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World in<br />

Transition<br />

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Dear readers,<br />

The fourth industrial revolution has long since ceased to be just a<br />

slogan. It is already in full swing. It is changing our world and the<br />

ways in which producers, suppliers and customers interact. It is<br />

making digital e-Procurement platforms possible, linking production<br />

facilities right through to complete logistics processes, and provides<br />

data for new findings in research and development, e.g. for new<br />

methods in artificial intelligence.<br />

One of the countries that has developed into a digital pioneer is<br />

China. Compared to other countries, there is no great difference as<br />

far as the state-of-the-art is concerned. What is different, however, is<br />

the attitude towards the subject of digitalization. Anyone who wants<br />

to be among the leaders in Industry 4.0 has already been active in<br />

China for many years. At the other end of the scale is Russia. But the<br />

groundwork has been laid and the government is looking to support<br />

the changeover to digital corporate processes. This is being supported<br />

i. a. by the German Russian Initiative for Digitalization (GRID). Founder<br />

members on the German side here are Siemens, SAP, Bosch and the<br />

VW Group Rus. Russian members of this initiative are the Russian<br />

employers’ association, RSPP, Rostelecom, Skolkowo and “Zyfra”.<br />

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and at the CeMAT Russia in Moscow, the International Exhibition<br />

for Materials Handling, Warehousing Equipment and Logistics<br />

(24-26 September <strong>2019</strong>).<br />

Let yourself be inspired by the global trends and technologies<br />

of tomorrow.<br />

Yours sincerely<br />

Nicole Steinicke<br />

Tel. +49 8542 1680<br />


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

22<br />

28<br />

18<br />

35<br />


03 EDITORIAL<br />

06 <strong>WORLD</strong>WIDE NEWS<br />







<strong>OF</strong> DOUBLE DIGIT GROWTH?<br />





DYNAMICS <strong>OF</strong> CHINA’S <strong>INDUSTRIES</strong><br />













FACTORY <strong>OF</strong> THE FUTURE<br />

4 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong>

10<br />






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SSI Schaefer is investing in the future<br />

In Giebelstadt, at the SSI Schaefer competence center for automated logistics solutions, the groundbreaking<br />

ceremony for a 5-story office building took place in September of last year. The building will<br />

provide space for 400 workplaces on almost 7,000 square meters in 2020. At the Friesach location in<br />

Austria, heart of the proprietary Wamas logistics software, an additional office complex is being built<br />

that reflects the company’s strength in IT. After its grand opening, which is scheduled for November<br />

<strong>2019</strong>, about 170 employees will be moving into the 1,000 square meter IT powerhouse.<br />

www.ssi-schaefer.com<br />

Pepperl+Fuchs to become an SE<br />

Pepperl+Fuchs GmbH has decided to undertake an incremental conversion<br />

into a European Company (Societas Europaea) by 2020 to ensure its growth<br />

strategy in the long term, and to be able to face future challenges on a global<br />

scale with flexibility and agility—in particular the challenges of Industry 4.0.<br />

“The legal regulations associated with an SE will facilitate trade and possible<br />

expansion activities in the EU area,” says Werner Guthier, CFO of the<br />

Pepperl+Fuchs Group (foto). “At the same time, the SE legal form also offers us<br />

new options on the capital markets in contrast to the GmbH legal form.<br />

Overall, we consider this to be an important step toward<br />

ensuring sustainable success for the Group in the future.”<br />

www.pepperl-fuchs.com<br />

Stemmer Imaging continues its<br />

international expansion strategy<br />

Stemmer Imaging confirms it<br />

has successfully concluded<br />

the acquisition of the<br />

Spanish group Infaimon<br />

S.L. today and is<br />

acquiring 100 % of the<br />

shares in the supplier of<br />

software and hardware<br />

for machine vision and<br />

robotics after approval of the<br />

transaction by all the relevant<br />

antitrust authorities. The machine vision specialist is<br />

now represented in all key European markets with<br />

local branch offices. With the acquisition, Stemmer<br />

Imaging is also underscoring the strategic importance<br />

of state-of-the-art bin-picking solutions, an<br />

important capability in the context of Industry 4.0<br />

applications which will further stengthen the<br />

company’s product and service portfolio.<br />

www.stemmer-imaging.com<br />

6 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong>

Rittal, Atos and Siemens form a global<br />

strategic partnership<br />

Logistics area<br />

doubled<br />

Paul Vahle has opened one of<br />

the most modern material flow<br />

systems of its kind in Kamen.<br />

The system provider for mobile<br />

industrial applications supplies<br />

the connected production<br />

facility with individual components<br />

from this site. Effective<br />

immediately, order picking<br />

takes place automatically with<br />

the latest warehousing<br />

equipment made by Jungheinrich.<br />

The heart of the new<br />

system is an automated<br />

miniload warehouse with 7,314<br />

storage locations. Boxes<br />

measuring 600 × 400 and 300 ×<br />

Rittal announced a new global strategic partnership with Atos<br />

and Siemens to develop intelligent edge datacenter solutions<br />

for smart industries, smart cities, smart retail, energy &<br />

utilities, and public sectors. The new ‘Intelligent Edge Data<br />

Center’ (IEDC) is a highly configurable datacenter solution<br />

that enables companies to process IoT data in real-time using<br />

solutions such as MindSphere, the cloud-based, open IoT<br />

operating system from Siemens, the new BullSequana Edge computing<br />

server and the BullSequana S server from Atos, Atos Codex Cloud Industrial<br />

Supervision (CIS) and thus optimize their entire value chain with an<br />

advanced data-, analytics solution.<br />

www.rittal.com<br />

400 millimeters are stored<br />

double-deep or quadrupledeep<br />

and crosswise. These are<br />

serviced by what Jungheinrich<br />

views as the most powerful<br />

stacker crane of its class, which<br />

moves at a speed of six meters<br />

per second. A wide-aisle<br />

warehouse, cantilever racks for<br />

the storage of long goods and<br />

drive-through racking were also<br />

built. The logistics area nearly<br />

doubled through the modernization,<br />

to around 3,500 square<br />

meters. With the Go Live of the<br />

miniload warehouse, Vahle is<br />

the first company in the world<br />

to utilise the Miniload STC<br />

which was introduced by<br />

Jungheinrich in 2018. It has<br />

energy storage devices called<br />

SuperCaps which are specially<br />

adaptedto the stacker crane’s<br />

driving characteristics.<br />

We facilitate reliable deliveries and highly flexible technical handling thanks to our<br />

intermodal network – from production to the end customer.<br />

See more good reasons for BLG LOGISTICS at<br />

www.blg-logistics.com/5reasons<br />

www.jungheinrich.com<br />

www.vahle.com<br />

BLG.indd 1 12.08.<strong>2019</strong> 13:12:59<br />

<strong>WORLD</strong> <strong>OF</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong> 7

Modest growth outlook for Russia,<br />

but opportunities to gain market share<br />

in various unorganized industry sectors<br />

Year on year, Russian economy is getting robust, as<br />

they find out ways to tackle external issues like<br />

sanctions, drop in oil prices or currency crisis. As the<br />

economy prepares itself with significant fiscal buffers,<br />

the internal demand, consumption and exports<br />

increases, thus boosting the demand for services like<br />

transportation, warehousing, and complete logistics<br />

solutions.<br />

Russia’s real GDP growth in 2018, reached nearly 2.5 %, surpassing<br />

the general expectations, mostly due to the one-off effects of<br />

energy sector. Growth forecasts for <strong>2019</strong>-21 is between 1.2-1.8 %,<br />

this reflects a more modest outlook in line with Russia’s current potential<br />

growth of about 1.5 %. In the first quarter of <strong>2019</strong>, GDP growth<br />

slowed for several reasons, mainly due to Russia agreeing on cutting<br />

down oil production along with other OPEC members, a tighter<br />

monetary policy and an increase in VAT rate from 18 % to 20 %.<br />

Instead of annual growth rates, let’s take a look at Russia’s potential<br />

growth rate, as this depicts a more accurate picture about the<br />

economy. In the last 10 years, potential growth all over the world<br />

has slowed, so Russia experiencing this slow down is nothing out of<br />

the normal. In the last 5 years, potential growth was below its longer-term<br />

average in most of advanced as well as emerging economies.<br />

However, the slowdown had a more serious impact in Russia,<br />

as it highlighted a weak productivity related growth and worsening<br />

demographics. Based on data from world bank, Russia’s potential<br />

growth is set to gradually decline from 1.5 % in 2017 to 1.3 % by<br />

2024. Russia seems to have undertaken certain reforms in-order to<br />

reverse this declining trend. Reforms that are focused on bringing<br />

more inward migration, higher investment, and increasing productivity,<br />

increasing in retirement age etc. If Russia succeeds in executing<br />

these reforms then it could bring about an increase of 1.5 % in<br />

potential growth within the next 10 years. Of all the factors men-<br />

Author: Sushen Doshi, International<br />

Correspondent for World of Industries<br />


tioned above, increase in productivity is the key driving factor, which has maximum impact<br />

on Russia’s potential growth. In order to increase productivity in such short span,<br />

Russia needs to heavily invest on innovation, skills and competition.<br />

Downside and Upside<br />

Downside risks to Russia’s medium-term growth outlook arise from the risk of deepening<br />

of economic sanctions, financial crisis in emerging markets, a deteriorating global trade<br />

environment due to trade war between US and China, and a dramatic drop in oil prices.<br />

Russia also suffers due to its limited portfolio of exports. For more than 30 years, oil, natural<br />

gas and energy products have been Russia’s largest exports. Through continued efforts<br />

from the government since 2014, growth in non-energy export volumes has been outpacing<br />

that of energy and contributing to export diversification. But despite this, Russia’s<br />

export portfolio is shallow, with the share of oil/gas products still totaling close to 60 %.<br />

In the last few years, Russia has prepared itself quite well for reducing the impact of<br />

external shocks and volatility of the commodity prices on it’s economy. Another area<br />

where Russian macro-economic strengths lie is the low public and external debts, no<br />

fiscal deficits, in-fact significant fiscal surpluses. On the upside, government has<br />

launched multiple national projects aimed at strengthening human capital and increasing<br />

productivity, if well-implemented, could positively affect Russia’s potential growth<br />

in the medium-term. Also, changes in labor legislation, with focus more on formalization<br />

of workforce is a strong step as it could benefit the economy by 2.5 % of the GDP. The<br />

share of informal labor is quite high in Russia, it is estimated to range between 15-20 %.<br />

Russia continued its efforts to improve the business and regulatory environment for<br />

SME sector by carrying out reforms in the areas such as getting faster permits for construction,<br />

electricity connections, paying taxes became less costly by allowing a higher<br />

tax depreciation rate for immovable assets, and cross border trading was improved with<br />

less bureaucracy and online customs clearance facility. As a result of this, Russia advanced<br />

to 31st place in the global ease of doing business ranking, representing an improvement<br />

from the 35th place last year and ranked 120th seven years ago.<br />

Russia’ logistics sector overview<br />

After struggling for years, growth and optimism has finally returned to the nation’s<br />

transport and logistics sector. From 2018 the industry saw a return to the high levels of<br />

freight entering and exiting Russia. Russia is stepping up both its exports and imports it<br />

receives from non-sanctioned trade partners. China, which is Russia’s second largest<br />

trading partner after the European Union, is keen to bump up Russia bound exports,<br />

and Russia is ready to reciprocate. And this brings with it enhanced opportunities for<br />

foreign companies, not just in terms of pure investment, but also as a market to sell<br />

transport services and technologies.<br />

With the rise of e-commerce industry, the market for 3pl service is expected to witness<br />

significant growth. As competition amongst manufacturers increases, they aim to focus<br />

more of their resources on their core competencies and outsource the logistics part of<br />

the operation to professional third party service providers. This is set to escalate the demand<br />

for 3pl service. Moreover, the 3pl services have a larger role to play as gains in<br />

productivity, reliability, and significant reductions in cost can be derived.<br />

Let’s take a look at the market situation of logistics service providers in the country.<br />

Revenues generated by the sector reached around $ 17 billion in 2015 and $ 19 billion in<br />

2017. Russia’s third party market is by far the largest in the CIS region, which is collectively<br />

valued more than $ 25 billion. Outsourcing of transportation services takes roughly<br />

of a fifth of market share in Russia. Comparatively, 3pl service providers cover more<br />

than two thirds of the European and almost half of China’s market. There are roughly<br />

4000-6000 logistics companies in Russia. Out of these, only 100 can really be considered<br />

true third party logistics service providers. Some of the big names include Eurosib, Nienshants<br />

Logistics, STS Logistics and a subsidiary of Russia’s railway, RZD Logistics. The<br />

unsaturated nature of the market means international firms are well positioned to progress<br />

in Russia. Firstly due to the fact that 3pl as an industry is a fairly new phenomenon<br />

in post-Soviet Russia, many Russian companies handle transportation in-house. Most<br />

of domestic firms also struggle to meet international service standards, this gives foreign<br />

firms a competitive edge. The fact that the Russian outsourced transport sector is relatively<br />

unorganized creates space for international companies to expand. So, third party<br />

logistics sector in Russia is currently underdeveloped, ready to expand and fertile<br />

ground for international companies to grow their Russian operations.<br />

Photographs: Lead Photo Fotolia<br />

<strong>WORLD</strong> <strong>OF</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong> 9<br />

Turkish Machinery.indd 1 14.08.<strong>2019</strong> 11:01:35

Author: Sushen Doshi,<br />

International Correspondent,<br />

World of Industries<br />

Is China loosing steam or is it gearing up<br />

for the next round of double digit growth?<br />


The “Made in China 2025” plan, technology<br />

upgradation, slowing down of GDP, trade war with<br />

the U.S, Belt and road initiative; China has a lot on its<br />

plate, and all this has immense implications on the<br />

global economy. China’s growth in the coming years<br />

will be much different than that of the of 90s. Xi’s<br />

China is strategically prepared, smart and ready to<br />

compete on any technological front.<br />

In the recent years, economists and experts have been buzzing<br />

about the slowdown of China’s economy. Official statistics placed<br />

real GDP growth at 6.6 % in 2018, the lowest rate since 1990. Various<br />

economic indicators, which track the performance of the economy<br />

by taking into consideration parameters ranging from industrial activity,<br />

purchasing indices, employment figures, sales numbers and<br />

investments in various sectors, all are a proof of dipping trend line in<br />

China’s GDP numbers. Yet, despite the doom and gloom China continues<br />

to rack up one of the most enviable growth rates in the world,<br />

adding more than a trillion dollars each year. The economy is expected<br />

to continue its softening in 2020 as well, with GDP growth forecasted<br />

to be somewhere between 6.0 and 6.2 %. Many companies will<br />

be facing the challenge of quickly adapting or changing their strategies<br />

to slower growth, as it will become extremely harder for corporations<br />

that require higher growth to thrive, or even survive. Survival<br />

will also be difficult for companies that took the growth rates for<br />

granted, and in turn created unsustainable amounts of debts.<br />

Consumption story now, and planning for the future<br />

A series of news reports of multinational as well as domestic companies<br />

reporting drastic drop in sales have created a wave of concern<br />

over the potential of China’s consumption power. But despite<br />

these concerns China still continues to be the best consumer market.<br />

Over the next decade as the per capita income of average Chinese<br />

individuals rise, China’s market will add more than $ 5 trillion,<br />

that’s way more than any other country. Beneath the slowdown lie<br />

changes in the patterns of consumption. Also sharper drops in sales<br />

of individual companies, or even of sales in categories like autos or<br />

cosmetics, does not tell the whole story.<br />

A lot of recent news reports have led many to believe that the<br />

trade spat between the US and China is leading to the current economic<br />

slowdown; this narrative is also convenient for the politicians.<br />

But the truth is China’s slowdown has been consistent since<br />

2015. In 2013, Chinese President Xi Jingping announced the long<br />

term economic reform to shift from a investment driven economy<br />

to consumer driven one. If you understand this blueprint for economic<br />

reform, all the warnings about China’s slowdown or collapse<br />

will be less alarming. China’s reform will shift the economy from<br />

one based on government spending, state-run companies, and<br />

low-cost exports. It moves it toward private investment, entrepreneurial<br />

innovation, and domestic consumption. In order to achieve<br />

this, China has decided to reduce overcapacity in factories, mostly<br />

in steel, cement and other state-owned manufacturing companies.<br />

These companies have been the pillars of its economic growth. But<br />

now many are bloated, ineffective, and unprofitable. The reforms<br />

were aimed to modernize them in order to attract private investors,<br />

but they ended up creating an oversupply of commodities, which<br />

caused the prices to plummet and consequently sabotaged the<br />

privatization efforts. Now China has decided to allow the market to<br />

absorb the stockpile, as a result, China is willing to accept a slower<br />

rate of growth of around 6.5 %. The government will also loosen<br />

price controls on water, electricity and natural resources. So that<br />

these industries can consolidate, grow and become profitable. In<br />

return, they will pay 30 % of earnings as dividends to the government.<br />

Proceeds will be used to fund social security programs by<br />

2020. Which will allow the Chinese people to save less, spend more,<br />

and boost consumption and demand.<br />

Always in focus “Made in China 2025”<br />

Launched in 2015, the “Made in China 2025” strategy aims to modernize<br />

and digitize country’s industrial set up with innovative technologies.<br />

With this strategy China seeks to create innovation-driven development,<br />

smart technologies, pursue green development and increase efforts<br />

to upgrade China from a manufacturer of quantity to one also of<br />

quality. The strategy focuses of 10 key industry sectors: Next-generation<br />

10 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong>

IT, including cyber-security; High-end numerical control tools and robotics,<br />

which are of high importance for China as they help in improving<br />

the manufacturing efficiency as labor costs rise; Aerospace and<br />

aviation equipment, which reflects China’s ambition to be a world leader<br />

in aviation and outer space exploration; hi-tech marine engineering<br />

equipment, as shipping plays a vital role in China’s export driven economy<br />

and also maritime security implications of China’s territorial<br />

claims in South and the East China Sea; Advanced railway equipment,<br />

as China is rapidly connecting regions not only within its territories but<br />

also in the Central Asia; Electric vehicles technology, which highlights<br />

China’s goal to replace traditional fuel vehicles; New generation electrical<br />

power equipment, which are part of China’s implementation of<br />

clean and green power; Agricultural machinery; New materials like<br />

graphene and nano materials; Biomedicine and high-performance<br />

medical devices, which includes China’s development of advanced<br />

chemicals and medical equipment. The Chinese government has so far<br />

invested vast resources, including subsidies and low interest loans to<br />

support domestic hi-tech enterprises and encourage more Chinese<br />

firms to expand overseas and acquire foreign firms with cutting-edge<br />

technologies. The government has also established 5 national manufacturing<br />

innovation centers and 48 provincial manufacturing innovation<br />

centers. By 2025, the number of national manufacturing innovation<br />

centers is set to reach 40. Initial results in some of the sectors have<br />

been positive. Huge advances have been made in large aircraft and engine<br />

manufacturing, semiconductor technologies, new material, and<br />

gas turbine, 5G mobile network equipment and electric vehicles.<br />

Trigger point<br />

One of the factors in the Made in China 2025 policy that has irked<br />

the western industrialized countries is China’s goal to reduce imports<br />

of high-end technologies from the EU and the U.S and replace<br />

it with home grown ones. This initiative has not gone down well<br />

with leaders in the west, as they fear that Beijing’s state-subsidized<br />

industries would get an unfair advantage over foreign firms and<br />

could lead to market distortions. This issue has become one of reasons<br />

for escalation of the trade and tariff war between the US and<br />

China. US President Donald Trump has imposed tariffs on goods<br />

worth $ 300 billion that are imported from the mainland. Tariffs will<br />

especially be levied on products in the 10 key areas identified in the<br />

“Made in China 2025” initiative. Despite advances it has made in<br />

hi-tech industries, China still depends on foreign technology transfer<br />

to push forward its own innovation agenda and next-generation<br />

manufacturing goals. These US tariff measures are hurting the implementation<br />

of China’s 2025 goals, production of industrial robots<br />

in mainland has seen a drop, production of integrated circuits, the<br />

semiconductors that power smartphones, computers and other<br />

electronic devices, as well as high-end industrial and military products,<br />

also fell. Meanwhile, growth in the new-energy car sector,<br />

which has been heavily subsidized by the government, slowed<br />

down from more than 20 to 15 %. Except a few specific industry sectors,<br />

the effect of trade war on the overall Chinese economy has<br />

been more indirect, as it impacts the consumer confidence and<br />

causes private sector companies to rethink before making any decisions<br />

on investing in adding manufacturing capacity in China.<br />

Some manufacturers are considering to shift their production bases<br />

at locations that less politically sensitive. For example, some robotics<br />

makers, have been considering Vietnam and India as a stable<br />

option, hence they have already reduced the capital investment in<br />

China.<br />

Photographs: Lead Photo Fotolia<br />

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<strong>WORLD</strong> <strong>OF</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong> 11

CeMAT Russia: fuelling growth in<br />

Russia’s logistics and transport sector<br />


Russia’s transport and logistics sector is fertile ground<br />

for foreign companies. Opportunities are plentiful<br />

across the length and breadth of the country. Investors<br />

and companies should certainly look to the world’s<br />

biggest nation as their next market for investment or<br />

expansion.<br />

Stretching across 17 million sq. kilometers, Russia is world’s largest<br />

country by size. It’s so huge that it’s geography is both a blessing<br />

and curse. It’s very size demands an extensive transport and logistics<br />

network. In order to cater to its 145 million inhabitants with<br />

all the goods and services, air, sea, road and rail logistics are in high<br />

demand. With over 86,000 kilometers in rail track, a road network<br />

over 1.4 million kilometers, plus numerous airports and seaports,<br />

Russia has a well-established intermodal network hub.<br />

Despite existing transport links, Russia ranks 85 out of 167 countries<br />

in the world bank’s logistics performance index. One of the<br />

reasons for this lackluster performance has been the bleeding of<br />

Russian economy mainly due to sanctions imposed by western<br />

countries and declining oil prices. But since 2016, Russian economy<br />

has been recovering at a steady pace so has been the transport and<br />

logistics sector. Country’s current logistics performance, however,<br />

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

points towards major opportunities for investment, as Russia is in<br />

need of modern technologies and scientific attitude when it comes<br />

to logistics. Domestic suppliers are competing with international<br />

companies to provide comprehensive services, but increasing participation<br />

from international companies will truly help this sector<br />

overcome its challenges.<br />

Considering the infrastructure and logistics competence there is<br />

room for Russia to improve and expand. The Russian transport and<br />

logistics market potential is estimated to be around $ 150 billion.<br />

Warehouses equipped with new technologies, modernized cargo<br />

handling facilities at ports, new airports, railway hubs and logistics<br />

centers are needed to satisfy the country’s rising demand. Foreign<br />

firms are positioned better than domestic ones to play a major role<br />

in development of Russia’s logistics sector. Due to a lack of competitiveness<br />

in domestic operators, foreign logistics businesses<br />

have already been invited for investment – often in the form of tieups,<br />

joint ventures or operational co-operation. Overseas investors<br />

and companies with interest, experience and skills are injecting<br />

large amounts into transport and logistics sector. For example,<br />

Dubai’s DP World, global port infrastructure and management specialists,<br />

inked a deal with the Russia Direct Investment Fund. The<br />

$ 2 billion investment is mainly targeted at enhancing Russia’s port<br />

infrastructure networks. Other foreign firms, such as DHL or Finnish<br />

company Itella Russia, are already well established in the market.<br />

Technological advantages, plus efficient operations and experience,<br />

puts international brands at a significant advantage. Russian<br />

government has welcomed these dynamic, cost-effective transport<br />

and logistics solutions, so international operators should look at the<br />

bigger opportunities present in Russia.<br />

12 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong>

01 At Cemat, visitors can find latest products and technologies,<br />

exchange ideas and get clarity in-order to make sound decisions<br />

Moscow’s prestigious Crocus Expo hosts the 10th edition of CeMAT<br />

Russia - the international exhibition for materials handling, warehousing<br />

equipment and logistic. This 3 day event is set be held from<br />

24th to 26th September <strong>2019</strong>, and is an ideal platform to interact<br />

and engage with leading companies from Russia’s logistics sector.<br />

CeMAT Russia provides a exceptional prospect to create new potential<br />

customers as industry professionals and managers from<br />

small and medium-sized enterprises to large corporations attend<br />

this event. CeMAT also assists in cultivating new relationships, creating<br />

new networks and catching up existing customers to gain insight<br />

and stay updated with the latest developments and requirements<br />

of end users. Interest in the event among Russian<br />

organizations has been steadily increasing with number of visitors<br />

increasing from 4,500 to 5,500 within two years. A large chunk of<br />

visitors were from the retail and wholesale segment, followed by<br />

cargo transportation and warehousing services, warehousing<br />

equipment, industrial goods production, consumer goods production<br />

including food, beverages, pharmaceuticals etc. Taking a look<br />

at the numbers of past years, most of the visitors placed their interest<br />

in lifting and handling equipment, rack and storage systems,<br />

warehouse management and automation equipment, packaging<br />

and order picking equipment, conveyors, lifting and handling<br />

equipment etc.<br />

The event, organized by one of the world leaders in exhibition industry<br />

– Germany’s Deutsche Messe RUS, is supported by various<br />

industry associations and the state as well as federal government of<br />

Russia. Deutsche Messe’s extensive market and industry knowledge<br />

along with international experience makes this business event<br />

of a truly global standard. Every year at the fairgrounds, organizers<br />

host a series interactive sessions which involves exchange of ideas,<br />

in depth discussions on important issues faced by the industry and<br />

understanding the upcoming trends in the market. Just like the<br />

manufacturing industry, the future of transportation and logistics<br />

also has new driving forces like digitalization, tectonic shifts in international<br />

trade, emergence of software driven and machine driven<br />

processes etc. Many decision makers and managers are concerned<br />

about how exactly will these changes affect them, what will<br />

be level of investment and which products and systems to choose<br />

for their operations, queries about integration of new systems with<br />

existing ones, all these questions will be answered on the floor of<br />

CeMAT, by interacting with experts, professionals, and manufacturers<br />

in Moscow. In 2017 and 2018, the forum discussions included<br />

topics like digital transformation of logistics; hardware or software?,<br />

rise of big data, drones, IoT, cloud technologies, AI, AR in logistics<br />

and intralogistics, developing successful strategies in the e-commerce<br />

era, warehouses of the future: design or reconstruction? etc.<br />

Product categories at CeMAT Russia<br />

CeMAT Russia <strong>2019</strong><br />

At CeMAT Russia, you can find the products with emphasis on functionality<br />

and innovative technologies in the movement and lifting<br />

of goods area, products that offer the right combination of cost-effectiveness,<br />

maximum usability and smooth movement and handling<br />

of materials. The Move & Lift section of the trade fair has on<br />

display industrial trucks, forklifts and its accessories, vertical lifting<br />

equipment and platforms, scissor lifts, escalators, cranes, hoists,<br />

mechanical handling equipment, monorails, remotely operated<br />

transportation systems, shelf storage & retrieval equipment, power<br />

and drive technology components, hydraulics, pneumatics and<br />

conveyor systems, complete supply chain management solutions,<br />

complete robotic handling systems and port related logistics equipment.<br />

The Store & Load section of the trade fair features automated<br />

systems designed to increase productivity, and reach maximum capacity.<br />

Visitors can find automated guided vehicles, conveyor systems<br />

that require extremely low drive energy, apps for storage planning,<br />

storage shelf systems, factory and workshop equipments,<br />

pallets, bins and containers, industrial doors & gates, cleaning facilities<br />

for warehouses, loading bridges and ramps, transfer bridges,<br />

loading systems for bulk goods and containers, and complete logistics<br />

service packages. The Manage & Service section of the trade fair<br />

will give you an excellent overview of all the logistics services now<br />

available for managing today’s challenges. This includes transport<br />

financing models, logistics planning, traffic control systems, integrated<br />

traffic systems, real estate & sites for logistics operations. Logistics<br />

IT is the technology zone dedicated to professional logistics<br />

software and systems. The focus here is on innovative IT solutions<br />

for production logistics, commercial logistics, cloud computing and<br />

mobile logistics applications in the warehouse. This section of Ce-<br />

MAT Russia features e-logistics services, intralogistics systems &<br />

software, computer & control systems, control technology & sensors,<br />

identification technology, Auto ID/RFID etc. In 2017, Russian<br />

e-commerce sector was valued at $ 16 billion and is set reach $ 25<br />

billion in the coming few years. E-commerce in Russia is only set to<br />

keep expanding. At CeMAT Russia, the Pick & Pack exhibition area<br />

focuses on latest packaging technology for warehouses, packaging<br />

and order picking systems, labelling and identification systems,<br />

measuring and dispensing units, and various kinds of packaging<br />

materials.<br />

Photographs: Lead Photo Fotolia, Deutsche Messe AG<br />

www.cemat-russia.ru/en<br />

<strong>WORLD</strong> <strong>OF</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong> 13

Experience the changing dynamics<br />

of China’s industries at IAS Shanghai<br />

Shanghai has been the engine of China’s growth over<br />

the last two decades. The city has grown from a mere<br />

fishing village to a hub of manufacturing, innovation,<br />

finance and culture. Given the magnitude of<br />

manufacturing activity in and around the city, it is an<br />

obvious choice for a top quality industrial exhibition<br />

of the international standards like the IAS Shanghai.<br />

Every year in September, Shanghai witnesses a large number of<br />

visitors coming in from Japan, South Korea, Germany, Italy,<br />

America, Switzerland, France, Austria, Britain, Israel, Singapore<br />

and India. What is so special about Shanghai in September?<br />

Month of September marks the beginning of autumn and end of<br />

summer, so the temperature still lingers on the higher side, but as<br />

days pass it starts to get cooler and cooler. Apart from changing<br />

weather, September plays host to multiple industrial trade fairs of<br />

international caliber. A wide range of trade fair venues, conference<br />

facilities along with its well-established transport system<br />


Author: Sushen Doshi,<br />

International correspondent<br />

for World of Industries<br />

14 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong>

make Shanghai a great business destination. Industrial Automation<br />

Show (IAS) Shanghai, is one such blockbuster event which<br />

the industrial community can’t miss out on. One of the world<br />

leaders in industrial goods trade fairs, Deutsche Messe AG, along<br />

with Hannover Milano Fairs Shanghai Ltd., organizes the Industrial<br />

Automation Show (IAS) Shanghai every September. This year<br />

the show is to be held from 17 th - 21 st September. The prestigious<br />

fair grounds of National Exhibition and Convention Center in<br />

Shanghai offer a display area of more than 70,000 m 2 for over 600<br />

exhibitor companies. This five-day show brings in close to 200,000<br />

trade visitors from home and abroad. Over the years, the popularity<br />

of IAS has seen a sharp rise not only in China but also around<br />

Asia. In 2018, more than 60 % of the exhibitors were from outside<br />

China, these figures represent the dominant market position this<br />

event holds amongst all of Asia’s industrial automation trade fairs.<br />

Along with IAS, the venue also co-hosts the Metalworking and<br />

CNC Machine Tool Show (MWCS) and the Energy show. MWCS<br />

is a leading international trade fair for the entire metal working<br />

sector in southeast China, focusing mainly on machine tools,<br />

sheet metal, pipes and tubes, mould and die construction etc. The<br />

energy show is an international exhibition on electrical power<br />

generation and distribution technologies.<br />

The exhibitors list at the Industrial Automation Show has a strong<br />

representation from the reputed German companies and global<br />

market leaders like Siemens, Bosch, Pheonix Contact, Mitsubishi<br />

Electric, Omron, Delta, Turck, Festo, Beckhoff, National Instruments,<br />

B&R, Lenze, Ritttal, Balluff, Wago, Pepperl+Fuchs, IFM, Sick,<br />

Harting, Baumer, Pilz, Hiwin, Nord and many more. Many of these<br />

organizations use this platform to make product launches and<br />

showcase their cutting-edge technologies. Innovation driven companies<br />

take this opportunities to display their capabilities in the<br />

field of industry 4.0 and smart manufacturing.<br />

<strong>WORLD</strong> <strong>OF</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong> 15

Product Category at IAS Shanghai<br />


The display areas at the trade fair is divided into respective sectors<br />

like production and process automation, electrical systems, robotics,<br />

industrial IT & software. The production and process automation<br />

area consists of exhibitors showcasing a vast array of products<br />

and systems ranging from PLC, scada, industrial PCs, control systems,<br />

embedded systems, assembly & handling technology, linear<br />

positioning systems, data capturing and identification systems, industrial<br />

image processing systems, sensors and actuators, communication<br />

networks and field bus systems, measuring and test systems,<br />

laser technology and compressed air generation equipments<br />

etc. The electrical systems category consists of electrical power<br />

transmission systems including transformers, accumulators and<br />

UPS, electric switchgear and equipment for electrical control systems,<br />

electric and electronic test and measuring equipment, electric<br />

motors & frequency inverters, motor drives, cables & cabling<br />

accessories, electronic and opto-electronic components, apart<br />

from electrical power generation companies also exhibit mechanical<br />

power and drive transmission systems as well. As China undergoes<br />

industrial transformation, more and more organizations are<br />

focusing on integration of IT and software systems. Choosing the<br />

right industrial IT and software systems for your industrial sector<br />

can be quite a complicated task. Before finalizing any of the products<br />

decision makers need to understand all the functionalities and<br />

also anticipate any possible problems that can arise with integration<br />

of new systems with the existing ones. Thus visiting the industrial<br />

automation IT and software segment of IAS Shanghai proves to<br />

be of immense importance for the decision makers and interested<br />

buyers, as it helps in understanding the utility and also complexity<br />

of the systems they are interested in. With detailed on-site discussions,<br />

buyers can also assess the technical competency and after<br />

sales support of various manufacturers and service providers all<br />

under one roof, thus making it easier for them to finalize the right<br />

product that suits the needs and requirement of their respective<br />

manufacturing processes. The IAS Shanghai has on display products<br />

like production and manufacturing software, systems and development<br />

tools for industry, internet, intranet and extranet solutions,<br />

industrial IT hardware. Visitors can also meet professionals<br />

and consultancies that play host to comprehensive IT services to<br />

maximize the benefits of software products.<br />

China’s special bond with industrial robotics<br />

In the last five years, China has become a dominant player in the<br />

field of robotics. According to the data from International federation<br />

of Robotics (IFR), In 2008, China’s stock of operational industrial<br />

robots was around 32,000, by 2016, this number had reached<br />

near 340,000, and in fact it is expected to witness a 15-20 % rise till<br />

2020. The main drivers of the growth are the automobile, electrical<br />

and electronics industry. Major contract manufacturers of electronic<br />

devices have already started to automate production. The semiconductor<br />

and the chip industries, for example, have strongly invested<br />

in automation. Large battery production facilities are being<br />

installed to meet the increasing demand for electric and hybrid<br />

cars. Automotive industry is one of the most a powerful drivers for<br />

industrial robot sales. China has become both the world’s largest<br />

car market and the world’s largest producer of cars – including electric<br />

cars – with much growth potential. Sales to China made up 25 %<br />

of the global supply of industrial robots to the automotive industry<br />

in 2016. Between 2011 and 2016, more than 100,000 units were installed,<br />

representing an average increase of 18 % per year. China is<br />

the largest growing consumer market with increasing demands for<br />

all kinds of consumer goods. Consequently, various other industries<br />

have also started to expand capacities and automate production.<br />

Over the next decade, there is no downside to this sector as the<br />

penetration of robots in China’s manufacturing set up is set to increase<br />

tremendously. At IAS Shanghai, the robotics display area will<br />

showcase the latest industrial robots, servo control, human-machine<br />

interaction techniques, robot vision and intelligent speech,<br />

robot simulation system, service robots, machinery, appliances &<br />

components for robotic products.<br />

One important reason why IAS Shanghai is one of the favorite<br />

events amongst automation professionals is the business culture of<br />

the host city. Shanghai has been the epicenter of technology startups<br />

in the last few years. The pace of growth of tech start-ups has<br />

been frightening. Unlike any other cosmopolitan city, Shanghai’s<br />

ability to rapidly reach mass scale is unparalleled. The city boasts an<br />

unending supply of highly skilled human resources with immense<br />

technological capabilities, increasing levels of foreign investment,<br />

large supplier base and ever improving research and development<br />

activities. Shanghai is also a major tourist destination, as it attracts<br />

a wide range of tourists due to its vibrant culture, nature, and modern<br />

infrastructure.<br />

Photographs: Lead Photo Fotolia, other Carmen Nawrath, Nicole Steinicke<br />

www.industrial-automation-show.com/EN<br />

16 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong>

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At the right place<br />

at the right time<br />


The system integrator Beumer Group installed its<br />

flexible and modular warehouse control system (WCS)<br />

at the new European Logistics Centre (ELC) of the<br />

Polish automotive parts supplier Inter Cars S. A. near<br />

Warsaw. This system controls the complete material<br />

flow from inbound to outbound in real time: picking,<br />

packaging and shipment are coordinated, throughput<br />

is optimized and costs are reduced. The products reach<br />

the right place in the desired time within the<br />

distribution center.<br />

Inter Cars is a leading distributor of spare parts for cars, vans and<br />

trucks in Central and Eastern Europe. The company, headquartered<br />

in Poland, has several hundred subsidiaries and branches<br />

spread all across the Baltic states and the Balkans. In addition, there<br />

is a nationwide network of approximately a thousand workshops.<br />

Until the end of 2016, the logistics center was located in Czosnów.<br />

From here, the goods were distributed to the smaller distribution<br />

centers in Europe, which on their side supplied the workshops and<br />

the customers. However, the quantity of spare parts to be stored and<br />

dispatched exceeded the capacities of the logistics center. The managers<br />

decided on a new automated European Logistics Centre in<br />

Zakroczym, approx. 30 km from Warsaw. The in-house logistics<br />

provider ILS was commissioned as general contractor − “and this is<br />

how we got involved as system supplier of intralogistics solutions”,<br />

says Sandra Lückmann. Sandra Lückmann is business development<br />

manager at Beumer Group in Beckum, Germany, and was<br />

responsible for the successful handling of this order. “As a system<br />

integrator, we not only designed and installed the entire conveyor,<br />

picking and sorting technology, but also our flexible WCS.” It integrates<br />

and controls the material flows including inbound, quality<br />

assurance, picking and shipping.<br />

Adaptable WCS<br />

In May 2017, the ELC went into operation. There, the Beumer WCS<br />

serves as link between the warehouse management system (WMS)<br />

of the owner and the entire material flow equipment. “While developing<br />

this software solution we did not focus on adapting the processes<br />

of the customer to our WCS, but we adapted our system<br />

project-related to the respective customer requirements”, explains<br />

Lückmann. Therefore it has a modular design. It controls the packing<br />

sorter and the shipping sorter as well as the pick-to-light system<br />

in the inbound area, coordinates the automatic supply and application<br />

of the shipping labels and supports the routing of the individual<br />

items on the conveyor lines. “This route planning optimizes the<br />

performance of the system and controls the distribution of the different<br />

types of spare parts, depending on the requirements”, says<br />

Lückmann. “The WCS ensures the optimal route of the goods.”<br />

The new European Logistics Centre currently stores around 7<br />

million pieces like spark plugs, brake disks, V-belts, batteries, but<br />

also more bulky parts, like exhausts and hoods. The complex is<br />

comprised of four buildings, the largest one with 30,000 square meters,<br />

ten meters in height. It is equipped with a four-story shelving<br />

rack. The other warehouses have a surface of 5,000 square meters<br />

each. They store tyres and hazardous material, such as oils and varnishes,<br />

that must be kept separate for reasons of fire safety.<br />

The employees use their hand-held scanner, where the company’s<br />

warehouse management system indicates which goods have to<br />

be commissioned in batches. The products are divided into different<br />

clusters, similar to clothing sizes into S, M, XL and XXL, depending<br />

on dimension and weight. The totes filled with S and M<br />

parts are placed on a roller conveyor which forwards them automatically<br />

to the packing sorter, the Beumer BS7 Belt Tray Sorter.<br />

18 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong>

There are currently stores around 7 million of pieces in Zakroczym like<br />

spark plugs, brake disks, V-belts, batteries, but also exhausts and hoods<br />

interface to the machine control”, describes Lückmann. “BG Fusion<br />

combines machine and system data, enabling the responsible employee<br />

to trace the order status in real time.”<br />

Task fulfilled, project successfully completed<br />

“This system achieves a throughput of approximately 14,000 parts<br />

per hour”, says Lückmann. “However, with presorting, it manages a<br />

throughput of approx. 27,500, almost twice as much.” Depending<br />

on the content, the WCS also distributes the incoming totes to one<br />

of three induction areas where the employees take the items out of<br />

the tote, identify them using matrix camera and place them on the<br />

sorter.<br />

“The WCS plays a crucial role in this project. After all, exactly this<br />

solution ensures that all spare parts within the European Logistics<br />

Centre are in the right place at the right time”, Lückmann explains.<br />

Beumer Group has completely fulfilled the targets requested by the<br />

customer. In addition, to be able to concentrate fully on its core<br />

business, ILS has also transferred the maintenance and servicing of<br />

the system to Beumer Group. Employees of Beumer Group are on<br />

site around the clock. As part of the residential service they take<br />

over responsibility for availability of machines and systems. The<br />

Beumer Group employees also perform preventive maintenance<br />

work. The team carries out maintenance and inspection work on<br />

the systems at defined intervals, checks the safety devices, electrical<br />

and control components as well as automation technology. And<br />

they can perform repairs that might be necessary in case of an unscheduled<br />

failure of components.<br />

Photographs: Beumer Group<br />

www.beumergroup.com<br />

WCS distinguishes between “light” and “heavy”<br />

In order to ensure a gentle handling of the goods and prevent packaging<br />

from getting damaged, the engineers of Beumer Group have<br />

divided the destinations of the packing sorter in two parts. If the<br />

spare part weighs up to 1.4 kilogram, the WCS classifies it as “light”,<br />

up to six kilogram as “heavy”. According to this classification, the<br />

software assigns the goods to the left or to the right side of the destination<br />

when picking the order, enabling the employee to place the<br />

heavy goods in the tote or the cardboard box first, then the light<br />

ones.<br />

The XL goods from the main storage however are so large that<br />

only one item fits in one totes. Therefore the WCS does not forward<br />

them to the packing sorter but directly to the consolidation area via<br />

the roller conveyors. Together with the goods from the other buildings,<br />

such as tyres and hazardous materials, as well as the products<br />

coming from the packing sorter, the orders are combined into shipping<br />

units. These are weighed in the Quality Assurance and compared<br />

with the target weight, closed, labelled and then strapped.<br />

Now, the WCS guides them over the roller conveyors to the connected<br />

shipping sorter that distributes the consolidated orders<br />

according to delivery routes at a capacity of 2,500 totes per hour.<br />

If spare parts are returned, they are checked by the employees. If<br />

the spare parts are ok, the employee enters them in the system and<br />

sends them back to the warehouse.<br />

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

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

Small Elektrokleinmotoren electric motors according bis 200 Watt to customer nach Kundenwunsch requirements.<br />

Clear overview of all processes<br />

Fortschritt hat unser Tempo<br />

Besides the modules which control the material flow, Beumer’s<br />

own BG Fusion tool is also in use. This visual display system offers<br />

the user a web-enabled user interface for configuration, control<br />

and reporting. It displays system data as alarms in a uniform and<br />

centralized way and shows status messages, fault messages and all<br />

relevant data. “The entire system status can be supervised via the<br />

Unsere modularen Elektro-Kleinmotoren und Getriebe ASTRO bauen Motoren wir GmbH in Millionen & Co. KG<br />

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www.astro-motoren.de<br />

<strong>WORLD</strong> <strong>OF</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong> 19<br />

ASTRO.indd 1 25.03.<strong>2019</strong> 13:05:23

Geared motors: Test area<br />

examines drive units thoroughly<br />

Conveyors in large intralogistics<br />

applications or baggage handling<br />

systems often have lengths of several<br />

kilometres. Such complex systems are<br />

powered by hundreds of geared motors. Experts<br />

from Nord Drivesystems gather precise knowledge<br />

about the behaviour and control of drive technology<br />

in an application test area in Bargteheide, Germany.<br />

There, new products and technologies are also tested.<br />


How do geared motors behave in practice? What conclusions<br />

about the service life and maintenance of a drive unit can be<br />

drawn from the operating data of a frequency inverter? Where does<br />

further optimisation need to be made to a new drive concept? To<br />

provide customers with optimally tailored products and innovative<br />

service concepts Nord Drivesystems seeks the answers to these<br />

questions in its own test area. The test system consists of an oval<br />

conveyor belt with rising and falling sections, as well as a bypass<br />

section with input and discharge points from the main route. The<br />

individual conveyor belts are driven by various types of Nord geared<br />

motors and frequency inverters. The fifteen drive units are networked<br />

with standard interfaces and can be monitored through the<br />

web. The frequency inverters and motor starters are controlled via a<br />

Profinet bus, but the Nord Drivesystems drive technology can also<br />

handle all other common bus systems.<br />

Industry 4.0: Drive data in the cloud<br />

As with all Nord drive units, the drive units in the application test<br />

area are fully Industry 4.0 ready. They regularly transmit their status<br />

data such as current consumption, speed and voltage via the bus<br />

cable using the UDP communication protocol, without affecting<br />

the control communication. To keep the data volume as low as<br />

possible only the values which have changed since the last transmission<br />

are sent. The status data are transmitted via an Internet<br />

gateway to a secure cloud, where they are available for further<br />

analysis and evaluation. Fault conditions and drive overload can be<br />

visualised and detected. In addition, status data can be evaluated<br />

for energy management and remote maintenance.<br />

Another important aim is to develop and provide economical<br />

concepts for web-based condition monitoring and predictive maintenance<br />

for smaller geared motors which are used in large numbers<br />

in intralogistics applications. For these systems, additional physical<br />

real sensors, such as those which are used for condition monitoring<br />

in industrial gear units are often too expensive. Virtual sensors i.e.<br />

pre-processing of internal status data enable determination of oil<br />

temperature and oil ageing for predictive maintenance without the<br />

use of physical sensors. NORD is currently working intensively on<br />

solutions for status monitoring with the aid of virtual sensors. For<br />

this, we use all of the facilities of our own application test area.<br />

20 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong>

01 02 03<br />

Obtaining qualified insights<br />

Further application data such as the data from connected sensors<br />

and actuators can be saved in the cloud at any time. Among other<br />

things, Nord Drivesystems has equipped the drives in the test area<br />

with encoders, in order to obtain deeper insights into the actual<br />

behaviour of the drives. By inserting a heavy object onto the running<br />

belt, dynamic properties are required in order to achieve the required<br />

torque. By means of the encoder, it can for example be determined<br />

whether the geared motors can provide the planned acceleration in<br />

reality with larger loads on the conveyor belt and actually meet the<br />

customer’s requirements. At the same time, Nord determines<br />

relationships and dependencies on ambient conditions in real use,<br />

which cannot be obtained with purely test bed operation under<br />

standardised conditions – valuable know-how for providing advice,<br />

troubleshooting and maintenance on the customer’s premises.<br />

Target and actual comparison with algorithms<br />

By means of light barriers on the conveyor belts in the application<br />

test area, the frequency inverter detects whether there is a load on its<br />

conveyor belt. If no load is present, it measures the electrical data<br />

and compares these values with a reference value. If this is exceeded,<br />

the inverter detects that something has changed in the mechanical<br />

system. This can be caused by increased friction, wear, a damaged<br />

bearing or gear unit or a trapped foreign body. By comparing<br />

the virtually determined status data with real measurements,<br />

mathematical relationships can be derived for the system and data<br />

evaluation algorithms can be validated and improved. Stresses to<br />

the system due to continuous operation or frequent starting and<br />

braking can be determined. The question of what information can<br />

be derived from the measured values with the aid of algorithms and<br />

how this can be utilised for predictive maintenance is tested in<br />

practice by Nord Drivesystems together with pilot customers.<br />

01 Intralogistics solutions such as the Nordac Link field distributor are<br />

fully Industry 4.0 ready and can transmit important drive status data for<br />

predictive maintenance concepts into the cloud<br />

02 In the application test area, drive experts from Nord Drivesystems<br />

obtain deeper insights into the actual behaviour of drive units in practical<br />

use via encoders and light barriers<br />

03 The status and operating data of the example system can be<br />

analysed and evaluated in the cloud and clearly visualised in a<br />

web-based browser view<br />

Realistic simulation of conveyor applications<br />

The objective is to be able to determine the normal current and load<br />

values for the customer’s installation during a learning phase. In<br />

future operation, algorithms will monitor whether all operating<br />

parameters are within the normal range. Calculation models which<br />

are produced with the aid of the application test area also help Nord<br />

Drivesystems in the planning of customers’ projects: The characteristics<br />

of a conveyor belt can be simulated on the basis of a mathematical<br />

model. Parameters such as belt friction or the inertia of the<br />

belt are known. Together with the values from practical tests in the<br />

application test area, a conveyor system can be simulated with<br />

adequate precision in order to provide the customer with more<br />

precise design recommendations than would be possible with<br />

merely the planned performance parameters. This avoids expensive<br />

over-engineering. Of course, the test area is also used as an illustrative<br />

demonstration to customers for the topic of Industry 4.0. Thanks<br />

to the link to the cloud, the application test area can also be demonstrated<br />

at exhibitions and on-site visits throughout the world.<br />

www.nord.com<br />

<strong>WORLD</strong> <strong>OF</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong> 21

Cool solution<br />

to a hot issue<br />


The transport of bulk materials makes heavy demands<br />

of the drive system, because belts and drives are<br />

mostly subjected to rough ambient conditions. The<br />

premium gear unit manufacturer Flender has in its<br />

portfolio three standard gear unit series based on<br />

helical- and bevel-helical gear units. In particular it<br />

succeeded in ramping up the increasingly important<br />

thermal rating by something like a further 20 per cent.<br />

The world’s population is growing – and with it the need to be able<br />

to produce valuable minerals and other resources as efficiently as<br />

possible. Against this background bulk-material conveyor technology<br />

is further gaining in importance, so that an unmistakable trend<br />

towards higher transport performances is becoming apparent. The<br />

big challenge is to develop economical drive solutions to this problem.<br />

Anyone manufacturing conveyor belts for worldwide operation<br />

in partly inhospitable environments knows what heavy demands<br />

Mother Nature makes. As well as efficiency and quality, the thermal<br />

rating is decisive. Flender is therefore applying its decades of Knowhow<br />

to developing gear unit solutions that, firstly, deliver lower power<br />

losses and, secondly, can transmit high power outputs. B3SE gear<br />

units meet this requirement without the need for external cooling.<br />

These come in ten standard unit sizes and can be used for drive tasks<br />

with very high power requirements – including as multiple drives.<br />

Up to 3,000 kW without external cooling<br />

The latest generation of these helical- and bevel-helical gear units<br />

whose market launch Flender is pressing ahead with on a broad<br />

scale in <strong>2019</strong> shows what is at all possible. Up to a range of between<br />

2,500 kW and 3,000 kW, depending on ambient conditions and gear<br />

unit design, external cooling systems can be dispensed with. The<br />

reason for the unusually high thermal rating of these gear units is a<br />

further increase in efficiency and heat dissipation.<br />

Just the extension of the housing surface in conjunction with the<br />

redesign of the air guide cover featuring a fan that is independent of<br />

the direction of rotation ensures something like 20 per cent more<br />

heat dissipation. On top of this come optimizations of gear unit design<br />

for reduction of power loss, so enabling torques of up to 490,000<br />

Nm to be standardly transmitted with the B3SEs. The result is that in<br />

practice there are situations where because of the high thermal rating<br />

of the new gear units one unit size smaller than before can be<br />

selected. If the mechanical system permits, users also profit from<br />

this technically and economically improved solution.<br />

Test rig confirms theory and practice<br />

Simple as the result sounds, the development of the new B3SE gear<br />

units is still pragmatic in detail. For this purpose Flender has invested<br />

in a high-performance test rig that intensively supports its<br />

own research and development department. It enables gear unit<br />

solutions with a rated mechanical output of up to 2,000 kW to be<br />

tested under actual practical conditions. Gear units are analyzed on<br />

it thermally, resulting in real detailed improvements in the case of<br />

the new B3SE gear units.<br />

At the same time a test rig of this kind provides the basis for testing<br />

calculation and simulation programs used in gear unit and<br />

drive solutions for consistency of theory and practice. In this respect,<br />

too, users profit from the gear unit manufacturer’s decades of<br />

experience. Because the huge standard modular gear unit system<br />

enables gear unit experts to carry out application-specific adaptations,<br />

so offering users the big advantage of short delivery times.<br />

The high level of standardization further underscores the servicefriendliness<br />

of Flender’s gear unit solutions.<br />

02 The compact gear units of<br />

the A series constructed can, as<br />

plug & play solutions, be operated<br />

flexibly and conveniently.<br />

01 Flender’s new B3SE helical- and<br />

bevel-gear gear units have been<br />

further-optimized to enable an up<br />

to 22 per cent higher thermal rating.<br />

22 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong> Advertisement

Easy gear unit selection thanks to<br />

electronic assistance<br />

An example of further benefit in combination with software is<br />

Flender’s new swing-base configurator by which complete drive<br />

trains can be configured in the same way as integrated drive systems.<br />

The gear unit manufacturer is thus underscoring its core expertise<br />

as a gear unit constructor and drive specialist. Electric motor,<br />

coupling, gear unit, cooling systems, supports – all must be<br />

perfectly coordinated. Starting theoretically from the conveyor belt<br />

project, users can with the help of the software select from Flender’s<br />

different modular product kits or standard portfolio and so use the<br />

German gear unit manufacturer’s Know-how to realize their own<br />

ideas. The decisive advantage: total technical drive solutions can be<br />

developed fast and be incorporated into users’ own engineering designs<br />

with the help of 3D data and dimensioned drawings.<br />

B3SE gear units described here form just one of many solutions<br />

in the Flender repertoire, which is extremely extensive, standardized<br />

and optimized to meet specific applications. Basically three<br />

series are distinguished for equipping bulk-material conveyor belts<br />

with drives. Alongside the new conveyor belt drives of the E series,<br />

which operate satisfactorily without external cooling, even in especially<br />

hostile environmental conditions, there is the extremely compact<br />

A series as well as the high-performance gear unit solutions of<br />

the H series generating torques of up to 1.4 million Nm and outputs<br />

of up to 4,500 kW. Common to all of these is that users profit qualitatively<br />

from decades of experience and because of this premium<br />

manufacturer’s high level of in-house production even project-specific<br />

designs are also rapidly possible.<br />

From compact plug & play through to<br />

high-performance system solutions<br />

Wherever space is tight, that is where the A series, with its biggest<br />

feature, its compact overall design, really comes into play. After all,<br />

not every mine offers enough space for complicated measuring,<br />

alignment and fitting work. This gear unit solution, comprising a<br />

motor, a coupling and a gear unit, is delivered ready to fit and need<br />

not be laboriously aligned on site. The reason for a plug & play of this<br />

kind is the patented self-aligning system thanks to which the gear<br />

unit is very easy to handle. It need only be plugged in and the torque<br />

then be absorbed by a torque arm. In short: flexibility with regard to<br />

location, fitting, available space and commissioning is the common<br />

denominator that had priority during development of the A series.<br />

By comparison, the H gear unit series for highest possible outputs<br />

and torques is being developed very application-specifically on the<br />

basis of standard component parts. 28 unit sizes here offer the economic<br />

and technical flexibility for putting together the total package<br />

04 As a specialist in<br />

gear unit construction<br />

and drive technology,<br />

Flender concentrates<br />

intensively on developing<br />

the latest high-performance<br />

solutions.<br />

03 The standard drive solution of<br />

the H series was developed for maximum<br />

outputs of up to 1.4 mill. Nm or<br />

5,000 kW.<br />

Great prices are waiting<br />

for you!<br />

For the bulk materials segment, premium<br />

gear manufacturer Flender has three standard<br />

series in its portfolio based on helical and<br />

bevel-helical gear units. Would you like more information<br />

about the Flender innovation and at the same time win great<br />

prices? Nothing easier than that! Scan the following QR code<br />

or enter www.flender-gewinnspiel.de in your browser - and<br />

you will be ready to start our lottery - good luck!<br />

project-specifically. Here, too, the wide standard range in conjunction<br />

with Flender’s great experience gives valuable support. Because,<br />

as well as the gear units and couplings, the company also<br />

builds the cooling systems itself. This has the advantage for users<br />

that during the project-specific design of a total solution not only in<br />

the area of gear units and gear teeth and during torque transmission<br />

but also during thermal adaptation further optimizations can be undertaken.<br />

Conveyor belts function not infrequently in tropical heat<br />

or Siberian cold, so perfectly coordinated total solutions are one of<br />

the most important prerequisites for the necessarily high availability<br />

of bulk-material conveyor belts. On top of this air- or water-type oil<br />

cooling systems open up the possibility of individual pressure lubrication<br />

for high-speed rolling bearings or for heavily loaded gear<br />

teeth and/or of a cleverly designed oil management system.<br />

Plug & play also plays an important role in the H series, so enabling<br />

the complete drive solutions to be fitted on base frames, designed<br />

by Flender project-specifically and delivered ready to fit. The<br />

standard portfolio for application-specific drive solutions that<br />

Flender can deliver anywhere in the world is extremely comprehensive<br />

and so one of the company’s important unique selling propositions:<br />

Cooling and heating systems, add-on flywheel masses, braking<br />

systems, special air filters, auxiliary drives, backstops, couplings<br />

with and without torque limitation, special shaft sealing systems to<br />

prevent abrasion damage in dust-laden ambiences, measuring systems,<br />

condition monitoring – and much, much more.<br />

Conveyor systems profit from experience, qualityconsciousness,<br />

in-house production level<br />

The German Bocholt-based gear unit manufacturer Flender’s aim is<br />

to bring its decades of experience in gear unit construction into line<br />

with users’ industry knowledge. Continuous detail improvements<br />

and continuous optimization of the standard modular gear unit<br />

system form the framework which users all over the world profit<br />

from. It is precisely in the case of bulk-material conveyor systems<br />

that are mostly exposed to harsh ambient conditions that highquality<br />

and perfectly designed drive solutions show positive effects<br />

in the area of performance capability, availability and servicefriendliness.<br />

The new E series of conveyor belt drives fitted with high-efficiency<br />

cooling systems and so improved thermal characteristics shows<br />

yet again what is possible. Complementarily to this conveyor technology<br />

profits from the compact standard gear units of the A series<br />

and H series for maximum drive outputs of up to 4,500 kW. This<br />

means in practice that users can choose from a huge range of standard<br />

solutions and so plan their projects conveniently. More still,<br />

for requirements that go beyond the normal there are specialists in<br />

Bocholt that also supply project-specific answers.<br />

Photographs: Flender<br />

www.flender.com/conveyorbeltdrives<br />

Advertisement <strong>WORLD</strong> <strong>OF</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong> 23

Challenges for cable manufacturers<br />

in the factory of the future<br />


Today, manufacturing is hardly conceivable<br />

without industrial robots and their areas of use<br />

are increasing continuously. But due to the<br />

permanent three-dimensional movements in<br />

the automated factory, the cables that supply<br />

the robot are subjected to extreme levels of<br />

stress. A special challenge for manufacturers<br />

of cables and connecting components.<br />

The International Federation of Robotics (IFR) predicts that by<br />

2020 more than 1.7 million industrial robots will be working in<br />

factories worldwide. A huge worldwide market for robot manufacturers.<br />

To ensure that robots are supplied with data and energy<br />

without any interruption, it is worth taking a look at the cables that<br />

have to “go along with” the 3D movement of robots, which are on<br />

the move continuously. Robot cables for applications where the<br />

cables are subjected to torsional stress have to be constructed and<br />

manufactured in a completely different way to cables for linear motion.<br />

They must be as compact and as closely braided as possible<br />

and have an outer jacket extruded at high pressure. The reason that<br />

this is important is because this special “hardness” enables the cable<br />

to follow the motion pattern of the energy chain.<br />

24 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong>

Robot cables have to withstand several million<br />

movements<br />

Robot cables, in contrast, need force-compensating elements, loose<br />

braiding elements, different slip planes and completely different<br />

shield concepts in order to ensure they continue to function<br />

correctly even after several million movements involving torsional<br />

stress. This is because the cables used in robot technology have to<br />

repeatedly change the directions in which they move. For example,<br />

the diameter of the braid structure can actually change with torsion<br />

angle. Cable specialist igus incorporates damping elements and<br />

torsional-force absorbing felt into the core groups, which are<br />

specially designed for use in applications involving continuous<br />

changes in torsional stress, in order to offset the forces acting on the<br />

cores. The requirements for the shielded cable types are especially<br />

high. In order to ensure that the forces acting on the shield wires are<br />

not too large, the motion plastics specialist places gliding elements<br />

above and below the shields. These elements ensure that the shield<br />

can move freely in relation to the overall braiding as well as the outer<br />

jacket. The shield structure is designed for force redistribution<br />

and has damping elements in the direction of that force redistribution.<br />

This “soft” mode of construction gives the entire cable the necessary<br />

freedom of movement, reduces tensile and compressive<br />

forces, and preventing shutdown of a machine due to a premature<br />

conductor breakage.<br />

Optimum protection with the energy chain<br />

On the basis of know-how gained over more than 50-years of experience<br />

in this area, the jacket materials have been optimally<br />

matched to the plastic of the triflex R robot energy chain, reducing<br />

abrasion and wear to a minimum. The triflex R TRCF is a closed<br />

energy tube based on the three-chamber principle: all three chambers<br />

of the TRCF can be opened and closed independently of each<br />

other. The supply hose is placed in one of the three chambers of the<br />

energy tube and is therefore protected against deformation. This<br />

makes the energy supply process reliable whatever the axial<br />

position of the robot is.<br />

The main feature that ensures reliable and operationally safe<br />

guidance of robot cables and hoses is compliance with the minimum<br />

bending radii. If the latter are not adhered to, there is a risk of<br />

cost-intensive plant failures. The technical design of the igus triflex<br />

R ensures that the prescribed minimum bending radius is adhered<br />

to whatever may be the working position of the robot - a circumfer-<br />

02<br />

01 The technical design of the igus triflex R ensures that the<br />

prescribed minimum bending radius is adhered to whatever<br />

may be the working position of the robot<br />

02 In the 3,800 square metre test laboratory, cables are<br />

tested extensively with 2 billion test cycles per year<br />

03 The jacket materials have been optimally matched to the<br />

plastic of the triflex R robot energy chain, reducing abrasion<br />

and wear to a minimum<br />

01<br />

03<br />

<strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong> 25


ential outer stop prevents bending<br />

below the minimum bending radius.<br />

Moreover, the modular design of the<br />

igus triflex R ensures that a torsion<br />

angle of approx. +-10° per chain link is<br />

not exceeded. This has the advantage<br />

that the torsional stress on the cables is<br />

distributed along their whole length and<br />

not only at one end, which is the case with<br />

other systems. The defined minimum bending<br />

radius of the triflex R robot energy supply<br />

system guarantees process reliability especially in robot applications<br />

with supply hoses as well as in the case of flow punch bolting.<br />

This is because a kink in the supply hose interrupts the power<br />

supplied to the screws on the tool and the process is disrupted.<br />

Tests offer plannable reliability and reduce costs<br />

„Chainflex Ethernet cable CFRobot8.Plus tackles<br />

15 million torsional movements up to 360 degrees<br />

and offers fast data transmission to 6-axis robots.“<br />

Igus has been repeatedly setting new standards for more than<br />

25 years with its range of “chainflex” moving cables in the areas of<br />

automation and robot technology. It is regarded in the industry as a<br />

leading company for special cables, available from stock, for<br />

continuous motion in applications involving energy chains and<br />

torsional stress. igus has a 3,800 square metre test laboratory, the<br />

world’s largest lab for dynamic cables. Here, igus twists the chainflex<br />

CFRobot cables millions of times while continuously measuring<br />

core resistance in different test set-ups. The undoubtedly greatest<br />

challenge in the tests is that it is difficult to reproduce every<br />

conceivable application that involves torsion over the service life of<br />

the product. Whereas the service life limits can be dependably<br />

predicted in the case of linear travel in energy chains due to fixed<br />

parameters and known ambient-influences, robot applications are<br />

usually much more complex. In particular, the sequence of movements<br />

per se is often not completely clear during the planning<br />

phase. For the cable supplier, it is therefore of prime importance to<br />

test, test and test again.<br />

Mechanical engineering processes<br />

can be precisely planned<br />

All the results of the tests are recorded in a database at igus. This –<br />

together with a decades-long experience in the area of plastics<br />

technology – enables igus to give a 36-month guarantee on the<br />

mechanical specifications of the chainflex cables. As a result, the<br />

mechanical engineering processes can be precisely planned. If a<br />

CFRobot cable failed when used for the purpose described in the<br />

catalogue, igus would supply a new cable immediately and free of<br />

charge. Users can order cables of one metre and longer and the<br />

goods will then be delivered within 24 hours. The great advantage of<br />

the CFRobot series for robot manufacturers and users is that they do<br />

not have to depend on expensive, special cables with long delivery<br />

times but can simply select from a standard range of products which<br />

has been specially developed for torsion applications and includes<br />

over 100 types of robot cables all available from stock.<br />

Industry 4.0 gets trouble-free motion<br />

The “smart plastics” from igus provide a glimpse into the near future<br />

of robotic cables. Under the name isense, igus carries sensors of<br />

various kinds that detect the condition of igus components such as<br />

cables or energy chains. They measure among other things the wear<br />

during the operation and alert the user early enough to plan repair<br />

or replacement. By networking with the icom communication module,<br />

the data is transmitted to an intelligent system. The module<br />

can be connected to all igus specific sensors. Once the measured<br />

values from a sensor have been transferred to the icom module,<br />

they have to be “interpreted”, i.e. understood in order to generate<br />

instructions from the same. So far, this has been possible via the<br />

connection to the igus cloud.<br />

Due to the increasing importance of IT security, however, many<br />

companies are increasingly relying on the development of their<br />

own Scada-systems, which is why igus has now advanced its data<br />

concentrator into icom.plus. With the new module, the customer<br />

can integrate the data in the way that best suits their equipment.<br />

With the online connection of the icom.plus, a continuous matching<br />

of the service life statement with the igus cloud takes place in<br />

order to enable maximum system runtimes with minimal failure<br />

risk. The data in the cloud draws on the 10 billion test cycles of<br />

energy chains and cables performed in the company’s own<br />

3,800 square metre test laboratory, and thanks to machine learning<br />

and AI, igus can provide precise information on the durability of the<br />

solutions used and inform the user about a necessary replacement<br />

beforehand.<br />

Photographs: igus<br />

www.igus.com<br />

04 Robot cables for applications<br />

where the cables are subjected to<br />

torsional stress need force-compensating<br />

elements, loose braiding<br />

elements, different slip planes<br />

26 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong>

Barley malt producer increases productivity<br />

with smart condition monitoring<br />

Muntons, one of the UK’s largest producers of malted<br />

barley protect vital parts of their production process<br />

against unscheduled downtime by using the Smart<br />

Condition Monitoring (SCM) system from Mitsubishi<br />

Electric.<br />

Used to make beer, spirits and a range of popular foodstuffs, malted<br />

barley is produced in large batches where environmental conditions<br />

are critical to a consistent product. Each batch is very valuable,<br />

not just in monetary terms but also to the customer, so<br />

Muntons is extremely pro-active when it comes to the servicing and<br />

maintenance of its equipment.<br />

As in many food industries, the principles of the barley malting<br />

process are quite traditional, but Muntons relies heavily on automation,<br />

electro-mechanical equipment and sensors to provide fine<br />

control over air flow, heat and moisture. Fans and motors are critical<br />

to the operation: the Muntons processes many tonnes of product<br />

at a time, with key operations relying on a steady supply of<br />

blown air. The chosen SCM installation provides condition monitoring<br />

for two large 315 kW fan sets and a single 90 kW fan set. Sensors<br />

monitor the electric motor, power transmission coupling and<br />

main fan shaft bearing on each fan set.<br />

„The investment in automation and<br />

predictive maintenance pays off very quickly<br />

by avoiding unscheduled downtime.“<br />

Plant Engineer Michael Plawecki says: “We now have a clear picture<br />

of the health of the fan sets and advance warning of any required<br />

maintenance. Remote monitoring and fast diagnosis of any issues<br />

has also made us very responsive should the limits on operating parameters<br />

that we have set be approached. As promised the system<br />

was easy to install and relatively simple to commission.”<br />

Early diagnosis avoids machine failures<br />

The impetus for the SCM installation came from issues previously<br />

experienced with difficult-to-reach bearings inside a large fan<br />

housing. A bearing failure inside a fan assembly caught the Muntons<br />

engineering team unawares, and proved significant in terms of<br />

downtime. “We only realised we had problems when it was too late,<br />

and we had to make an unscheduled stop on one of the lines to<br />

make repairs,” says Plawecki. Determined to learn from that lesson,<br />

Muntons looked for a monitoring solution with predictive maintenance<br />

technology that could be linked into the company’s existing<br />

Scada system.<br />

Concept of smart condition monitoring<br />

The SCM solution provided by Mitsubishi Electric comprises smart<br />

sensors that can be attached to bearing housings, gearboxes, pumps<br />

and motors to detect when equipment starts to operate outside its<br />

normal envelope due to wear. It provides a sophisticated early<br />

warning system for critical pieces of rotating plant equipment.<br />

Vibration frequencies and temperature readouts are monitored<br />

continuously and fed back to an L Series Mitsubishi Electric PLC via<br />

an industrial Ethernet network cable. The PLC offers simple integration<br />

to other network system hardware and software platforms,<br />

in this case integrating seamlessly with the Scada system at Muntons<br />

Malt.<br />

Sensors monitor changes in the complex vibration<br />

patterns<br />

The sensors, developed by bearing expert FAG, monitor for changes<br />

in the complex vibration patterns specific to the type of equipment<br />

it is attached to. The software compares that data with highly developed<br />

data models from thousands of previous installations, providing<br />

an effective analysis and alert system for the user.<br />

Live information and any alarms are displayed on a Mitsubishi<br />

Electric GOT Series HMI mounted to the control enclosure. The system<br />

can work autonomously of any other automation, with multiple<br />

sensors located and recognised by unique IP addresses. At Muntons,<br />

the visual information and the alarms being generated were easily<br />

connected into the existing automation software platform.<br />

Photographs: Mitsubishi Electric Europe B.V.<br />

eu3a.mitsubishielectric.com/fa<br />

<strong>WORLD</strong> <strong>OF</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong> 27

The DNA of the Industrial<br />

Internet of Things<br />

Single Pair Ethernet - or SPE for short - is currently one<br />

of the mega-trends in industrial data transmission.<br />

If you want to understand the applications and<br />

advantages of reducing data cabling to a single wire<br />

pair, you must learn about the history of Ethernet<br />

and industrial automation.<br />


As a non-standardized software protocol, Ethernet was developed<br />

in the 1970s for the internal and locally limited transmission<br />

of data packets in wired computer networks (LAN - Local Area<br />

Network). The Institute of Electrical and Electronics Engineers<br />

(IEEE) defined the software protocol and the physical layer - including<br />

physical interfaces such as connectors and cables - in the<br />

following two decades and laid the foundation for the modern Internet<br />

with the introduction of various protocols such as 802.4 (Token<br />

Bus), 802.5 (Token Ring) and finally 802.11 (WLAN).<br />

Common language<br />

Parallel to this, fieldbus technology developed in the 1980s, driven<br />

by the increased use of electrical automation technology. The basic<br />

idea was the same: Different communication participants should<br />

communicate with each other in an orderly manner and in a common<br />

system. However, the various fieldbus protocols, such as Interbus,<br />

DeviceNet and Profibus, were not used for networking computers<br />

at company level, but for serial or parallel connection of<br />

sensors and actuators to the control and management level.<br />

Ultimately, the parallel development of the two transmission<br />

protocols established the form of the automation pyramid that is<br />

still valid today. The highest levels represent locally limited computer<br />

networks which are used for rough and detailed production<br />

planning. The lower levels comprise the signal, data and power<br />

transmission for recording, controlling and regulating the physical<br />

production process (Fig. 1).<br />

The shape of the pyramid resulted primarily from the hierarchical-logical<br />

arrangement of the different levels. However, it also rep-<br />

Author: Dipl.-Wirt.-Ing. Verena Neuhaus, Manager Product Marketing<br />

Data Connectors, Phoenix Contact GmbH & Co. KG, Blomberg, Germany<br />

resents the previously valid framework conditions for industrial<br />

data transmission: High transmission rates and short distances via<br />

Ethernet, low transmission rates and long distances via fieldbus.<br />

Turned upside down<br />

So why this digression? Industrial Ethernet and especially Single<br />

Pair Ethernet are turning this automation pyramid upside down.<br />

With the development of Ethernet-based protocols such as Ether-<br />

Net/IP, Profinet or EtherCAT, real-time data transmission from the<br />

company level to the field level was introduced.<br />

The physical interfaces became more powerful, but also more<br />

complex in electrical terms, since data transmission had to be protected<br />

from interference such as dirt, vibrations and electromagnetic<br />

radiation. Manufacturers of connection technology therefore<br />

developed special, IP6x-protected Ethernet interfaces to meet these<br />

increased requirements at the field level. For the top of the automation<br />

pyramid - the enterprise and operational level - IP20 solutions<br />

were still sufficient.<br />

Data transmission to the second power<br />

So far, standardization efforts have been limited to ever higher data<br />

rates and higher demands on cabling technology. These requirements<br />

were defined by ever higher performance classes in copperbased<br />

cabling - the Categories.<br />

The Single Pair Ethernet does not again define higher bandwidths<br />

or transmission distances, but forms the normative framework for<br />

reduced cabling to suit the application. The IEC 63171-2 (IP20) and<br />

IEC 63171-5 (IP67) standards focus on lower transmission rates of<br />

10 to 100 Mbps. The data cabling with only one pair of wires nevertheless<br />

enables transmission distances of up to 1000 meters. Thus,<br />

for the first time, SPE allows areas of application and applications<br />

that conventional Ethernet has not allowed to date, for example in<br />

28 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong>

02 Efficiently wired: Single-pair and<br />

four-pair MICE interfaces are used for<br />

cabling IP20 and IP6x applications<br />

01 Paradigm shift: SPE turns the conventional<br />

automation pyramid upside down<br />

From the sensor up to the cloud<br />

Single Pair Ethernet (SPE) connects the IP20 world of the<br />

enterprise and operating level with the IP6x world of the<br />

control and field level – and thus opens up new areas of<br />

application. The goal is the seamless connection of all<br />

communication participants on the basis of the same<br />

protocol language and uniform interfaces. Thanks to the<br />

reduced cabling with only one or four individual wire pairs,<br />

users can build efficient network and cabling structures<br />

from the sensor to the control and company level right<br />

up to the cloud. And in addition to data rates of up to<br />

1000 Mbps, the SPE cabling also allows the end devices<br />

to be supplied with power of up to 60 watts.<br />

process technology. The advantage for plant operators: data cabling<br />

can be carried out continuously on the basis of the Ethernet protocol,<br />

i.e. identical interfaces and pin connector patterns can be used<br />

in different environments.<br />

Another advantage is that single-pair interfaces are considerably<br />

more compact than two- or four-pair device and cable connectors.<br />

SPE thus supports the continuing trend towards compact, decentralized<br />

devices in industrial automation, process technology,<br />

building automation and in telecommunications and infrastructure<br />

applications. SPE can thus turn application-neutral into the<br />

DNA of the Industrial Internet of Things (IIoT).<br />

New pin connector pattern, well-known reliability<br />

In order to ensure the consistent compatibility of all interfaces, the<br />

IEEE has formed working groups for the normative description of<br />

different applications with transmission rates of 10, 100 and 1000<br />

Mbps. Standards for 100-Base-T1 and 1000-Base-T1 have already<br />

been adopted, with 10-Base-T1 standards expected to follow by the<br />

third quarter of <strong>2019</strong>.<br />

Phoenix Contact is a major driving force behind the standardization<br />

of the corresponding interfaces. Together with market partners<br />

Reichle & De-Massari, Weidmüller, Fluke Networks and Belden, the<br />

connection technology specialist develops protected and unprotected<br />

pin connector patterns for single-pair and four-pair cables.<br />

The MICE model describes their mechanical robustness (M1 or<br />

M2/3), IP protection (I1 or I2/3), chemical and climatic resistance<br />

(C1 or C2/3), and electromagnetic safety (E1 or E2/3) (Fig. 2).<br />

The compact pin connector patterns are ideally suited for efficient<br />

cabling of numerous communication participants - either via<br />

a single wire pair or via four wire pairs for four participants sharing<br />

a common line and interface. Thanks to the common interface,<br />

single- and four-pair cabling concepts can be mixed as well as IP20<br />

and IP6x solutions. Possible applications are the splitting of eightwire<br />

cabling concepts into four individual SPE strings for four different<br />

communication participants, or the dimensioning of individual<br />

pairs within the eight-wire device interfaces. The two-wire<br />

technology also permits the application-specific supply of terminal<br />

devices with outputs of up to 60 watts via the same pair of wires<br />

(Power over Data Line - PoDL).<br />

The future of communication technology<br />

SPE cannot be seen as a mega-trend in industrial data transmission<br />

independent of other standardization efforts. The basic framework<br />

for the future of industrial communication technology is being created<br />

in parallel in various committees and projects. New communication<br />

standards such as the Open Platform Communications Unified<br />

Architecture (OPC UA), Time-Sensitive Networking (TSN) and<br />

5G form the basis for continuous networking from the sensor via<br />

the machine and higher-level systems into the cloud.<br />

The new standards will outperform existing protocols and interfaces<br />

in terms of cost, data throughput, latency and deterministics.<br />

As a technology leader with more than 30 years of experience in industrial<br />

communication, Phoenix Contact is thus active in all the<br />

relevant standardization committees. The goal: nothing less than a<br />

new, manufacturer-independent communication standard for automation.<br />

Today, OPC UA already serves as a superimposed communication<br />

standard in plants. OPC UA is now being expanded by standardized<br />

application profiles in the field - for I/O, safety or drive<br />

applications, for example. In addition, standardized device models<br />

are defined for uniform configuration and diagnostics of the devices<br />

in the network.<br />

Photographs: Phoenix Contact<br />

www.phoenixcontact.com<br />

<strong>WORLD</strong> <strong>OF</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong> 29

A bridge<br />

between two worlds<br />

More and more industrial processes are going digital.<br />

It is now also the turn of level measurement with float<br />

switches. A float switch for this purpose features a<br />

semiconductor sensor. This form of limit level monitoring<br />

represents a decisive step towards Industry 4.0.<br />


Virtually no machine or plant manages without them: millions of<br />

float switches are employed to monitor liquid levels every single<br />

year. They are reliable, simple and robust. Float switches consist of<br />

only a few components, which is partly why they are the most economical<br />

measuring principle for this type of task. They are mainly<br />

used to monitor limit levels and respond if a critical level is reached.<br />

Float switches protect against overflow or dry running. This functionality<br />

is stipulated for certain tank plants, for example by the<br />

German Water Resources Act, to prevent overfilling or leakage of<br />

the medium into the groundwater. In industrial applications, float<br />

switches monitor limit levels as a precautionary measure: pumps as<br />

well as hydraulic or lubrication systems are supplied with the right<br />

media on demand or switched off in good time if they run dry, so<br />

that no damage can occur, e.g. due to overheating.<br />

As effective as necessary, as easy as possible<br />

The float switch principle is as simple as it is effective: a float with a builtin<br />

magnet moves on a guide tube according to the liquid level in a vessel<br />

or tank. At defined measuring points it operates hermetically sealed<br />

reed contacts with a normally open, normally closed or change-over<br />

function. These mechanical switch contacts are energised by the float’s<br />

magnetic field. The switching operation is contact-free and hence also<br />

potential-free. Another advantage of this type of measuring instrument<br />

is that the float switch can be adapted to the density of the medium in<br />

the tank, so that there is no influence on measuring accuracy.<br />

The design and operating principle of conventional float switches –<br />

including all their positive features – have now been incorporated<br />

into the digital version. The new GLS-1000 switch type from Wika replaces<br />

the classic reed contact with a semiconductor sensor which,<br />

once again, is activated by the magnetic field of the float magnet. This<br />

results in a measurable resistance change, which is detected and processed<br />

by the electronics, so that an electrical switching signal is<br />

tripped in the same way as with a conventional float switch.<br />

The digital signal via the PNP / NPN switching output offers an<br />

unlimited number of switching cycles. Since no mechanical switching<br />

contact is used, the sensor is free from wear and thus extremely<br />

durable within its operating limits.<br />

Like their conventional equivalents, digital float switches represent<br />

a reliable and economical solution. Similar to a classic float<br />

switch, the GLS-1000 can be provided with up to four switch points.<br />

It has an optional temperature output which can be used, for instance,<br />

as a Pt100 / Pt1000 resistance thermometer for monitoring<br />

the temperature of the medium. Since the external design and<br />

geometry of the device are identical, mechanical float switches are<br />

very easy to replace with digital ones.<br />

Automating the manufacturing processes<br />

of tomorrow<br />

The extremely reliable switching function and built-in long service<br />

life are not the only arguments for choosing the new switch. Thanks<br />

30 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong>

to its digital signal processing capabilities,<br />

02 Float switch for industrial applications with<br />

the GLS-1000 is an ideal component for circular connector M12 x 1 and cylindrical float<br />

automating the manufacturing processes<br />

of tomorrow. Depending on the model, it 03 GLS-1000 float switch in a tank<br />

can in future be integrated into appropriately<br />

automated machine and plant controls,<br />

for example using IO-Link 1.1. This is currently<br />

only possible with much more expensive level<br />

measuring technologies like guided microwave,<br />

ultrasound or vibration limit switches. Moreover, the<br />

advanced electronics open the door for additional functionalities such as<br />

internal diagnostic capabilities, sensor parameterising options or an<br />

operational status display.<br />

Conclusion<br />

01 Float switch for industrial applications<br />

with cable outlet and float from Buna<br />

02<br />

03<br />

With their PNP / NPN switching output signals, long service life and excellent<br />

resistance to shock and vibration, float switches with semiconductor<br />

sensors provide access to new applications in the field of limit level monitoring.<br />

Smarter sensors capable of collecting additional diagnostic and<br />

measured data will ensure that in the future, too, float switches are the<br />

solution of choice for integration into highly automated processes. At the<br />

same time, semiconductor float switches are extremely economical compared<br />

to other digital solutions. Yet in spite of this, they are by no means<br />

the beginning of the end for tried-and-tested reed contact switches.<br />

Owing to their proven reliability, classic float switches will continue to be<br />

a good alternative for many applications in tomorrow’s world where the<br />

benefits of mechanical switching are decisive – such as potential-free<br />

switching or safe isolation of circuits and cables.<br />

01<br />

Photographs: Wika Alexander Wiegand SE & Co. KG, Germany<br />


A taste of the future of industry<br />

The great promise of new connected concepts of<br />

industry like Industrie 4.0 is their ability to deliver a<br />

historically unparalleled level of responsiveness and<br />

flexibility. While modern supply chains are already<br />

heavily integrated and designed to be fluid and fast<br />

moving, a large swathe of manufacturing still remains<br />

beholden to economies of scale, large production runs,<br />

and careful preplanning.<br />

The Industrial Internet of Things is set to change this by allowing<br />

small-batch or even custom manufacturing on a truly industrial<br />

scale. With machines whose functions are not set in stone, but flexible<br />

and determined by their operating software and with a new form of<br />

connectivity bringing industrial engineers, product manufacturers,<br />

and end users closer together than ever before, ad-hoc adjustments to<br />

e.g. automotive parts during active product runs or the bespoke manufacturing<br />

of custom sneakers become very viable options indeed.<br />

Much of this remains a theoretical vision, but IUNO, the German<br />

national reference project for IT security in Industry 4.0, demonstrates<br />

the new capabilities in action with a secure technology data<br />

marketplace running a smart drinks mixer.<br />

The solution<br />

The IUNO demonstrator consists<br />

of two ends to the simulated supply<br />

chain: The technological data<br />

marketplace, where inventors of<br />

drinks can upload the recipes, and<br />

a cocktail mixing machine, which<br />

is connected to the marketplace<br />

and can license the encrypted<br />

recipes. The system uses Wibu-<br />

Systems’ cloud-based CodeMeter<br />

License Central to protect the<br />

recipes, the production data that<br />

acts as a currency in this smart<br />

production network, with full<br />

encryption both when it is sent to<br />

the mixer and when the drink is made in the machine itself – whose<br />

inner workings are again secured with a CodeMeter dongle as anchor<br />

of trust and dependable proof of identity, powered by Infineon’s SLM<br />

97 security controller. On the front end, the drinks are mixed and<br />

ready for the buyer to enjoy.<br />

The results<br />

The IUNO demonstrator is a template for a secure technology data<br />

marketplace that is both fully protected with Wibu-Systems’ solutions<br />

and open enough to accommodate additional actors and vendors,<br />

the IUNO cocktail mixing machine becomes a model for a new paradigm<br />

in manufacturing. Where vertical integration once meant<br />

physical control and ownership over every link in the supply chain, it<br />

can now mean the integration of independent partners. Like the<br />

recipes, production data can be traded, licensed, and securely transported<br />

through the Industrial Internet to smart factories that offer<br />

manufacturing as a service. This creates new commercial freedom<br />

and access for sellers, buyers, and makers, all of whom can rest<br />

assured that their data is protected from theft, illicit use by more<br />

unscrupulous partners in the supply chain, or tampering along the way<br />

with the power of CodeMeter’s licensing and protection capabilities.<br />

A chance to see smart custom manufacturing<br />

in action<br />

The future of industry is connected, intelligent, responsive, and customized.<br />

With concepts like Industrie 4.0, we have a roadmap and a<br />

vision to follow. The protocols for machine communication and new<br />

HMI interfaces are available<br />

and continue to be refined.<br />

From the new data infrastructure<br />

to the industrial<br />

machines on the ground,<br />

the hardware is being<br />

rolled out, in upgraded<br />

and retrofitted brownfield<br />

installations or completely<br />

new greenfield sites.<br />

Industrial engineers and<br />

the operators of their<br />

products on the ground<br />

have also begun to take<br />

the threat of cyber-crimi-<br />


32 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> <strong>2019</strong>

A high-tech drinks mixer showcases how a secure technology data marketplace can work as the front end<br />

of a smart, connected, and fully secured and licensed supply chain<br />

nality seriously and are investing in protection and licensing<br />

capabilities. Still, the opportunities to truly experience the Industrial<br />

Internet of Things and smart factories in action are few and far<br />

between. IUNO, the German national reference project for IT security<br />

in Industrie 4.0, is set to change this with a show-stopping technology<br />

demonstrator: a high-tech drinks mixer that showcases how<br />

a secure technology data marketplace can work as the front end of a<br />

smart, connected, and fully secured and licensed supply chain.<br />

The role of a cloud solution for license<br />

management<br />

Developed in a multivendor project partnership including the<br />

IUNO members Wibu-Systems and Trumpf, the drinks mixer<br />

works by combining a technology data marketplace – a repository<br />

of drinks that would-be vendors can add their favorite recipes to<br />

– with a secure data transmission concept and similarly protected<br />

front-end hardware. With a selection of recipes at the customer’s<br />

disposal, the drinks are chosen from the custommade sales platform<br />

at https://iuno.axoom.cloud and paid for by Testnet Bitcoin.<br />

Once the customer has made his or her selection and the Bitcoin<br />

transaction has been processed, the technology marketplace<br />

sends the order for the right recipe in fully encrypted form to the<br />

physical mixer, using Wibu-Systems’ CodeMeter License Central,<br />

the cloud solution for license management, to do the heavy lifting<br />

of encrypting, licensing, and securing the operation. In the mixer<br />

itself, a CodeMeter dongle provides an anchor of trust for the protected<br />

operating software of the mixer and for the mixer’s correct<br />

identity in its transaction with the IUNO marketplace, using an<br />

industry-grade Infineon SLM 97 security controller. At no stage in<br />

the supply chain can the recipe be read out or tampered with,<br />

neither in the cloud marketplace nor in its transmission or in the<br />

mixer itself.<br />

On top of protecting the IP in the recipes, the CodeMeter technology<br />

is used to enforce the licensing for each recipe. Only the<br />

paid number of items (drinks in this case) can be produced. The<br />

encrypted recipe is worthless without the corresponding license<br />

which defines the amount of goods allowed for production. As in<br />

more regular manufacturing operations, the manufacturer of the<br />

technology (the mixer) and the vendor of the product (the recipe)<br />

– who could be one and the same or separate entities – can rest<br />

assured that their intellectual property is safe and sound.<br />

The customer on the front end sees little of the intricate software<br />

and hardware that goes into making his or her drink of choice.<br />

Whatever drink the customer goes for, one thing is certain: the end<br />

result is more than a refreshing beverage. It is a taste of the future of<br />

industry.<br />

Photographs: Wibu-Systems<br />

www.wibu.com<br />

Access to marketplaces and ownership over<br />

data are becoming the gatekeepers for<br />

participation in Industrie 4.0 – but neither<br />

can function without the level of protection<br />

afforded by Wibu-Systems’ cloud-based<br />

technology.<br />

Oliver Winzenried, CEO,<br />

Wibu-Systems AG<br />

<strong>WORLD</strong> <strong>OF</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong> 33

Smooth and trouble-free<br />

With its clutches, couplings and brakes, mayr<br />

power transmission offers complete solutions from<br />

a single source – for the reliable protection of machine tools<br />

and machining centres. For example, a wide spectrum of<br />

backlash-free, high-performance servo couplings provides<br />

a secure connection between the shafts. mayr power<br />

transmission has developed a wide portfolio of reliable safety<br />

brakes specifically for the safeguarding of gravity-loaded axes.<br />

This is because hanging loads represent a substantial risk<br />

potential in machines and systems. Picture: backlash-free,<br />

flexible Roba-ES<br />

elastomer coupling (left)<br />

and Roba-topstop, the<br />

modular safety brake<br />

system (right).<br />

www.mayr.com<br />

Solution for real-time thermal analysis<br />

The high performance Flir A6750 MWIR camera offers short<br />

exposure times and high-speed windowed frame rates,<br />

making it an ideal choice for recording rapid thermal events<br />

and fast-moving targets. Freeze motion or achieve accurate<br />

temperature measurements on moving subjects, and perform<br />

a variety of non-destructive testing with this cooled InSb<br />

camera. The 327, 680 (640 x 512) pixel IR resolution and high<br />

sensitivity produce crisp imagery, well suited to electronics<br />

inspections, medical thermography,<br />

and more. The camera<br />

is plug-and-play with third-party<br />

software, and works seamlessly<br />

with Flir ResearchIR for intuitive<br />

viewing, recording, and advanced<br />

processing of thermal data.<br />

www.flir.com<br />

Machine learning for control systems<br />

Beckhoff now offers a machine learning (ML) solution that<br />

is seamlessly integrated into TwinCAT 3 software. Building<br />

on established standards, TwinCAT 3 Machine Learning<br />

brings to ML applications the advantages of system openness<br />

familiar from PC-based control. In addition, the TwinCAT<br />

solution supports machine learning in real-time, allowing it<br />

to handle even demanding tasks like motion control. These<br />

capabilities provide machine builders and manufacturers<br />

with an optimum foundation to enhance machine performance,<br />

e.g. through prescriptive maintenance and process<br />

self-optimisation. Picture:<br />

With TwinCAT 3 software,<br />

experts can tap into new<br />

machine learning and deep<br />

learning possibilities.<br />

www.beckhoff.com<br />

Launch of laser thru-beam sensors<br />

With the new laser thru-beam sensor series HG-T, Panasonic<br />

launches an easy-to-use and customer-friendly laser<br />

measurement systems with many features and is responding<br />

to the needs of the market. The HG-T sensors work like optical<br />

micrometers that can precisely measure µm even over large<br />

distances. A laser belt with a width of 10 mm allows the<br />

high-precision monitoring of wide webs, for example in the<br />

printing industry. The laser measurement system consists of<br />

a controller and a sensor head<br />

with an emitter and a receiver.<br />

The controller offers many preset<br />

functions such as edge detection,<br />

diameter measuring, or<br />

measuring of transparent<br />

objects.<br />

www.panasonic-electric-works.com<br />


Editorial board:<br />

Winfried Bauer (Editor-in-chief), E-mail: w.bauer@vfmz.de<br />

Peter Becker (Editor-in-chief), E-mail: p.becker@vfmz.de<br />

Nicole Steinicke (Editor-in-chief), E-mail: s.steinicke@vfmz.de<br />

Manfred Weber, E-mail: m.weber@vfmz.de<br />

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Managing editor:<br />

Winfried Bauer<br />

Assistant editors:<br />

Petra Weidt, Melanie Lerch, Angelina Haas, Ulla Winter<br />

Design/Layout:<br />

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

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Correspondent India: Sushen Haresh Doshi M.Sc.<br />

Advertising sales director:<br />

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Oliver Jennen, E-mail: o.jennen@vfmz.de<br />

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34 <strong>WORLD</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong>

Digital future must<br />

be actively shaped<br />

Today, supply chains are complex and global networks<br />

that can increasingly only be handled through<br />

digitalisation. Intralogistics as a cross-sectional<br />

discipline is gaining in importance and occupies key<br />

positions in many areas.<br />

Because the more transparent the digital flow of information, the<br />

smoother the actual physical transport of materials runs – and<br />

that equally in a smart factory or in a modern warehouse. Therefore,<br />

the future of the industry can only lie in networked solutions and<br />

digital services. The major drivers worldwide are still the automotive<br />

industry and the rapidly growing e-commerce sector. Like<br />

other industries, they depend on smooth and highly adaptable processes.<br />

Automation in this context is not a new, but still important<br />

keyword.<br />

In the past, automation was primarily an issue for large companies<br />

with a high proportion of standardized processes. Today, the<br />

massively increased computing power and increasingly intelligent<br />

technologies and components are opening the way to automation<br />

even for smaller companies – with the necessary flexibility at manageable<br />

costs and justifiable effort.<br />

Regardless of the customer industry – everywhere there are farreaching<br />

changes that have to be mapped and implemented in the<br />

logistics processes. For suppliers of intralogistics and materials<br />

handling systems, this means actively shaping the step towards Industrie<br />

4.0 and consistently moving forward. They offer the customer<br />

individual solutions with which he can shape his path to a smart<br />

factory or a smart warehouse.<br />

This is important because the next paradigm shift in the industry<br />

is already in sight: Automation will become autonomy in the future.<br />

Dr. Klaus-Dieter Rosenbach, Chairman of the Executive Board of VDMA<br />

Materials Handling and Intralogistics<br />

The goal are intralogistics systems, capable of networking autonomously,<br />

controlling and optimizing their own operations. However,<br />

intensive research and development work is still needed here.<br />

Communication standards are a large work package. In the industrial<br />

environment, OPC UA is the main winner in this context.<br />

Therefore, intralogistics is also working on the first Companion<br />

Specifications - an exciting development that will give the industry<br />

and its solutions many interesting impulses in the coming years.<br />

<strong>WORLD</strong> <strong>OF</strong> <strong>OF</strong> <strong>INDUSTRIES</strong> 4/<strong>2019</strong> 35


<strong>WORLD</strong>WIDE<br />





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