeing up space. The Cube67 field<br />

bus system makes it possible to change bus without changing<br />

system: installation concepts can be implemented<br />

independent of existing control concepts. Simply select the<br />

bus module with the desired field bus protocol; Murrelektronik<br />

can provide bus nodes for the most common field bus<br />

systems.<br />

www.murrelektronik.com<br />

New camera series for embedded<br />

vision<br />

The all-new Alvium camera<br />

series is a new camera<br />

platform developed by<br />

Allied Vision that opens the<br />

gates of industrial machine<br />

vision to embedded system<br />

designers. Alvium offers a full range of digital cameras<br />

designed on an innovative platform which offers three<br />

configurations (board level, open-housing and closed<br />

housing) utilizing MIPI CSI-2 and USB3 Vision interfaces. At<br />

the core of Alvium is the unique Alvium technology, a<br />

proprietary System-on-chip (SoC) designed by Allied Vision<br />

which completes on-board image processing through a<br />

comprehensive image processing library (IPL). Integration<br />

into systems from the software prospective is made easier as<br />

one driver is needed for each platform to operate all Alvium<br />

camera models. Furthermore, designers/integrators can<br />

control the camera via Video4Linux, GStreamer, Direct<br />

Register Access, and GenICam. Models from the 1 500 Series<br />

and the 1 800 Series will be the first to be made available.<br />

www.alliedvision.com<br />

22 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/2<strong>01</strong>9

Safe handling of motion and dynamics<br />

Machine areas that continue running after switching off are often<br />

part of automated production processes. If one thinks, for example,<br />

of a large flywheel mass or slowly running down saw blades, it is<br />

absolutely essential that the machine operator is prevented from<br />

accessing them with the help of a safety guard until the dangerous<br />

movement has come to a complete standstill. Safety interlocking<br />

devices with guard locking such as the new SLC (Safety Lock),<br />

ensure, that protective guards, safety doors and other covers stay<br />

closed as long as a dangerous condition exists.<br />

www.bernstein.com<br />

Optical sensors with an impressive function<br />

variety<br />

The O200 sensors from Baumer considerably raise the performance bar for optical<br />

miniature sensors. The sensors ignore ambient light by machine reflections or<br />

other sensors, even bright LEDs emitting a similar spectrum of light and operating<br />

on similar switching frequencies. With<br />

conventional sensors, such disturbances<br />

result in the object not being detected<br />

or sensor operation being slowed<br />

down. O200 sensors feature high-power<br />

mode to reliably detect ultra-black,<br />

light-absorbing objects even at long<br />

distance. Product variants with V-optics<br />

specialize in glossy or transparent<br />

objects. O200 sensors with IO-Link are<br />

ready for Industry 4.0 and IIoT. The<br />

latest IO-Link standard allows the sensors to be configured automatically.<br />

The series comprises around 130 variants with different properties and<br />

combinations.<br />

www.baumer.com<br />

Piezo sensor module also with digital I²C signal<br />

Integrative pressure measurement in the smallest of spaces: Wika has expanded<br />

its portfolio for OEM applications with the very compact MPR-1 piezo sensor<br />

module with standardised output signal. With a diameter of 19 mm and a height<br />

starting from 17 mm (depending on the process connection), the sensor module<br />

can be integrated into a wide variety of products and systems. The custom-fit<br />

specification is supported by the<br />

selection of analogue and digital output<br />

signals. The version with digital I²C<br />

signal features very low power<br />

consumption and a fast response time<br />

(3 ms). It is therefore ideal for<br />

applications with battery operation. In<br />

addition, a temperature value can be<br />

output via the I²C signal. The model<br />

MPR-1 is available, as standard, with gauge and absolute pressure measuring<br />

ranges (from 0 ... 0.4 bar to 0 ... 25 bar) as well as vacuum measuring ranges. It<br />

measures with an accuracy of ≤ ±0.5 % of the span. On request, a higher accuracy<br />

and other pressure ranges can be realised.<br />

Some industries operate like<br />

clockwork in the constant battle to<br />

staycompetitive. In over200<br />

countries,thoseare the industries<br />

working with us.<br />

With over<br />

11.000<br />

members, we represent the<br />

Turkish engineering<br />

industry.<br />

5TOP<br />

The main export products of<br />

Turkish machinery:<br />

air conditioners and cooling machines;<br />

engines;<br />

washing and drying machines;<br />

contruction machines;<br />

pumps andcompressors<br />

www.turkishmachinery.com<br />

Main Foyer/F10<br />

www.wika.com<br />

<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/2<strong>01</strong>9 23<br />

Turkish-Machinery.indd 1 11.02.2<strong>01</strong>9 10:33:06

Fully serviced<br />

in Europe<br />


Beumer Group installed the entire conveying, picking<br />

and sortation technology for car parts dealer Inter Cars<br />

S. A. at its new European Logistics Centre (ELC) near<br />

Warsaw. This includes a warehouse control system<br />

(WCS) that manages the entire material flow.<br />

Optimizing throughput and minimizing costs, Inter<br />

Cars gets its spare parts now even faster to workshops<br />

and customers all across Europe. For this project, the<br />

system supplier has permanently stationed employees<br />

on site as part of its residential service.<br />

“Inter Cars was one of the most important projects for us to<br />

successfully complete in Poland,” Sandra Lückmann sums up. She<br />

is business development manager at Beumer Group in Beckum,<br />

Germany, and was responsible for the successful handling of this<br />

order. What was remarkable: “As system integrator, we designed<br />

and installed the entire conveying, picking and sortation technology<br />

for the spare parts dealer at its European logistics centre, including<br />

our WCS, that controls the inbound area, quality assurance, picking<br />

and shipping.”<br />

Spare parts distributor with potential<br />

Inter Cars is one of the leading spare parts distributors for passenger<br />

cars, transport vehicles and trucks. The company, headquartered in<br />

Poland, has more than one hundred subsidiaries and branches<br />

spread all across the Baltic states and the Balkans. In addition, there<br />

is a nationwide network of approximately a thousand workshops.<br />

The previous logistics centre in Czosnów, Poland, supplied smaller<br />

24 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/2<strong>01</strong>9

distribution centres all over Europe who then supplied the<br />

workshops and customers. The increasing number of stored and<br />

delivered parts however started to exceed its capacities. The managers<br />

decided to build a new automated European logistics centre<br />

in Zakroczym, approx. 30 km from Warsaw. The in-house logistics<br />

provider ILS was commissioned as general contractor – “and this is<br />

how we got involved as system supplier of intralogistics solutions”,<br />

says Sandra Lückmann. “At the end of 2<strong>01</strong>3, ILS called our Polish<br />

subsidiary. At the time, the project was still in its design phase. We<br />

only knew how many parts needed to be sorted in a given period of<br />

time.”<br />

Up to seven million products<br />

In January of 2<strong>01</strong>5, Beumer Group got awarded the contract,<br />

installation started in September of 2<strong>01</strong>5, and the start-up process<br />

began the following September, with completion in December.<br />

Inter Cars closed the previous logistics centre at the end of 2<strong>01</strong>6, the<br />

new European logistics centre started fully operating in May 2<strong>01</strong>7.<br />

“There are currently stores around 7 million pieces like spark plugs,<br />

brake disks, V-belts, batteries, but also more bulky parts, like exhausts<br />

and hoods, basically everything needed for cars,” explains<br />

Lückmann. The complex is comprised of four buildings, the largest<br />

one with 40,000 m², ten metres in height. It is equipped with a fourstory<br />

shelving rack. The other buildings are 5,000 m². Here they<br />

store tyres and hazardous material, such as oils and varnishes, that<br />

must be kept separate due to fire protection measures.<br />

The products are divided into different clusters, similar to clothing<br />

sizes into S, M and XL and XXL, depending on dimension and<br />

weight. “Items are picked in two stages,” describes Lückmann. With<br />

a set number of totes placed on a trolley, the employee drives along<br />

the aisles of the shelves, collecting all the components displayed on<br />

the hand-held scanner. The small and medium parts are taken out<br />

of the shelves in batches, consolidating multiple orders into one<br />

picking wave. The totes are then placed on the roller conveyor and<br />

transported automatically to the packing sorter. “Depending on the<br />

<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 1/2<strong>01</strong>9 25


content, the WCS distributes the incoming totes to one of three<br />

induction areas,” explains Lückmann. The conveying technology<br />

transports them to the workplaces where the items are taken out of<br />

the totes. Each item is identified with a matrix camera and placed<br />

on the sorter. Empty totes are returned to the conveying system and<br />

follow the track back to the receiving area. “We provided our<br />

Beumer BS7 Belt Tray Sorter for this sorting process,” explains<br />

Lückmann. This system manages a throughput of around 14,000<br />

without presorting, and up to 27,500 items per hour when using the<br />

described presorting process.<br />

Destinations ensure gentle sortation<br />

Power and data transmission on the Beumer BS7 is contactless.<br />

This prevents mechanical friction losses and wear and tear.<br />

Compared to conventional cross-belt sorters, this sorter has 50<br />

percent less components, which reduces maintenance costs by 80<br />

percent. Energy requirements are also reduced during production<br />

and operation. The distance between the individual conveying<br />

elements on the Beumer Group systems is reduced to a minimum.<br />

The use of belt trays makes it possible to have narrower, more<br />

closely arranged destinations. Therefore, the sorter requires less<br />

square footage. “The special feature of our BS7 are the 361 specially<br />

developed destinations, that ensure careful handling of the very<br />

different spare parts,” so Lückmann. Everything must be sorted and<br />

discharged while keeping the packaging intact. To this end the<br />

destinations are divided in two parts. If the spare part weighs up to<br />

1.4 kg, the WCS classifies it as “light”, up to six kilogram as “heavy”.<br />

This way the heavier parts are placed in the tote or cardboard<br />

box before the lighter parts when the order is picked.<br />

“The XL items from the main storage are handled differently,”<br />

explains Lückmann. “Their size means that only one spare part fits<br />

in one tote or box.” They are picked separately and conveyed<br />

directly to the consolidation area. The same happens with items<br />

from other buildings like tyres and hazardous material. Together<br />

with the items from the packing sorter, the orders are consolidated<br />

in totes and boxes and put together into shipping units. The units<br />

are then weighed, compared with the target weight, closed,<br />

labelled and then strapped. They are conveyed to the connected<br />

shipping sorter that distributes the consolidated orders to up to 50<br />

different dispatch destinations, at a capacity of 2,500 totes per<br />

hour.<br />

And what if the spare parts are not working or are no longer<br />

needed by the customer? “They go back to the logistics centre in<br />

Zakroczym,” explains Lückmann. Employees examine the<br />

returns: is the part damaged, was it just not needed or was it the<br />

wrong choice? If it is still in its original condition, it goes back to<br />

the warehouse. The material flow for all these processes<br />

throughout the entire distribution centre is controlled by the<br />

WCS, from inbound to outbound. The orders are sent from the<br />

operator’s warehouse management system.

02 The totes are placed on the roller conveyor and transported<br />

automatically to the packing sorter<br />

03 The Beumer BS7 Belt Tray Sorter manages a throughput of around<br />

14,000 without presorting, and up to 27,500 items per hour when using<br />

the described presorting process<br />

<strong>01</strong> Beumer Group installed the entire<br />

conveying, picking and sortation<br />

technology for car parts dealer Inter<br />

Cars S. A. at its new European<br />

Logistics Centre<br />

Residential service: Beumer Group takes<br />

responsibility<br />

Beumer Group continues supporting the project even after this<br />

point. ILS opted for the residential service, a special component of<br />

the Beumer’s comprehensive customer support, to focus more on<br />

the their own core business. “With this 24/7 service, the Beumer<br />

employees ensure availability of the machines and systems,” reports<br />

Jaroslaw Gorczynski, General Technical Director, Poland. “It must<br />

be perfectly coordinated during the entire operating time, so that all<br />

processes run smoothly.” The team has its own control room, and<br />

the workplaces were designed in a way so that potentially critical<br />

areas can be reached as quickly as possible.<br />

The Beumer Group employees also perform preventive maintenance<br />

work. Gorczynski explains: “This way, we can avoid<br />

unplanned machine breakdowns that can get very expensive for the<br />

customer.” The team carries out maintenance and inspection work<br />

on the systems at defined intervals. They also check the safety<br />

devices, electrical components and automation technology. And<br />

they can perform repairs that might be necessary in case of an<br />

unscheduled failure of components. The team checks the technical<br />

installations and maintains them regularly, at agreed intervals. The<br />

contract with Beumer Group runs over five years until 2022.<br />

Guaranteed system flexibility<br />

“Our systems and machines fully met the customer’s targets.<br />

The system offers high level of availability, high and precise<br />

throughput and can be easily adjusted to changing customer requirements.<br />

The same holds true for our modular WCS,” describes<br />

Lückmann. The owner is very happy with the cooperation: “We<br />

were able to accommodate all requirements. Delivery, installation<br />

and commissioning went all according to plan.” The companies are<br />

currently in talks about an extension of the system.<br />

Photographs: Beumer Group<br />

www.beumergroup.com<br />

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Please find media information here: www.vereinigte-fachverlage.info

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