WORLD OF INDUSTRIES 4/2019

04/2019
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EDITORIAL
World in
Transition
Confocal sensor systems
for displacement,
distance and thickness
Dear readers,
The fourth industrial revolution has long since ceased to be just a
slogan. It is already in full swing. It is changing our world and the
ways in which producers, suppliers and customers interact. It is
making digital e-Procurement platforms possible, linking production
facilities right through to complete logistics processes, and provides
data for new findings in research and development, e.g. for new
methods in artificial intelligence.
One of the countries that has developed into a digital pioneer is
China. Compared to other countries, there is no great difference as
far as the state-of-the-art is concerned. What is different, however, is
the attitude towards the subject of digitalization. Anyone who wants
to be among the leaders in Industry 4.0 has already been active in
China for many years. At the other end of the scale is Russia. But the
groundwork has been laid and the government is looking to support
the changeover to digital corporate processes. This is being supported
i. a. by the German Russian Initiative for Digitalization (GRID). Founder
members on the German side here are Siemens, SAP, Bosch and the
VW Group Rus. Russian members of this initiative are the Russian
employers’ association, RSPP, Rostelecom, Skolkowo and “Zyfra”.
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You can already experience part of the modernization of industry
and business even today: at the IAS – Industrial Automation Show
in Shanghai (17-21 September 2019) that will be presenting the
complex interaction of components, machines, software and IT,
and at the CeMAT Russia in Moscow, the International Exhibition
for Materials Handling, Warehousing Equipment and Logistics
(24-26 September 2019).
Let yourself be inspired by the global trends and technologies
of tomorrow.
Yours sincerely
Nicole Steinicke
Tel. +49 8542 1680
www.micro-epsilon.com/confocal

TABLE OF CONTENT
22
28
18
35
NEWS AND MARKETS
03 EDITORIAL
06 WORLDWIDE NEWS
08 MODEST GROWTH OUTLOOK FOR
RUSSIA, BUT OPPORTUNITIES TO GAIN
MARKET SHARE IN VARIOUS
UNORGANIZED INDUSTRY SECTORS
10 IS CHINA LOOSING STEAM OR IS IT
GEARING UP FOR THE NEXT ROUND
OF DOUBLE DIGIT GROWTH?
12 CEMAT RUSSIA: FUELLING GROWTH
IN RUSSIA’S LOGISTICS AND
TRANSPORT SECTOR
14 EXPERIENCE THE CHANGING
DYNAMICS OF CHINA’S INDUSTRIES
AT IAS SHANGHAI
LOGISTICS
18 AT THE RIGHT PLACE AT
THE RIGHT TIME
MOTION AND DRIVES
20 GEARED MOTORS: TEST AREA
EXAMINES DRIVE UNITS
THOROUGHLY
22 COOL SOLUTION TO A HOT ISSUE
AUTOMATION
24 CHALLENGES FOR CABLE
MANUFACTURERS IN THE
FACTORY OF THE FUTURE
4 WORLD OF INDUSTRIES 4/2019

10
AUTOMATION
27 BARLEY MALT PRODUCER
INCREASES PRODUCTIVITY
WITH SMART CONDITION
MONITORING
28 THE DNA OF THE INDUSTRIAL
INTERNET OF THINGS
30 A BRIDGE BETWEEN TWO WORLDS
32 A TASTE OF THE FUTURE OF INDUSTRY
34 PRODUCT NEWS
10 TH ANNIVERSARY
35 DIGITAL FUTURE MUST BE
ACTIVELY SHAPED
DER ANTRIEB
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nord.com

NEWS AND MARKETS
W RLDWIDE NEWS
SSI Schaefer is investing in the future
In Giebelstadt, at the SSI Schaefer competence center for automated logistics solutions, the groundbreaking
ceremony for a 5-story office building took place in September of last year. The building will
provide space for 400 workplaces on almost 7,000 square meters in 2020. At the Friesach location in
Austria, heart of the proprietary Wamas logistics software, an additional office complex is being built
that reflects the company’s strength in IT. After its grand opening, which is scheduled for November
2019, about 170 employees will be moving into the 1,000 square meter IT powerhouse.
www.ssi-schaefer.com
Pepperl+Fuchs to become an SE
Pepperl+Fuchs GmbH has decided to undertake an incremental conversion
into a European Company (Societas Europaea) by 2020 to ensure its growth
strategy in the long term, and to be able to face future challenges on a global
scale with flexibility and agility—in particular the challenges of Industry 4.0.
“The legal regulations associated with an SE will facilitate trade and possible
expansion activities in the EU area,” says Werner Guthier, CFO of the
Pepperl+Fuchs Group (foto). “At the same time, the SE legal form also offers us
new options on the capital markets in contrast to the GmbH legal form.
Overall, we consider this to be an important step toward
ensuring sustainable success for the Group in the future.”
www.pepperl-fuchs.com
Stemmer Imaging continues its
international expansion strategy
Stemmer Imaging confirms it
has successfully concluded
the acquisition of the
Spanish group Infaimon
S.L. today and is
acquiring 100 % of the
shares in the supplier of
software and hardware
for machine vision and
robotics after approval of the
transaction by all the relevant
antitrust authorities. The machine vision specialist is
now represented in all key European markets with
local branch offices. With the acquisition, Stemmer
Imaging is also underscoring the strategic importance
of state-of-the-art bin-picking solutions, an
important capability in the context of Industry 4.0
applications which will further stengthen the
company’s product and service portfolio.
www.stemmer-imaging.com
6 WORLD OF INDUSTRIES 4/2019

Rittal, Atos and Siemens form a global
strategic partnership
Logistics area
doubled
Paul Vahle has opened one of
the most modern material flow
systems of its kind in Kamen.
The system provider for mobile
industrial applications supplies
the connected production
facility with individual components
from this site. Effective
immediately, order picking
takes place automatically with
the latest warehousing
equipment made by Jungheinrich.
The heart of the new
system is an automated
miniload warehouse with 7,314
storage locations. Boxes
measuring 600 × 400 and 300 ×
Rittal announced a new global strategic partnership with Atos
and Siemens to develop intelligent edge datacenter solutions
for smart industries, smart cities, smart retail, energy &
utilities, and public sectors. The new ‘Intelligent Edge Data
Center’ (IEDC) is a highly configurable datacenter solution
that enables companies to process IoT data in real-time using
solutions such as MindSphere, the cloud-based, open IoT
operating system from Siemens, the new BullSequana Edge computing
server and the BullSequana S server from Atos, Atos Codex Cloud Industrial
Supervision (CIS) and thus optimize their entire value chain with an
advanced data-, analytics solution.
www.rittal.com
400 millimeters are stored
double-deep or quadrupledeep
and crosswise. These are
serviced by what Jungheinrich
views as the most powerful
stacker crane of its class, which
moves at a speed of six meters
per second. A wide-aisle
warehouse, cantilever racks for
the storage of long goods and
drive-through racking were also
built. The logistics area nearly
doubled through the modernization,
to around 3,500 square
meters. With the Go Live of the
miniload warehouse, Vahle is
the first company in the world
to utilise the Miniload STC
which was introduced by
Jungheinrich in 2018. It has
energy storage devices called
SuperCaps which are specially
adaptedto the stacker crane’s
driving characteristics.
We facilitate reliable deliveries and highly flexible technical handling thanks to our
intermodal network – from production to the end customer.
See more good reasons for BLG LOGISTICS at
www.blg-logistics.com/5reasons
www.jungheinrich.com
www.vahle.com
BLG.indd 1 12.08.2019 13:12:59
WORLD OF OF INDUSTRIES 4/2019 7

Modest growth outlook for Russia,
but opportunities to gain market share
in various unorganized industry sectors
Year on year, Russian economy is getting robust, as
they find out ways to tackle external issues like
sanctions, drop in oil prices or currency crisis. As the
economy prepares itself with significant fiscal buffers,
the internal demand, consumption and exports
increases, thus boosting the demand for services like
transportation, warehousing, and complete logistics
solutions.
Russia’s real GDP growth in 2018, reached nearly 2.5 %, surpassing
the general expectations, mostly due to the one-off effects of
energy sector. Growth forecasts for 2019-21 is between 1.2-1.8 %,
this reflects a more modest outlook in line with Russia’s current potential
growth of about 1.5 %. In the first quarter of 2019, GDP growth
slowed for several reasons, mainly due to Russia agreeing on cutting
down oil production along with other OPEC members, a tighter
monetary policy and an increase in VAT rate from 18 % to 20 %.
Instead of annual growth rates, let’s take a look at Russia’s potential
growth rate, as this depicts a more accurate picture about the
economy. In the last 10 years, potential growth all over the world
has slowed, so Russia experiencing this slow down is nothing out of
the normal. In the last 5 years, potential growth was below its longer-term
average in most of advanced as well as emerging economies.
However, the slowdown had a more serious impact in Russia,
as it highlighted a weak productivity related growth and worsening
demographics. Based on data from world bank, Russia’s potential
growth is set to gradually decline from 1.5 % in 2017 to 1.3 % by
2024. Russia seems to have undertaken certain reforms in-order to
reverse this declining trend. Reforms that are focused on bringing
more inward migration, higher investment, and increasing productivity,
increasing in retirement age etc. If Russia succeeds in executing
these reforms then it could bring about an increase of 1.5 % in
potential growth within the next 10 years. Of all the factors men-
Author: Sushen Doshi, International
Correspondent for World of Industries
NEWS AND MARKETS

tioned above, increase in productivity is the key driving factor, which has maximum impact
on Russia’s potential growth. In order to increase productivity in such short span,
Russia needs to heavily invest on innovation, skills and competition.
Downside and Upside
Downside risks to Russia’s medium-term growth outlook arise from the risk of deepening
of economic sanctions, financial crisis in emerging markets, a deteriorating global trade
environment due to trade war between US and China, and a dramatic drop in oil prices.
Russia also suffers due to its limited portfolio of exports. For more than 30 years, oil, natural
gas and energy products have been Russia’s largest exports. Through continued efforts
from the government since 2014, growth in non-energy export volumes has been outpacing
that of energy and contributing to export diversification. But despite this, Russia’s
export portfolio is shallow, with the share of oil/gas products still totaling close to 60 %.
In the last few years, Russia has prepared itself quite well for reducing the impact of
external shocks and volatility of the commodity prices on it’s economy. Another area
where Russian macro-economic strengths lie is the low public and external debts, no
fiscal deficits, in-fact significant fiscal surpluses. On the upside, government has
launched multiple national projects aimed at strengthening human capital and increasing
productivity, if well-implemented, could positively affect Russia’s potential growth
in the medium-term. Also, changes in labor legislation, with focus more on formalization
of workforce is a strong step as it could benefit the economy by 2.5 % of the GDP. The
share of informal labor is quite high in Russia, it is estimated to range between 15-20 %.
Russia continued its efforts to improve the business and regulatory environment for
SME sector by carrying out reforms in the areas such as getting faster permits for construction,
electricity connections, paying taxes became less costly by allowing a higher
tax depreciation rate for immovable assets, and cross border trading was improved with
less bureaucracy and online customs clearance facility. As a result of this, Russia advanced
to 31st place in the global ease of doing business ranking, representing an improvement
from the 35th place last year and ranked 120th seven years ago.
Russia’ logistics sector overview
After struggling for years, growth and optimism has finally returned to the nation’s
transport and logistics sector. From 2018 the industry saw a return to the high levels of
freight entering and exiting Russia. Russia is stepping up both its exports and imports it
receives from non-sanctioned trade partners. China, which is Russia’s second largest
trading partner after the European Union, is keen to bump up Russia bound exports,
and Russia is ready to reciprocate. And this brings with it enhanced opportunities for
foreign companies, not just in terms of pure investment, but also as a market to sell
transport services and technologies.
With the rise of e-commerce industry, the market for 3pl service is expected to witness
significant growth. As competition amongst manufacturers increases, they aim to focus
more of their resources on their core competencies and outsource the logistics part of
the operation to professional third party service providers. This is set to escalate the demand
for 3pl service. Moreover, the 3pl services have a larger role to play as gains in
productivity, reliability, and significant reductions in cost can be derived.
Let’s take a look at the market situation of logistics service providers in the country.
Revenues generated by the sector reached around $ 17 billion in 2015 and $ 19 billion in
2017. Russia’s third party market is by far the largest in the CIS region, which is collectively
valued more than $ 25 billion. Outsourcing of transportation services takes roughly
of a fifth of market share in Russia. Comparatively, 3pl service providers cover more
than two thirds of the European and almost half of China’s market. There are roughly
4000-6000 logistics companies in Russia. Out of these, only 100 can really be considered
true third party logistics service providers. Some of the big names include Eurosib, Nienshants
Logistics, STS Logistics and a subsidiary of Russia’s railway, RZD Logistics. The
unsaturated nature of the market means international firms are well positioned to progress
in Russia. Firstly due to the fact that 3pl as an industry is a fairly new phenomenon
in post-Soviet Russia, many Russian companies handle transportation in-house. Most
of domestic firms also struggle to meet international service standards, this gives foreign
firms a competitive edge. The fact that the Russian outsourced transport sector is relatively
unorganized creates space for international companies to expand. So, third party
logistics sector in Russia is currently underdeveloped, ready to expand and fertile
ground for international companies to grow their Russian operations.
Photographs: Lead Photo Fotolia
WORLD OF OF INDUSTRIES 4/2019 9
Turkish Machinery.indd 1 14.08.2019 11:01:35

Author: Sushen Doshi,
International Correspondent,
World of Industries
Is China loosing steam or is it gearing up
for the next round of double digit growth?
NEWS AND MARKETS
The “Made in China 2025” plan, technology
upgradation, slowing down of GDP, trade war with
the U.S, Belt and road initiative; China has a lot on its
plate, and all this has immense implications on the
global economy. China’s growth in the coming years
will be much different than that of the of 90s. Xi’s
China is strategically prepared, smart and ready to
compete on any technological front.
In the recent years, economists and experts have been buzzing
about the slowdown of China’s economy. Official statistics placed
real GDP growth at 6.6 % in 2018, the lowest rate since 1990. Various
economic indicators, which track the performance of the economy
by taking into consideration parameters ranging from industrial activity,
purchasing indices, employment figures, sales numbers and
investments in various sectors, all are a proof of dipping trend line in
China’s GDP numbers. Yet, despite the doom and gloom China continues
to rack up one of the most enviable growth rates in the world,
adding more than a trillion dollars each year. The economy is expected
to continue its softening in 2020 as well, with GDP growth forecasted
to be somewhere between 6.0 and 6.2 %. Many companies will
be facing the challenge of quickly adapting or changing their strategies
to slower growth, as it will become extremely harder for corporations
that require higher growth to thrive, or even survive. Survival
will also be difficult for companies that took the growth rates for
granted, and in turn created unsustainable amounts of debts.
Consumption story now, and planning for the future
A series of news reports of multinational as well as domestic companies
reporting drastic drop in sales have created a wave of concern
over the potential of China’s consumption power. But despite
these concerns China still continues to be the best consumer market.
Over the next decade as the per capita income of average Chinese
individuals rise, China’s market will add more than $ 5 trillion,
that’s way more than any other country. Beneath the slowdown lie
changes in the patterns of consumption. Also sharper drops in sales
of individual companies, or even of sales in categories like autos or
cosmetics, does not tell the whole story.
A lot of recent news reports have led many to believe that the
trade spat between the US and China is leading to the current economic
slowdown; this narrative is also convenient for the politicians.
But the truth is China’s slowdown has been consistent since
2015. In 2013, Chinese President Xi Jingping announced the long
term economic reform to shift from a investment driven economy
to consumer driven one. If you understand this blueprint for economic
reform, all the warnings about China’s slowdown or collapse
will be less alarming. China’s reform will shift the economy from
one based on government spending, state-run companies, and
low-cost exports. It moves it toward private investment, entrepreneurial
innovation, and domestic consumption. In order to achieve
this, China has decided to reduce overcapacity in factories, mostly
in steel, cement and other state-owned manufacturing companies.
These companies have been the pillars of its economic growth. But
now many are bloated, ineffective, and unprofitable. The reforms
were aimed to modernize them in order to attract private investors,
but they ended up creating an oversupply of commodities, which
caused the prices to plummet and consequently sabotaged the
privatization efforts. Now China has decided to allow the market to
absorb the stockpile, as a result, China is willing to accept a slower
rate of growth of around 6.5 %. The government will also loosen
price controls on water, electricity and natural resources. So that
these industries can consolidate, grow and become profitable. In
return, they will pay 30 % of earnings as dividends to the government.
Proceeds will be used to fund social security programs by
2020. Which will allow the Chinese people to save less, spend more,
and boost consumption and demand.
Always in focus “Made in China 2025”
Launched in 2015, the “Made in China 2025” strategy aims to modernize
and digitize country’s industrial set up with innovative technologies.
With this strategy China seeks to create innovation-driven development,
smart technologies, pursue green development and increase efforts
to upgrade China from a manufacturer of quantity to one also of
quality. The strategy focuses of 10 key industry sectors: Next-generation
10 WORLD OF INDUSTRIES 4/2019

IT, including cyber-security; High-end numerical control tools and robotics,
which are of high importance for China as they help in improving
the manufacturing efficiency as labor costs rise; Aerospace and
aviation equipment, which reflects China’s ambition to be a world leader
in aviation and outer space exploration; hi-tech marine engineering
equipment, as shipping plays a vital role in China’s export driven economy
and also maritime security implications of China’s territorial
claims in South and the East China Sea; Advanced railway equipment,
as China is rapidly connecting regions not only within its territories but
also in the Central Asia; Electric vehicles technology, which highlights
China’s goal to replace traditional fuel vehicles; New generation electrical
power equipment, which are part of China’s implementation of
clean and green power; Agricultural machinery; New materials like
graphene and nano materials; Biomedicine and high-performance
medical devices, which includes China’s development of advanced
chemicals and medical equipment. The Chinese government has so far
invested vast resources, including subsidies and low interest loans to
support domestic hi-tech enterprises and encourage more Chinese
firms to expand overseas and acquire foreign firms with cutting-edge
technologies. The government has also established 5 national manufacturing
innovation centers and 48 provincial manufacturing innovation
centers. By 2025, the number of national manufacturing innovation
centers is set to reach 40. Initial results in some of the sectors have
been positive. Huge advances have been made in large aircraft and engine
manufacturing, semiconductor technologies, new material, and
gas turbine, 5G mobile network equipment and electric vehicles.
Trigger point
One of the factors in the Made in China 2025 policy that has irked
the western industrialized countries is China’s goal to reduce imports
of high-end technologies from the EU and the U.S and replace
it with home grown ones. This initiative has not gone down well
with leaders in the west, as they fear that Beijing’s state-subsidized
industries would get an unfair advantage over foreign firms and
could lead to market distortions. This issue has become one of reasons
for escalation of the trade and tariff war between the US and
China. US President Donald Trump has imposed tariffs on goods
worth $ 300 billion that are imported from the mainland. Tariffs will
especially be levied on products in the 10 key areas identified in the
“Made in China 2025” initiative. Despite advances it has made in
hi-tech industries, China still depends on foreign technology transfer
to push forward its own innovation agenda and next-generation
manufacturing goals. These US tariff measures are hurting the implementation
of China’s 2025 goals, production of industrial robots
in mainland has seen a drop, production of integrated circuits, the
semiconductors that power smartphones, computers and other
electronic devices, as well as high-end industrial and military products,
also fell. Meanwhile, growth in the new-energy car sector,
which has been heavily subsidized by the government, slowed
down from more than 20 to 15 %. Except a few specific industry sectors,
the effect of trade war on the overall Chinese economy has
been more indirect, as it impacts the consumer confidence and
causes private sector companies to rethink before making any decisions
on investing in adding manufacturing capacity in China.
Some manufacturers are considering to shift their production bases
at locations that less politically sensitive. For example, some robotics
makers, have been considering Vietnam and India as a stable
option, hence they have already reduced the capital investment in
China.
Photographs: Lead Photo Fotolia
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WORLD OF OF INDUSTRIES 4/2019 11

CeMAT Russia: fuelling growth in
Russia’s logistics and transport sector
NEWS AND MARKETS
Russia’s transport and logistics sector is fertile ground
for foreign companies. Opportunities are plentiful
across the length and breadth of the country. Investors
and companies should certainly look to the world’s
biggest nation as their next market for investment or
expansion.
Stretching across 17 million sq. kilometers, Russia is world’s largest
country by size. It’s so huge that it’s geography is both a blessing
and curse. It’s very size demands an extensive transport and logistics
network. In order to cater to its 145 million inhabitants with
all the goods and services, air, sea, road and rail logistics are in high
demand. With over 86,000 kilometers in rail track, a road network
over 1.4 million kilometers, plus numerous airports and seaports,
Russia has a well-established intermodal network hub.
Despite existing transport links, Russia ranks 85 out of 167 countries
in the world bank’s logistics performance index. One of the
reasons for this lackluster performance has been the bleeding of
Russian economy mainly due to sanctions imposed by western
countries and declining oil prices. But since 2016, Russian economy
has been recovering at a steady pace so has been the transport and
logistics sector. Country’s current logistics performance, however,
Author: Sushen Doshi, International Correspondent for World of Industries
points towards major opportunities for investment, as Russia is in
need of modern technologies and scientific attitude when it comes
to logistics. Domestic suppliers are competing with international
companies to provide comprehensive services, but increasing participation
from international companies will truly help this sector
overcome its challenges.
Considering the infrastructure and logistics competence there is
room for Russia to improve and expand. The Russian transport and
logistics market potential is estimated to be around $ 150 billion.
Warehouses equipped with new technologies, modernized cargo
handling facilities at ports, new airports, railway hubs and logistics
centers are needed to satisfy the country’s rising demand. Foreign
firms are positioned better than domestic ones to play a major role
in development of Russia’s logistics sector. Due to a lack of competitiveness
in domestic operators, foreign logistics businesses
have already been invited for investment – often in the form of tieups,
joint ventures or operational co-operation. Overseas investors
and companies with interest, experience and skills are injecting
large amounts into transport and logistics sector. For example,
Dubai’s DP World, global port infrastructure and management specialists,
inked a deal with the Russia Direct Investment Fund. The
$ 2 billion investment is mainly targeted at enhancing Russia’s port
infrastructure networks. Other foreign firms, such as DHL or Finnish
company Itella Russia, are already well established in the market.
Technological advantages, plus efficient operations and experience,
puts international brands at a significant advantage. Russian
government has welcomed these dynamic, cost-effective transport
and logistics solutions, so international operators should look at the
bigger opportunities present in Russia.
12 WORLD OF INDUSTRIES 4/2019

01 At Cemat, visitors can find latest products and technologies,
exchange ideas and get clarity in-order to make sound decisions
Moscow’s prestigious Crocus Expo hosts the 10th edition of CeMAT
Russia - the international exhibition for materials handling, warehousing
equipment and logistic. This 3 day event is set be held from
24th to 26th September 2019, and is an ideal platform to interact
and engage with leading companies from Russia’s logistics sector.
CeMAT Russia provides a exceptional prospect to create new potential
customers as industry professionals and managers from
small and medium-sized enterprises to large corporations attend
this event. CeMAT also assists in cultivating new relationships, creating
new networks and catching up existing customers to gain insight
and stay updated with the latest developments and requirements
of end users. Interest in the event among Russian
organizations has been steadily increasing with number of visitors
increasing from 4,500 to 5,500 within two years. A large chunk of
visitors were from the retail and wholesale segment, followed by
cargo transportation and warehousing services, warehousing
equipment, industrial goods production, consumer goods production
including food, beverages, pharmaceuticals etc. Taking a look
at the numbers of past years, most of the visitors placed their interest
in lifting and handling equipment, rack and storage systems,
warehouse management and automation equipment, packaging
and order picking equipment, conveyors, lifting and handling
equipment etc.
The event, organized by one of the world leaders in exhibition industry
– Germany’s Deutsche Messe RUS, is supported by various
industry associations and the state as well as federal government of
Russia. Deutsche Messe’s extensive market and industry knowledge
along with international experience makes this business event
of a truly global standard. Every year at the fairgrounds, organizers
host a series interactive sessions which involves exchange of ideas,
in depth discussions on important issues faced by the industry and
understanding the upcoming trends in the market. Just like the
manufacturing industry, the future of transportation and logistics
also has new driving forces like digitalization, tectonic shifts in international
trade, emergence of software driven and machine driven
processes etc. Many decision makers and managers are concerned
about how exactly will these changes affect them, what will
be level of investment and which products and systems to choose
for their operations, queries about integration of new systems with
existing ones, all these questions will be answered on the floor of
CeMAT, by interacting with experts, professionals, and manufacturers
in Moscow. In 2017 and 2018, the forum discussions included
topics like digital transformation of logistics; hardware or software?,
rise of big data, drones, IoT, cloud technologies, AI, AR in logistics
and intralogistics, developing successful strategies in the e-commerce
era, warehouses of the future: design or reconstruction? etc.
Product categories at CeMAT Russia
CeMAT Russia 2019
At CeMAT Russia, you can find the products with emphasis on functionality
and innovative technologies in the movement and lifting
of goods area, products that offer the right combination of cost-effectiveness,
maximum usability and smooth movement and handling
of materials. 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.
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 packages. 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 Ce-
MAT Russia features e-logistics services, intralogistics systems &
software, computer & control systems, control technology & sensors,
identification technology, Auto ID/RFID etc. In 2017, Russian
e-commerce sector was valued at $ 16 billion and is set reach $ 25
billion in the coming few years. E-commerce in Russia is only set to
keep expanding. 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, Deutsche Messe AG
www.cemat-russia.ru/en
WORLD OF OF INDUSTRIES 4/2019 13

Experience the changing dynamics
of China’s industries at IAS Shanghai
Shanghai has been the engine of China’s growth over
the last two decades. The city has grown from a mere
fishing village to a hub of manufacturing, innovation,
finance and culture. Given the magnitude of
manufacturing activity in and around the city, it is an
obvious choice for a top quality industrial exhibition
of the international standards like the IAS Shanghai.
Every year in September, Shanghai witnesses a large number of
visitors coming in from Japan, South Korea, Germany, Italy,
America, Switzerland, France, Austria, Britain, Israel, Singapore
and India. What is so special about Shanghai in September?
Month of September marks the beginning of autumn and end of
summer, so the temperature still lingers on the higher side, but as
days pass it starts to get cooler and cooler. Apart from changing
weather, September plays host to multiple industrial trade fairs of
international caliber. A wide range of trade fair venues, conference
facilities along with its well-established transport system
NEWS AND MARKETS
Author: Sushen Doshi,
International correspondent
for World of Industries
14 WORLD OF INDUSTRIES 4/2019

make Shanghai a great business destination. Industrial Automation
Show (IAS) Shanghai, is one such blockbuster event which
the industrial community can’t miss out on. One of the world
leaders in industrial goods trade fairs, Deutsche Messe AG, along
with Hannover Milano Fairs Shanghai Ltd., organizes the Industrial
Automation Show (IAS) Shanghai every September. This year
the show is to be held from 17 th - 21 st September. The prestigious
fair grounds of National Exhibition and Convention Center in
Shanghai offer a display area of more than 70,000 m 2 for over 600
exhibitor companies. This five-day show brings in close to 200,000
trade visitors from home and abroad. Over the years, the popularity
of IAS has seen a sharp rise not only in China but also around
Asia. In 2018, more than 60 % of the exhibitors were from outside
China, these figures represent the dominant market position this
event holds amongst all of Asia’s industrial automation trade fairs.
Along with IAS, the venue also co-hosts the Metalworking and
CNC Machine Tool Show (MWCS) and the Energy show. MWCS
is a leading international trade fair for the entire metal working
sector in southeast China, focusing mainly on machine tools,
sheet metal, pipes and tubes, mould and die construction etc. The
energy show is an international exhibition on electrical power
generation and distribution technologies.
The exhibitors list at the Industrial Automation Show has a strong
representation from the reputed German companies and global
market leaders like Siemens, Bosch, Pheonix Contact, Mitsubishi
Electric, Omron, Delta, Turck, Festo, Beckhoff, National Instruments,
B&R, Lenze, Ritttal, Balluff, Wago, Pepperl+Fuchs, IFM, Sick,
Harting, Baumer, Pilz, Hiwin, Nord and many more. Many of these
organizations use this platform to make product launches and
showcase their cutting-edge technologies. Innovation driven companies
take this opportunities to display their capabilities in the
field of industry 4.0 and smart manufacturing.
WORLD OF OF INDUSTRIES 4/2019 15

Product Category at IAS Shanghai
NEWS AND MARKETS
The display areas at the trade fair is divided into respective sectors
like production and process automation, electrical systems, robotics,
industrial IT & software. The production and process automation
area consists of exhibitors showcasing a vast array of products
and systems ranging from PLC, scada, industrial PCs, control systems,
embedded systems, assembly & handling technology, linear
positioning 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 equipments
etc. The electrical systems category consists of electrical power
transmission systems including 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, apart
from electrical power generation companies also exhibit mechanical
power and drive transmission systems as well. As China undergoes
industrial transformation, more and more organizations are
focusing on integration of IT and software systems. Choosing the
right industrial IT and software systems for your industrial sector
can be quite a complicated task. Before finalizing any of the products
decision makers need to understand all the functionalities and
also anticipate any possible problems that can arise with integration
of new systems with the existing ones. Thus visiting the industrial
automation IT and software segment of IAS Shanghai proves to
be of immense importance for the decision makers and interested
buyers, as it helps in understanding the utility and also complexity
of the systems they are interested in. With detailed on-site discussions,
buyers can also assess the technical competency and after
sales support of various manufacturers and service providers all
under one roof, thus making it easier for them to finalize the right
product that suits the needs and requirement of their respective
manufacturing processes. The IAS Shanghai has on display products
like production and manufacturing software, systems and development
tools for industry, internet, intranet and extranet solutions,
industrial IT hardware. Visitors can also meet professionals
and consultancies that play host to comprehensive IT services to
maximize the benefits of software products.
China’s special bond with industrial robotics
In the last five years, China has become a dominant player in the
field of robotics. According to the data from International federation
of Robotics (IFR), In 2008, China’s stock of operational industrial
robots was around 32,000, by 2016, this number had reached
near 340,000, and in fact it is expected to witness a 15-20 % rise till
2020. The main drivers of the growth are the automobile, electrical
and electronics industry. Major contract manufacturers of electronic
devices have already started to automate production. The semiconductor
and the chip industries, for example, have strongly invested
in automation. Large battery production facilities are being
installed to meet the increasing demand for electric and hybrid
cars. Automotive industry is one of the most a powerful drivers for
industrial robot sales. China has become both the world’s largest
car market and the world’s largest producer of cars – including electric
cars – with much growth potential. Sales to China made up 25 %
of the global supply of industrial robots to the automotive industry
in 2016. Between 2011 and 2016, more than 100,000 units were installed,
representing an average increase of 18 % per year. China is
the largest growing consumer market with increasing demands for
all kinds of consumer goods. Consequently, various other industries
have also started to expand capacities and automate production.
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, human-machine
interaction techniques, robot vision and intelligent speech,
robot simulation system, service robots, machinery, appliances &
components for robotic products.
One important reason why IAS Shanghai is one of the favorite
events amongst automation professionals is the business culture of
the host city. Shanghai has been the epicenter of technology startups
in the last few years. The pace of growth of tech start-ups has
been frightening. Unlike any other cosmopolitan city, Shanghai’s
ability to rapidly reach mass scale is unparalleled. The city boasts an
unending supply of highly skilled human resources with immense
technological capabilities, increasing levels of foreign investment,
large supplier base and ever improving research and development
activities. Shanghai is also a major tourist destination, as it attracts
a wide range of tourists due to its vibrant culture, nature, and modern
infrastructure.
Photographs: Lead Photo Fotolia, other Carmen Nawrath, Nicole Steinicke
www.industrial-automation-show.com/EN
16 WORLD OF INDUSTRIES 4/2019

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At the right place
at the right time
LOGISTICS
The system integrator Beumer Group installed its
flexible and modular warehouse control system (WCS)
at the new European Logistics Centre (ELC) of the
Polish automotive parts supplier Inter Cars S. A. near
Warsaw. This system controls the complete material
flow from inbound to outbound in real time: picking,
packaging and shipment are coordinated, throughput
is optimized and costs are reduced. The products reach
the right place in the desired time within the
distribution center.
Inter Cars is a leading distributor of spare parts for cars, vans and
trucks in Central and Eastern Europe. The company, headquartered
in Poland, has several hundred subsidiaries and branches
spread all across the Baltic states and the Balkans. In addition, there
is a nationwide network of approximately a thousand workshops.
Until the end of 2016, the logistics center was located in Czosnów.
From here, the goods were distributed to the smaller distribution
centers in Europe, which on their side supplied the workshops and
the customers. However, the quantity of spare parts to be stored and
dispatched exceeded the capacities of the logistics center. The managers
decided on a new automated European Logistics Centre in
Zakroczym, approx. 30 km from Warsaw. The in-house logistics
provider ILS was commissioned as general contractor − “and this is
how we got involved as system supplier of intralogistics solutions”,
says Sandra Lückmann. Sandra Lückmann is business development
manager at Beumer Group in Beckum, Germany, and was
responsible for the successful handling of this order. “As a system
integrator, we not only designed and installed the entire conveyor,
picking and sorting technology, but also our flexible WCS.” It integrates
and controls the material flows including inbound, quality
assurance, picking and shipping.
Adaptable WCS
In May 2017, the ELC went into operation. There, the Beumer WCS
serves as link between the warehouse management system (WMS)
of the owner and the entire material flow equipment. “While developing
this software solution we did not focus on adapting the processes
of the customer to our WCS, but we adapted our system
project-related to the respective customer requirements”, explains
Lückmann. Therefore it has a modular design. It controls the packing
sorter and the shipping sorter as well as the pick-to-light system
in the inbound area, coordinates the automatic supply and application
of the shipping labels and supports the routing of the individual
items on the conveyor lines. “This route planning optimizes the
performance of the system and controls the distribution of the different
types of spare parts, depending on the requirements”, says
Lückmann. “The WCS ensures the optimal route of the goods.”
The new European Logistics Centre currently stores around 7
million pieces like spark plugs, brake disks, V-belts, batteries, but
also more bulky parts, like exhausts and hoods. The complex is
comprised of four buildings, the largest one with 30,000 square meters,
ten meters in height. It is equipped with a four-story shelving
rack. The other warehouses have a surface of 5,000 square meters
each. They store tyres and hazardous material, such as oils and varnishes,
that must be kept separate for reasons of fire safety.
The employees use their hand-held scanner, where the company’s
warehouse management system indicates which goods have to
be commissioned in batches. The products are divided into different
clusters, similar to clothing sizes into S, M, XL and XXL, depending
on dimension and weight. The totes filled with S and M
parts are placed on a roller conveyor which forwards them automatically
to the packing sorter, the Beumer BS7 Belt Tray Sorter.
18 WORLD OF INDUSTRIES 4/2019

There are currently stores around 7 million of pieces in Zakroczym like
spark plugs, brake disks, V-belts, batteries, but also exhausts and hoods
interface to the machine control”, describes Lückmann. “BG Fusion
combines machine and system data, enabling the responsible employee
to trace the order status in real time.”
Task fulfilled, project successfully completed
“This system achieves a throughput of approximately 14,000 parts
per hour”, says Lückmann. “However, with presorting, it manages a
throughput of approx. 27,500, almost twice as much.” Depending
on the content, the WCS also distributes the incoming totes to one
of three induction areas where the employees take the items out of
the tote, identify them using matrix camera and place them on the
sorter.
“The WCS plays a crucial role in this project. After all, exactly this
solution ensures that all spare parts within the European Logistics
Centre are in the right place at the right time”, Lückmann explains.
Beumer Group has completely fulfilled the targets requested by the
customer. In addition, to be able to concentrate fully on its core
business, ILS has also transferred the maintenance and servicing of
the system to Beumer Group. Employees of Beumer Group are on
site around the clock. As part of the residential service they take
over responsibility for availability of machines and systems. The
Beumer Group employees also perform preventive maintenance
work. The team carries out maintenance and inspection work on
the systems at defined intervals, checks the safety devices, electrical
and control components as well as automation technology. And
they can perform repairs that might be necessary in case of an unscheduled
failure of components.
Photographs: Beumer Group
www.beumergroup.com
WCS distinguishes between “light” and “heavy”
In order to ensure a gentle handling of the goods and prevent packaging
from getting damaged, the engineers of Beumer Group have
divided the destinations of the packing sorter in two parts. If the
spare part weighs up to 1.4 kilogram, the WCS classifies it as “light”,
up to six kilogram as “heavy”. According to this classification, the
software assigns the goods to the left or to the right side of the destination
when picking the order, enabling the employee to place the
heavy goods in the tote or the cardboard box first, then the light
ones.
The XL goods from the main storage however are so large that
only one item fits in one totes. Therefore the WCS does not forward
them to the packing sorter but directly to the consolidation area via
the roller conveyors. Together with the goods from the other buildings,
such as tyres and hazardous materials, as well as the products
coming from the packing sorter, the orders are combined into shipping
units. These are weighed in the Quality Assurance and compared
with the target weight, closed, labelled and then strapped.
Now, the WCS guides them over the roller conveyors to the connected
shipping sorter that distributes the consolidated orders
according to delivery routes at a capacity of 2,500 totes per hour.
If spare parts are returned, they are checked by the employees. If
the spare parts are ok, the employee enters them in the system and
sends them back to the warehouse.
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.
Clear overview of all processes
Fortschritt hat unser Tempo
Besides the modules which control the material flow, Beumer’s
own BG Fusion tool is also in use. This visual display system offers
the user a web-enabled user interface for configuration, control
and reporting. It displays system data as alarms in a uniform and
centralized way and shows status messages, fault messages and all
relevant data. “The entire system status can be supervised via the
Unsere modularen Elektro-Kleinmotoren und Getriebe ASTRO bauen Motoren wir GmbH in Millionen & Co. KG
Debstedt · Große Beek 7 · 27607 Geestland
Kombinationen – passgenau zu den AnforderungenTel.: jedes (0)47 43 Kunden.
/ 27 69 · astro@astro-motoren.de
2017
Debstedt · Große Beek 7 · D-27607 Geestland · Germany
Tel.: +49 (0) 4743 27690 · astro@astro-motoren.de
www.astro-motoren.de
WORLD OF OF INDUSTRIES 4/2019 19
ASTRO.indd 1 25.03.2019 13:05:23

Geared motors: Test area
examines drive units thoroughly
Conveyors in large intralogistics
applications or baggage handling
systems often have lengths of several
kilometres. Such complex systems are
powered by hundreds of geared motors. Experts
from Nord Drivesystems gather precise knowledge
about the behaviour and control of drive technology
in an application test area in Bargteheide, Germany.
There, new products and technologies are also tested.
MOTION AND DRIVES
How do geared motors behave in practice? What conclusions
about the service life and maintenance of a drive unit can be
drawn from the operating data of a frequency inverter? Where does
further optimisation need to be made to a new drive concept? To
provide customers with optimally tailored products and innovative
service concepts Nord Drivesystems seeks the answers to these
questions in its own test area. The test system consists of an oval
conveyor belt with rising and falling sections, as well as a bypass
section with input and discharge points from the main route. The
individual conveyor belts are driven by various types of Nord geared
motors and frequency inverters. The fifteen drive units are networked
with standard interfaces and can be monitored through the
web. The frequency inverters and motor starters are controlled via a
Profinet bus, but the Nord Drivesystems drive technology can also
handle all other common bus systems.
Industry 4.0: Drive data in the cloud
As with all Nord drive units, the drive units in the application test
area are fully Industry 4.0 ready. They regularly transmit their status
data such as current consumption, speed and voltage via the bus
cable using the UDP communication protocol, without affecting
the control communication. To keep the data volume as low as
possible only the values which have changed since the last transmission
are sent. The status data are transmitted via an Internet
gateway to a secure cloud, where they are available for further
analysis and evaluation. Fault conditions and drive overload can be
visualised and detected. In addition, status data can be evaluated
for energy management and remote maintenance.
Another important aim is to develop and provide economical
concepts for web-based condition monitoring and predictive maintenance
for smaller geared motors which are used in large numbers
in intralogistics applications. For these systems, additional physical
real sensors, such as those which are used for condition monitoring
in industrial gear units are often too expensive. Virtual sensors i.e.
pre-processing of internal status data enable determination of oil
temperature and oil ageing for predictive maintenance without the
use of physical sensors. NORD is currently working intensively on
solutions for status monitoring with the aid of virtual sensors. For
this, we use all of the facilities of our own application test area.
20 WORLD OF INDUSTRIES 4/2019

01 02 03
Obtaining qualified insights
Further application data such as the data from connected sensors
and actuators can be saved in the cloud at any time. Among other
things, Nord Drivesystems has equipped the drives in the test area
with encoders, in order to obtain deeper insights into the actual
behaviour of the drives. By inserting a heavy object onto the running
belt, dynamic properties are required in order to achieve the required
torque. By means of the encoder, it can for example be determined
whether the geared motors can provide the planned acceleration in
reality with larger loads on the conveyor belt and actually meet the
customer’s requirements. At the same time, Nord determines
relationships and dependencies on ambient conditions in real use,
which cannot be obtained with purely test bed operation under
standardised conditions – valuable know-how for providing advice,
troubleshooting and maintenance on the customer’s premises.
Target and actual comparison with algorithms
By means of light barriers on the conveyor belts in the application
test area, the frequency inverter detects whether there is a load on its
conveyor belt. If no load is present, it measures the electrical data
and compares these values with a reference value. If this is exceeded,
the inverter detects that something has changed in the mechanical
system. This can be caused by increased friction, wear, a damaged
bearing or gear unit or a trapped foreign body. By comparing
the virtually determined status data with real measurements,
mathematical relationships can be derived for the system and data
evaluation algorithms can be validated and improved. Stresses to
the system due to continuous operation or frequent starting and
braking can be determined. The question of what information can
be derived from the measured values with the aid of algorithms and
how this can be utilised for predictive maintenance is tested in
practice by Nord Drivesystems together with pilot customers.
01 Intralogistics solutions such as the Nordac Link field distributor are
fully Industry 4.0 ready and can transmit important drive status data for
predictive maintenance concepts into the cloud
02 In the application test area, drive experts from Nord Drivesystems
obtain deeper insights into the actual behaviour of drive units in practical
use via encoders and light barriers
03 The status and operating data of the example system can be
analysed and evaluated in the cloud and clearly visualised in a
web-based browser view
Realistic simulation of conveyor applications
The objective is to be able to determine the normal current and load
values for the customer’s installation during a learning phase. In
future operation, algorithms will monitor whether all operating
parameters are within the normal range. Calculation models which
are produced with the aid of the application test area also help Nord
Drivesystems in the planning of customers’ projects: The characteristics
of a conveyor belt can be simulated on the basis of a mathematical
model. Parameters such as belt friction or the inertia of the
belt are known. Together with the values from practical tests in the
application test area, a conveyor system can be simulated with
adequate precision in order to provide the customer with more
precise design recommendations than would be possible with
merely the planned performance parameters. This avoids expensive
over-engineering. Of course, the test area is also used as an illustrative
demonstration to customers for the topic of Industry 4.0. Thanks
to the link to the cloud, the application test area can also be demonstrated
at exhibitions and on-site visits throughout the world.
www.nord.com
WORLD OF OF INDUSTRIES 4/2019 21

Cool solution
to a hot issue
MOTION AND DRIVES
The transport of bulk materials makes heavy demands
of the drive system, because belts and drives are
mostly subjected to rough ambient conditions. The
premium gear unit manufacturer Flender has in its
portfolio three standard gear unit series based on
helical- and bevel-helical gear units. In particular it
succeeded in ramping up the increasingly important
thermal rating by something like a further 20 per cent.
The world’s population is growing – and with it the need to be able
to produce valuable minerals and other resources as efficiently as
possible. Against this background bulk-material conveyor technology
is further gaining in importance, so that an unmistakable trend
towards higher transport performances is becoming apparent. The
big challenge is to develop economical drive solutions to this problem.
Anyone manufacturing conveyor belts for worldwide operation
in partly inhospitable environments knows what heavy demands
Mother Nature makes. As well as efficiency and quality, the thermal
rating is decisive. Flender is therefore applying its decades of Knowhow
to developing gear unit solutions that, firstly, deliver lower power
losses and, secondly, can transmit high power outputs. B3SE gear
units meet this requirement without the need for external cooling.
These come in ten standard unit sizes and can be used for drive tasks
with very high power requirements – including as multiple drives.
Up to 3,000 kW without external cooling
The latest generation of these helical- and bevel-helical gear units
whose market launch Flender is pressing ahead with on a broad
scale in 2019 shows what is at all possible. Up to a range of between
2,500 kW and 3,000 kW, depending on ambient conditions and gear
unit design, external cooling systems can be dispensed with. The
reason for the unusually high thermal rating of these gear units is a
further increase in efficiency and heat dissipation.
Just the extension of the housing surface in conjunction with the
redesign of the air guide cover featuring a fan that is independent of
the direction of rotation ensures something like 20 per cent more
heat dissipation. On top of this come optimizations of gear unit design
for reduction of power loss, so enabling torques of up to 490,000
Nm to be standardly transmitted with the B3SEs. The result is that in
practice there are situations where because of the high thermal rating
of the new gear units one unit size smaller than before can be
selected. If the mechanical system permits, users also profit from
this technically and economically improved solution.
Test rig confirms theory and practice
Simple as the result sounds, the development of the new B3SE gear
units is still pragmatic in detail. For this purpose Flender has invested
in a high-performance test rig that intensively supports its
own research and development department. It enables gear unit
solutions with a rated mechanical output of up to 2,000 kW to be
tested under actual practical conditions. Gear units are analyzed on
it thermally, resulting in real detailed improvements in the case of
the new B3SE gear units.
At the same time a test rig of this kind provides the basis for testing
calculation and simulation programs used in gear unit and
drive solutions for consistency of theory and practice. In this respect,
too, users profit from the gear unit manufacturer’s decades of
experience. Because the huge standard modular gear unit system
enables gear unit experts to carry out application-specific adaptations,
so offering users the big advantage of short delivery times.
The high level of standardization further underscores the servicefriendliness
of Flender’s gear unit solutions.
02 The compact gear units of
the A series constructed can, as
plug & play solutions, be operated
flexibly and conveniently.
01 Flender’s new B3SE helical- and
bevel-gear gear units have been
further-optimized to enable an up
to 22 per cent higher thermal rating.
22 WORLD OF INDUSTRIES 4/2019 Advertisement

Easy gear unit selection thanks to
electronic assistance
An example of further benefit in combination with software is
Flender’s new swing-base configurator by which complete drive
trains can be configured in the same way as integrated drive systems.
The gear unit manufacturer is thus underscoring its core expertise
as a gear unit constructor and drive specialist. Electric motor,
coupling, gear unit, cooling systems, supports – all must be
perfectly coordinated. Starting theoretically from the conveyor belt
project, users can with the help of the software select from Flender’s
different modular product kits or standard portfolio and so use the
German gear unit manufacturer’s Know-how to realize their own
ideas. The decisive advantage: total technical drive solutions can be
developed fast and be incorporated into users’ own engineering designs
with the help of 3D data and dimensioned drawings.
B3SE gear units described here form just one of many solutions
in the Flender repertoire, which is extremely extensive, standardized
and optimized to meet specific applications. Basically three
series are distinguished for equipping bulk-material conveyor belts
with drives. Alongside the new conveyor belt drives of the E series,
which operate satisfactorily without external cooling, even in especially
hostile environmental conditions, there is the extremely compact
A series as well as the high-performance gear unit solutions of
the H series generating torques of up to 1.4 million Nm and outputs
of up to 4,500 kW. Common to all of these is that users profit qualitatively
from decades of experience and because of this premium
manufacturer’s high level of in-house production even project-specific
designs are also rapidly possible.
From compact plug & play through to
high-performance system solutions
Wherever space is tight, that is where the A series, with its biggest
feature, its compact overall design, really comes into play. After all,
not every mine offers enough space for complicated measuring,
alignment and fitting work. This gear unit solution, comprising a
motor, a coupling and a gear unit, is delivered ready to fit and need
not be laboriously aligned on site. The reason for a plug & play of this
kind is the patented self-aligning system thanks to which the gear
unit is very easy to handle. It need only be plugged in and the torque
then be absorbed by a torque arm. In short: flexibility with regard to
location, fitting, available space and commissioning is the common
denominator that had priority during development of the A series.
By comparison, the H gear unit series for highest possible outputs
and torques is being developed very application-specifically on the
basis of standard component parts. 28 unit sizes here offer the economic
and technical flexibility for putting together the total package
04 As a specialist in
gear unit construction
and drive technology,
Flender concentrates
intensively on developing
the latest high-performance
solutions.
03 The standard drive solution of
the H series was developed for maximum
outputs of up to 1.4 mill. Nm or
5,000 kW.
Great prices are waiting
for you!
For the bulk materials segment, premium
gear manufacturer Flender has three standard
series in its portfolio based on helical and
bevel-helical gear units. Would you like more information
about the Flender innovation and at the same time win great
prices? Nothing easier than that! Scan the following QR code
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project-specifically. Here, too, the wide standard range in conjunction
with Flender’s great experience gives valuable support. Because,
as well as the gear units and couplings, the company also
builds the cooling systems itself. This has the advantage for users
that during the project-specific design of a total solution not only in
the area of gear units and gear teeth and during torque transmission
but also during thermal adaptation further optimizations can be undertaken.
Conveyor belts function not infrequently in tropical heat
or Siberian cold, so perfectly coordinated total solutions are one of
the most important prerequisites for the necessarily high availability
of bulk-material conveyor belts. On top of this air- or water-type oil
cooling systems open up the possibility of individual pressure lubrication
for high-speed rolling bearings or for heavily loaded gear
teeth and/or of a cleverly designed oil management system.
Plug & play also plays an important role in the H series, so enabling
the complete drive solutions to be fitted on base frames, designed
by Flender project-specifically and delivered ready to fit. The
standard portfolio for application-specific drive solutions that
Flender can deliver anywhere in the world is extremely comprehensive
and so one of the company’s important unique selling propositions:
Cooling and heating systems, add-on flywheel masses, braking
systems, special air filters, auxiliary drives, backstops, couplings
with and without torque limitation, special shaft sealing systems to
prevent abrasion damage in dust-laden ambiences, measuring systems,
condition monitoring – and much, much more.
Conveyor systems profit from experience, qualityconsciousness,
in-house production level
The German Bocholt-based gear unit manufacturer Flender’s aim is
to bring its decades of experience in gear unit construction into line
with users’ industry knowledge. Continuous detail improvements
and continuous optimization of the standard modular gear unit
system form the framework which users all over the world profit
from. It is precisely in the case of bulk-material conveyor systems
that are mostly exposed to harsh ambient conditions that highquality
and perfectly designed drive solutions show positive effects
in the area of performance capability, availability and servicefriendliness.
The new E series of conveyor belt drives fitted with high-efficiency
cooling systems and so improved thermal characteristics shows
yet again what is possible. Complementarily to this conveyor technology
profits from the compact standard gear units of the A series
and H series for maximum drive outputs of up to 4,500 kW. This
means in practice that users can choose from a huge range of standard
solutions and so plan their projects conveniently. More still,
for requirements that go beyond the normal there are specialists in
Bocholt that also supply project-specific answers.
Photographs: Flender
www.flender.com/conveyorbeltdrives
Advertisement WORLD OF OF INDUSTRIES 4/2019 23

Challenges for cable manufacturers
in the factory of the future
AUTOMATION
Today, manufacturing is hardly conceivable
without industrial robots and their areas of use
are increasing continuously. But due to the
permanent three-dimensional movements in
the automated factory, the cables that supply
the robot are subjected to extreme levels of
stress. A special challenge for manufacturers
of cables and connecting components.
The International Federation of Robotics (IFR) predicts that by
2020 more than 1.7 million industrial robots will be working in
factories worldwide. A huge worldwide market for robot manufacturers.
To ensure that robots are supplied with data and energy
without any interruption, it is worth taking a look at the cables that
have to “go along with” the 3D movement of robots, which are on
the move continuously. Robot cables for applications where the
cables are subjected to torsional stress have to be constructed and
manufactured in a completely different way to cables for linear motion.
They must be as compact and as closely braided as possible
and have an outer jacket extruded at high pressure. The reason that
this is important is because this special “hardness” enables the cable
to follow the motion pattern of the energy chain.
24 WORLD OF INDUSTRIES 4/2019

Robot cables have to withstand several million
movements
Robot cables, in contrast, need force-compensating elements, loose
braiding elements, different slip planes and completely different
shield concepts in order to ensure they continue to function
correctly even after several million movements involving torsional
stress. This is because the cables used in robot technology have to
repeatedly change the directions in which they move. For example,
the diameter of the braid structure can actually change with torsion
angle. Cable specialist igus incorporates damping elements and
torsional-force absorbing felt into the core groups, which are
specially designed for use in applications involving continuous
changes in torsional stress, in order to offset the forces acting on the
cores. The requirements for the shielded cable types are especially
high. In order to ensure that the forces acting on the shield wires are
not too large, the motion plastics specialist places gliding elements
above and below the shields. These elements ensure that the shield
can move freely in relation to the overall braiding as well as the outer
jacket. The shield structure is designed for force redistribution
and has damping elements in the direction of that force redistribution.
This “soft” mode of construction gives the entire cable the necessary
freedom of movement, reduces tensile and compressive
forces, and preventing shutdown of a machine due to a premature
conductor breakage.
Optimum protection with the energy chain
On the basis of know-how gained over more than 50-years of experience
in this area, the jacket materials have been optimally
matched to the plastic of the triflex R robot energy chain, reducing
abrasion and wear to a minimum. The triflex R TRCF is a closed
energy tube based on the three-chamber principle: all three chambers
of the TRCF can be opened and closed independently of each
other. The supply hose is placed in one of the three chambers of the
energy tube and is therefore protected against deformation. This
makes the energy supply process reliable whatever the axial
position of the robot is.
The main feature that ensures reliable and operationally safe
guidance of robot cables and hoses is compliance with the minimum
bending radii. If the latter are not adhered to, there is a risk of
cost-intensive plant failures. The technical design of the igus triflex
R ensures that the prescribed minimum bending radius is adhered
to whatever may be the working position of the robot - a circumfer-
02
01 The technical design of the igus triflex R ensures that the
prescribed minimum bending radius is adhered to whatever
may be the working position of the robot
02 In the 3,800 square metre test laboratory, cables are
tested extensively with 2 billion test cycles per year
03 The jacket materials have been optimally matched to the
plastic of the triflex R robot energy chain, reducing abrasion
and wear to a minimum
01
03
WORLD OF INDUSTRIES 4/2019 25

AUTOMATION
ential outer stop prevents bending
below the minimum bending radius.
Moreover, the modular design of the
igus triflex R ensures that a torsion
angle of approx. +-10° per chain link is
not exceeded. This has the advantage
that the torsional stress on the cables is
distributed along their whole length and
not only at one end, which is the case with
other systems. The defined minimum bending
radius of the triflex R robot energy supply
system guarantees process reliability especially in robot applications
with supply hoses as well as in the case of flow punch bolting.
This is because a kink in the supply hose interrupts the power
supplied to the screws on the tool and the process is disrupted.
Tests offer plannable reliability and reduce costs
„Chainflex Ethernet cable CFRobot8.Plus tackles
15 million torsional movements up to 360 degrees
and offers fast data transmission to 6-axis robots.“
Igus has been repeatedly setting new standards for more than
25 years with its range of “chainflex” moving cables in the areas of
automation and robot technology. It is regarded in the industry as a
leading company for special cables, available from stock, for
continuous motion in applications involving energy chains and
torsional stress. igus has a 3,800 square metre test laboratory, the
world’s largest lab for dynamic cables. Here, igus twists the chainflex
CFRobot cables millions of times while continuously measuring
core resistance in different test set-ups. The undoubtedly greatest
challenge in the tests is that it is difficult to reproduce every
conceivable application that involves torsion over the service life of
the product. Whereas the service life limits can be dependably
predicted in the case of linear travel in energy chains due to fixed
parameters and known ambient-influences, robot applications are
usually much more complex. In particular, the sequence of movements
per se is often not completely clear during the planning
phase. For the cable supplier, it is therefore of prime importance to
test, test and test again.
Mechanical engineering processes
can be precisely planned
All the results of the tests are recorded in a database at igus. This –
together with a decades-long experience in the area of plastics
technology – enables igus to give a 36-month guarantee on the
mechanical specifications of the chainflex cables. As a result, the
mechanical engineering processes can be precisely planned. If a
CFRobot cable failed when used for the purpose described in the
catalogue, igus would supply a new cable immediately and free of
charge. Users can order cables of one metre and longer and the
goods will then be delivered within 24 hours. The great advantage of
the CFRobot series for robot manufacturers and users is that they do
not have to depend on expensive, special cables with long delivery
times but can simply select from a standard range of products which
has been specially developed for torsion applications and includes
over 100 types of robot cables all available from stock.
Industry 4.0 gets trouble-free motion
The “smart plastics” from igus provide a glimpse into the near future
of robotic cables. Under the name isense, igus carries sensors of
various kinds that detect the condition of igus components such as
cables or energy chains. They measure among other things the wear
during the operation and alert the user early enough to plan repair
or replacement. By networking with the icom communication module,
the data is transmitted to an intelligent system. The module
can be connected to all igus specific sensors. Once the measured
values from a sensor have been transferred to the icom module,
they have to be “interpreted”, i.e. understood in order to generate
instructions from the same. So far, this has been possible via the
connection to the igus cloud.
Due to the increasing importance of IT security, however, many
companies are increasingly relying on the development of their
own Scada-systems, which is why igus has now advanced its data
concentrator into icom.plus. With the new module, the customer
can integrate the data in the way that best suits their equipment.
With the online connection of the icom.plus, a continuous matching
of the service life statement with the igus cloud takes place in
order to enable maximum system runtimes with minimal failure
risk. The data in the cloud draws on the 10 billion test cycles of
energy chains and cables performed in the company’s own
3,800 square metre test laboratory, and thanks to machine learning
and AI, igus can provide precise information on the durability of the
solutions used and inform the user about a necessary replacement
beforehand.
Photographs: igus
www.igus.com
04 Robot cables for applications
where the cables are subjected to
torsional stress need force-compensating
elements, loose braiding
elements, different slip planes
26 WORLD OF INDUSTRIES 4/2019

Barley malt producer increases productivity
with smart condition monitoring
Muntons, one of the UK’s largest producers of malted
barley protect vital parts of their production process
against unscheduled downtime by using the Smart
Condition Monitoring (SCM) system from Mitsubishi
Electric.
Used to make beer, spirits and a range of popular foodstuffs, malted
barley is produced in large batches where environmental conditions
are critical to a consistent product. Each batch is very valuable,
not just in monetary terms but also to the customer, so
Muntons is extremely pro-active when it comes to the servicing and
maintenance of its equipment.
As in many food industries, the principles of the barley malting
process are quite traditional, but Muntons relies heavily on automation,
electro-mechanical equipment and sensors to provide fine
control over air flow, heat and moisture. Fans and motors are critical
to the operation: the Muntons processes many tonnes of product
at a time, with key operations relying on a steady supply of
blown air. The chosen SCM installation provides condition monitoring
for two large 315 kW fan sets and a single 90 kW fan set. Sensors
monitor the electric motor, power transmission coupling and
main fan shaft bearing on each fan set.
„The investment in automation and
predictive maintenance pays off very quickly
by avoiding unscheduled downtime.“
Plant Engineer Michael Plawecki says: “We now have a clear picture
of the health of the fan sets and advance warning of any required
maintenance. Remote monitoring and fast diagnosis of any issues
has also made us very responsive should the limits on operating parameters
that we have set be approached. As promised the system
was easy to install and relatively simple to commission.”
Early diagnosis avoids machine failures
The impetus for the SCM installation came from issues previously
experienced with difficult-to-reach bearings inside a large fan
housing. A bearing failure inside a fan assembly caught the Muntons
engineering team unawares, and proved significant in terms of
downtime. “We only realised we had problems when it was too late,
and we had to make an unscheduled stop on one of the lines to
make repairs,” says Plawecki. Determined to learn from that lesson,
Muntons looked for a monitoring solution with predictive maintenance
technology that could be linked into the company’s existing
Scada system.
Concept of smart condition monitoring
The SCM solution provided by Mitsubishi Electric comprises smart
sensors that can be attached to bearing housings, gearboxes, pumps
and motors to detect when equipment starts to operate outside its
normal envelope due to wear. It provides a sophisticated early
warning system for critical pieces of rotating plant equipment.
Vibration frequencies and temperature readouts are monitored
continuously and fed back to an L Series Mitsubishi Electric PLC via
an industrial Ethernet network cable. The PLC offers simple integration
to other network system hardware and software platforms,
in this case integrating seamlessly with the Scada system at Muntons
Malt.
Sensors monitor changes in the complex vibration
patterns
The sensors, developed by bearing expert FAG, monitor for changes
in the complex vibration patterns specific to the type of equipment
it is attached to. The software compares that data with highly developed
data models from thousands of previous installations, providing
an effective analysis and alert system for the user.
Live information and any alarms are displayed on a Mitsubishi
Electric GOT Series HMI mounted to the control enclosure. The system
can work autonomously of any other automation, with multiple
sensors located and recognised by unique IP addresses. At Muntons,
the visual information and the alarms being generated were easily
connected into the existing automation software platform.
Photographs: Mitsubishi Electric Europe B.V.
eu3a.mitsubishielectric.com/fa
WORLD OF OF INDUSTRIES 4/2019 27

The DNA of the Industrial
Internet of Things
Single Pair Ethernet - or SPE for short - is currently one
of the mega-trends in industrial data transmission.
If you want to understand the applications and
advantages of reducing data cabling to a single wire
pair, you must learn about the history of Ethernet
and industrial automation.
AUTOMATION
As a non-standardized software protocol, Ethernet was developed
in the 1970s for the internal and locally limited transmission
of data packets in wired computer networks (LAN - Local Area
Network). The Institute of Electrical and Electronics Engineers
(IEEE) defined the software protocol and the physical layer - including
physical interfaces such as connectors and cables - in the
following two decades and laid the foundation for the modern Internet
with the introduction of various protocols such as 802.4 (Token
Bus), 802.5 (Token Ring) and finally 802.11 (WLAN).
Common language
Parallel to this, fieldbus technology developed in the 1980s, driven
by the increased use of electrical automation technology. The basic
idea was the same: Different communication participants should
communicate with each other in an orderly manner and in a common
system. However, the various fieldbus protocols, such as Interbus,
DeviceNet and Profibus, were not used for networking computers
at company level, but for serial or parallel connection of
sensors and actuators to the control and management level.
Ultimately, the parallel development of the two transmission
protocols established the form of the automation pyramid that is
still valid today. The highest levels represent locally limited computer
networks which are used for rough and detailed production
planning. The lower levels comprise the signal, data and power
transmission for recording, controlling and regulating the physical
production process (Fig. 1).
The shape of the pyramid resulted primarily from the hierarchical-logical
arrangement of the different levels. However, it also rep-
Author: Dipl.-Wirt.-Ing. Verena Neuhaus, Manager Product Marketing
Data Connectors, Phoenix Contact GmbH & Co. KG, Blomberg, Germany
resents the previously valid framework conditions for industrial
data transmission: High transmission rates and short distances via
Ethernet, low transmission rates and long distances via fieldbus.
Turned upside down
So why this digression? Industrial Ethernet and especially Single
Pair Ethernet are turning this automation pyramid upside down.
With the development of Ethernet-based protocols such as Ether-
Net/IP, Profinet or EtherCAT, real-time data transmission from the
company level to the field level was introduced.
The physical interfaces became more powerful, but also more
complex in electrical terms, since data transmission had to be protected
from interference such as dirt, vibrations and electromagnetic
radiation. Manufacturers of connection technology therefore
developed special, IP6x-protected Ethernet interfaces to meet these
increased requirements at the field level. For the top of the automation
pyramid - the enterprise and operational level - IP20 solutions
were still sufficient.
Data transmission to the second power
So far, standardization efforts have been limited to ever higher data
rates and higher demands on cabling technology. These requirements
were defined by ever higher performance classes in copperbased
cabling - the Categories.
The Single Pair Ethernet does not again define higher bandwidths
or transmission distances, but forms the normative framework for
reduced cabling to suit the application. The IEC 63171-2 (IP20) and
IEC 63171-5 (IP67) standards focus on lower transmission rates of
10 to 100 Mbps. The data cabling with only one pair of wires nevertheless
enables transmission distances of up to 1000 meters. Thus,
for the first time, SPE allows areas of application and applications
that conventional Ethernet has not allowed to date, for example in
28 WORLD OF INDUSTRIES 4/2019

02 Efficiently wired: Single-pair and
four-pair MICE interfaces are used for
cabling IP20 and IP6x applications
01 Paradigm shift: SPE turns the conventional
automation pyramid upside down
From the sensor up to the cloud
Single Pair Ethernet (SPE) connects the IP20 world of the
enterprise and operating level with the IP6x world of the
control and field level – and thus opens up new areas of
application. The goal is the seamless connection of all
communication participants on the basis of the same
protocol language and uniform interfaces. Thanks to the
reduced cabling with only one or four individual wire pairs,
users can build efficient network and cabling structures
from the sensor to the control and company level right
up to the cloud. And in addition to data rates of up to
1000 Mbps, the SPE cabling also allows the end devices
to be supplied with power of up to 60 watts.
process technology. The advantage for plant operators: data cabling
can be carried out continuously on the basis of the Ethernet protocol,
i.e. identical interfaces and pin connector patterns can be used
in different environments.
Another advantage is that single-pair interfaces are considerably
more compact than two- or four-pair device and cable connectors.
SPE thus supports the continuing trend towards compact, decentralized
devices in industrial automation, process technology,
building automation and in telecommunications and infrastructure
applications. SPE can thus turn application-neutral into the
DNA of the Industrial Internet of Things (IIoT).
New pin connector pattern, well-known reliability
In order to ensure the consistent compatibility of all interfaces, the
IEEE has formed working groups for the normative description of
different applications with transmission rates of 10, 100 and 1000
Mbps. Standards for 100-Base-T1 and 1000-Base-T1 have already
been adopted, with 10-Base-T1 standards expected to follow by the
third quarter of 2019.
Phoenix Contact is a major driving force behind the standardization
of the corresponding interfaces. Together with market partners
Reichle & De-Massari, Weidmüller, Fluke Networks and Belden, the
connection technology specialist develops protected and unprotected
pin connector patterns for single-pair and four-pair cables.
The MICE model describes their mechanical robustness (M1 or
M2/3), IP protection (I1 or I2/3), chemical and climatic resistance
(C1 or C2/3), and electromagnetic safety (E1 or E2/3) (Fig. 2).
The compact pin connector patterns are ideally suited for efficient
cabling of numerous communication participants - either via
a single wire pair or via four wire pairs for four participants sharing
a common line and interface. Thanks to the common interface,
single- and four-pair cabling concepts can be mixed as well as IP20
and IP6x solutions. Possible applications are the splitting of eightwire
cabling concepts into four individual SPE strings for four different
communication participants, or the dimensioning of individual
pairs within the eight-wire device interfaces. The two-wire
technology also permits the application-specific supply of terminal
devices with outputs of up to 60 watts via the same pair of wires
(Power over Data Line - PoDL).
The future of communication technology
SPE cannot be seen as a mega-trend in industrial data transmission
independent of other standardization efforts. The basic framework
for the future of industrial communication technology is being created
in parallel in various committees and projects. New communication
standards such as the Open Platform Communications Unified
Architecture (OPC UA), Time-Sensitive Networking (TSN) and
5G form the basis for continuous networking from the sensor via
the machine and higher-level systems into the cloud.
The new standards will outperform existing protocols and interfaces
in terms of cost, data throughput, latency and deterministics.
As a technology leader with more than 30 years of experience in industrial
communication, Phoenix Contact is thus active in all the
relevant standardization committees. The goal: nothing less than a
new, manufacturer-independent communication standard for automation.
Today, OPC UA already serves as a superimposed communication
standard in plants. OPC UA is now being expanded by standardized
application profiles in the field - for I/O, safety or drive
applications, for example. In addition, standardized device models
are defined for uniform configuration and diagnostics of the devices
in the network.
Photographs: Phoenix Contact
www.phoenixcontact.com
WORLD OF OF INDUSTRIES 4/2019 29

A bridge
between two worlds
More and more industrial processes are going digital.
It is now also the turn of level measurement with float
switches. A float switch for this purpose features a
semiconductor sensor. This form of limit level monitoring
represents a decisive step towards Industry 4.0.
AUTOMATION
Virtually no machine or plant manages without them: millions of
float switches are employed to monitor liquid levels every single
year. They are reliable, simple and robust. Float switches consist of
only a few components, which is partly why they are the most economical
measuring principle for this type of task. They are mainly
used to monitor limit levels and respond if a critical level is reached.
Float switches protect against overflow or dry running. This functionality
is stipulated for certain tank plants, for example by the
German Water Resources Act, to prevent overfilling or leakage of
the medium into the groundwater. In industrial applications, float
switches monitor limit levels as a precautionary measure: pumps as
well as hydraulic or lubrication systems are supplied with the right
media on demand or switched off in good time if they run dry, so
that no damage can occur, e.g. due to overheating.
As effective as necessary, as easy as possible
The float switch principle is as simple as it is effective: a float with a builtin
magnet moves on a guide tube according to the liquid level in a vessel
or tank. At defined measuring points it operates hermetically sealed
reed contacts with a normally open, normally closed or change-over
function. These mechanical switch contacts are energised by the float’s
magnetic field. The switching operation is contact-free and hence also
potential-free. Another advantage of this type of measuring instrument
is that the float switch can be adapted to the density of the medium in
the tank, so that there is no influence on measuring accuracy.
The design and operating principle of conventional float switches –
including all their positive features – have now been incorporated
into the digital version. The new GLS-1000 switch type from Wika replaces
the classic reed contact with a semiconductor sensor which,
once again, is activated by the magnetic field of the float magnet. This
results in a measurable resistance change, which is detected and processed
by the electronics, so that an electrical switching signal is
tripped in the same way as with a conventional float switch.
The digital signal via the PNP / NPN switching output offers an
unlimited number of switching cycles. Since no mechanical switching
contact is used, the sensor is free from wear and thus extremely
durable within its operating limits.
Like their conventional equivalents, digital float switches represent
a reliable and economical solution. Similar to a classic float
switch, the GLS-1000 can be provided with up to four switch points.
It has an optional temperature output which can be used, for instance,
as a Pt100 / Pt1000 resistance thermometer for monitoring
the temperature of the medium. Since the external design and
geometry of the device are identical, mechanical float switches are
very easy to replace with digital ones.
Automating the manufacturing processes
of tomorrow
The extremely reliable switching function and built-in long service
life are not the only arguments for choosing the new switch. Thanks
30 WORLD OF INDUSTRIES 4/2019

to its digital signal processing capabilities,
02 Float switch for industrial applications with
the GLS-1000 is an ideal component for circular connector M12 x 1 and cylindrical float
automating the manufacturing processes
of tomorrow. Depending on the model, it 03 GLS-1000 float switch in a tank
can in future be integrated into appropriately
automated machine and plant controls,
for example using IO-Link 1.1. This is currently
only possible with much more expensive level
measuring technologies like guided microwave,
ultrasound or vibration limit switches. Moreover, the
advanced electronics open the door for additional functionalities such as
internal diagnostic capabilities, sensor parameterising options or an
operational status display.
Conclusion
01 Float switch for industrial applications
with cable outlet and float from Buna
02
03
With their PNP / NPN switching output signals, long service life and excellent
resistance to shock and vibration, float switches with semiconductor
sensors provide access to new applications in the field of limit level monitoring.
Smarter sensors capable of collecting additional diagnostic and
measured data will ensure that in the future, too, float switches are the
solution of choice for integration into highly automated processes. At the
same time, semiconductor float switches are extremely economical compared
to other digital solutions. Yet in spite of this, they are by no means
the beginning of the end for tried-and-tested reed contact switches.
Owing to their proven reliability, classic float switches will continue to be
a good alternative for many applications in tomorrow’s world where the
benefits of mechanical switching are decisive – such as potential-free
switching or safe isolation of circuits and cables.
01
Photographs: Wika Alexander Wiegand SE & Co. KG, Germany
https://en.wika.com

A taste of the future of industry
The great promise of new connected concepts of
industry like Industrie 4.0 is their ability to deliver a
historically unparalleled level of responsiveness and
flexibility. While modern supply chains are already
heavily integrated and designed to be fluid and fast
moving, a large swathe of manufacturing still remains
beholden to economies of scale, large production runs,
and careful preplanning.
The Industrial Internet of Things is set to change this by allowing
small-batch or even custom manufacturing on a truly industrial
scale. With machines whose functions are not set in stone, but flexible
and determined by their operating software and with a new form of
connectivity bringing industrial engineers, product manufacturers,
and end users closer together than ever before, ad-hoc adjustments to
e.g. automotive parts during active product runs or the bespoke manufacturing
of custom sneakers become very viable options indeed.
Much of this remains a theoretical vision, but IUNO, the German
national reference project for IT security in Industry 4.0, demonstrates
the new capabilities in action with a secure technology data
marketplace running a smart drinks mixer.
The solution
The IUNO demonstrator consists
of two ends to the simulated supply
chain: The technological data
marketplace, where inventors of
drinks can upload the recipes, and
a cocktail mixing machine, which
is connected to the marketplace
and can license the encrypted
recipes. The system uses Wibu-
Systems’ cloud-based CodeMeter
License Central to protect the
recipes, the production data that
acts as a currency in this smart
production network, with full
encryption both when it is sent to
the mixer and when the drink is made in the machine itself – whose
inner workings are again secured with a CodeMeter dongle as anchor
of trust and dependable proof of identity, powered by Infineon’s SLM
97 security controller. On the front end, the drinks are mixed and
ready for the buyer to enjoy.
The results
The IUNO demonstrator is a template for a secure technology data
marketplace that is both fully protected with Wibu-Systems’ solutions
and open enough to accommodate additional actors and vendors,
the IUNO cocktail mixing machine becomes a model for a new paradigm
in manufacturing. Where vertical integration once meant
physical control and ownership over every link in the supply chain, it
can now mean the integration of independent partners. Like the
recipes, production data can be traded, licensed, and securely transported
through the Industrial Internet to smart factories that offer
manufacturing as a service. This creates new commercial freedom
and access for sellers, buyers, and makers, all of whom can rest
assured that their data is protected from theft, illicit use by more
unscrupulous partners in the supply chain, or tampering along the way
with the power of CodeMeter’s licensing and protection capabilities.
A chance to see smart custom manufacturing
in action
The future of industry is connected, intelligent, responsive, and customized.
With concepts like Industrie 4.0, we have a roadmap and a
vision to follow. The protocols for machine communication and new
HMI interfaces are available
and continue to be refined.
From the new data infrastructure
to the industrial
machines on the ground,
the hardware is being
rolled out, in upgraded
and retrofitted brownfield
installations or completely
new greenfield sites.
Industrial engineers and
the operators of their
products on the ground
have also begun to take
the threat of cyber-crimi-
AUTOMATION
32 WORLD OF INDUSTRIES 2019

A high-tech drinks mixer showcases how a secure technology data marketplace can work as the front end
of a smart, connected, and fully secured and licensed supply chain
nality seriously and are investing in protection and licensing
capabilities. Still, the opportunities to truly experience the Industrial
Internet of Things and smart factories in action are few and far
between. IUNO, the German national reference project for IT security
in Industrie 4.0, is set to change this with a show-stopping technology
demonstrator: a high-tech drinks mixer that showcases how
a secure technology data marketplace can work as the front end of a
smart, connected, and fully secured and licensed supply chain.
The role of a cloud solution for license
management
Developed in a multivendor project partnership including the
IUNO members Wibu-Systems and Trumpf, the drinks mixer
works by combining a technology data marketplace – a repository
of drinks that would-be vendors can add their favorite recipes to
– with a secure data transmission concept and similarly protected
front-end hardware. With a selection of recipes at the customer’s
disposal, the drinks are chosen from the custommade sales platform
at https://iuno.axoom.cloud and paid for by Testnet Bitcoin.
Once the customer has made his or her selection and the Bitcoin
transaction has been processed, the technology marketplace
sends the order for the right recipe in fully encrypted form to the
physical mixer, using Wibu-Systems’ CodeMeter License Central,
the cloud solution for license management, to do the heavy lifting
of encrypting, licensing, and securing the operation. In the mixer
itself, a CodeMeter dongle provides an anchor of trust for the protected
operating software of the mixer and for the mixer’s correct
identity in its transaction with the IUNO marketplace, using an
industry-grade Infineon SLM 97 security controller. At no stage in
the supply chain can the recipe be read out or tampered with,
neither in the cloud marketplace nor in its transmission or in the
mixer itself.
On top of protecting the IP in the recipes, the CodeMeter technology
is used to enforce the licensing for each recipe. Only the
paid number of items (drinks in this case) can be produced. The
encrypted recipe is worthless without the corresponding license
which defines the amount of goods allowed for production. As in
more regular manufacturing operations, the manufacturer of the
technology (the mixer) and the vendor of the product (the recipe)
– who could be one and the same or separate entities – can rest
assured that their intellectual property is safe and sound.
The customer on the front end sees little of the intricate software
and hardware that goes into making his or her drink of choice.
Whatever drink the customer goes for, one thing is certain: the end
result is more than a refreshing beverage. It is a taste of the future of
industry.
Photographs: Wibu-Systems
www.wibu.com
Access to marketplaces and ownership over
data are becoming the gatekeepers for
participation in Industrie 4.0 – but neither
can function without the level of protection
afforded by Wibu-Systems’ cloud-based
technology.
Oliver Winzenried, CEO,
Wibu-Systems AG
WORLD OF OF INDUSTRIES 4/2019 33

Smooth and trouble-free
With its clutches, couplings and brakes, mayr
power transmission offers complete solutions from
a single source – for the reliable protection of machine tools
and machining centres. For example, a wide spectrum of
backlash-free, high-performance servo couplings provides
a secure connection between the shafts. mayr power
transmission has developed a wide portfolio of reliable safety
brakes specifically for the safeguarding of gravity-loaded axes.
This is because hanging loads represent a substantial risk
potential in machines and systems. Picture: backlash-free,
flexible Roba-ES
elastomer coupling (left)
and Roba-topstop, the
modular safety brake
system (right).
www.mayr.com
Solution for real-time thermal analysis
The high performance Flir A6750 MWIR camera offers short
exposure times and high-speed windowed frame rates,
making it an ideal choice for recording rapid thermal events
and fast-moving targets. Freeze motion or achieve accurate
temperature measurements on moving subjects, and perform
a variety of non-destructive testing with this cooled InSb
camera. The 327, 680 (640 x 512) pixel IR resolution and high
sensitivity produce crisp imagery, well suited to electronics
inspections, medical thermography,
and more. The camera
is plug-and-play with third-party
software, and works seamlessly
with Flir ResearchIR for intuitive
viewing, recording, and advanced
processing of thermal data.
www.flir.com
Machine learning for control systems
Beckhoff now offers a machine learning (ML) solution that
is seamlessly integrated into TwinCAT 3 software. Building
on established standards, TwinCAT 3 Machine Learning
brings to ML applications the advantages of system openness
familiar from PC-based control. In addition, the TwinCAT
solution supports machine learning in real-time, allowing it
to handle even demanding tasks like motion control. These
capabilities provide machine builders and manufacturers
with an optimum foundation to enhance machine performance,
e.g. through prescriptive maintenance and process
self-optimisation. Picture:
With TwinCAT 3 software,
experts can tap into new
machine learning and deep
learning possibilities.
www.beckhoff.com
Launch of laser thru-beam sensors
With the new laser thru-beam sensor series HG-T, Panasonic
launches an easy-to-use and customer-friendly laser
measurement systems with many features and is responding
to the needs of the market. The HG-T sensors work like optical
micrometers that can precisely measure µm even over large
distances. A laser belt with a width of 10 mm allows the
high-precision monitoring of wide webs, for example in the
printing industry. The laser measurement system consists of
a controller and a sensor head
with an emitter and a receiver.
The controller offers many preset
functions such as edge detection,
diameter measuring, or
measuring of transparent
objects.
www.panasonic-electric-works.com
PRODUCTS
Editorial board:
Winfried Bauer (Editor-in-chief), E-mail: w.bauer@vfmz.de
Peter Becker (Editor-in-chief), E-mail: p.becker@vfmz.de
Nicole Steinicke (Editor-in-chief), E-mail: s.steinicke@vfmz.de
Manfred Weber, E-mail: m.weber@vfmz.de
Svenja Stenner, E-mail: s.stenner@vfmz.de
Managing editor:
Winfried Bauer
Assistant editors:
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E-mail: verlagsbuero-greiner@vfmz.de
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34 WORLD OF INDUSTRIES 4/2019

Digital future must
be actively shaped
Today, supply chains are complex and global networks
that can increasingly only be handled through
digitalisation. Intralogistics as a cross-sectional
discipline is gaining in importance and occupies key
positions in many areas.
Because the more transparent the digital flow of information, the
smoother the actual physical transport of materials runs – and
that equally in a smart factory or in a modern warehouse. Therefore,
the future of the industry can only lie in networked solutions and
digital services. The major drivers worldwide are still the automotive
industry and the rapidly growing e-commerce sector. Like
other industries, they depend on smooth and highly adaptable processes.
Automation in this context is not a new, but still important
keyword.
In the past, automation was primarily an issue for large companies
with a high proportion of standardized processes. Today, the
massively increased computing power and increasingly intelligent
technologies and components are opening the way to automation
even for smaller companies – with the necessary flexibility at manageable
costs and justifiable effort.
Regardless of the customer industry – everywhere there are farreaching
changes that have to be mapped and implemented in the
logistics processes. For suppliers of intralogistics and materials
handling systems, this means actively shaping the step towards Industrie
4.0 and consistently moving forward. They offer the customer
individual solutions with which he can shape his path to a smart
factory or a smart warehouse.
This is important because the next paradigm shift in the industry
is already in sight: Automation will become autonomy in the future.
Dr. Klaus-Dieter Rosenbach, Chairman of the Executive Board of VDMA
Materials Handling and Intralogistics
The goal are intralogistics systems, capable of networking autonomously,
controlling and optimizing their own operations. However,
intensive research and development work is still needed here.
Communication standards are a large work package. In the industrial
environment, OPC UA is the main winner in this context.
Therefore, intralogistics is also working on the first Companion
Specifications - an exciting development that will give the industry
and its solutions many interesting impulses in the coming years.
WORLD OF OF INDUSTRIES 4/2019 35

HANNOVER MESSE
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NEW HORIZONS.
NEW MARKETS. NEW LEADS.
NEW CUSTOMERS.
→ hannovermesse.de/worldwide
36 WORLD OF INDUSTRIES 3/2019