WORLD OF INDUSTRIES 2/2020

www.world-of-industries.com 

Double hoist unit solution 

provides additional flexibility 

and improves handling rates 

in cooperation with

SOME THINK 

DELIVERY ERRORS 

ARE INEVITABLE. 

WE THINK 

DIFFERENT. 

2 WORLD OF INDUSTRIES 2019 1/2020 

beumer.com

EDITORIAL 

Digitalization has 

long been in everyday 

industrial use 

Dear readers, 

The World of Industries editorial team often wonder what will be the 

largest challenge industrial companies face in coming years. As can 

be expected, there is currently a lot of uncertainty with regard to the 

long-term effects of SARS-CoV-2. However our research and surveys 

repeatedly tell us that the effects of the pandemic are not considered a 

major challenge for future business, neither is climate change or trade 

wars. Instead, managers in industrial companies believe technological 

changes in the context of digitalization is the main challenge they 

are facing. 

The editorial team was rather surprised by these results and believes 

they should be considered with a certain amount of skepticism. In 

this issue, we will therefore focus on digitalization technologies that 

have been successfully implemented in the industrial sector for a long 

time: A digital market to supply spare parts, decentralized data 

management as part of the Industrial Internet of Things, high-performance 

milling machines that are fit for Industry 4.0. 

These are just a few examples of a digitalized reality that is already 

being implemented. I believe the uncertainty around this subject is 

due to the fact that many decision makers have the latent feeling that 

digitalization measures in their own company are inadequate and are 

never really complete because they are always 

focusing on a type of “digitalization standard”. 

However, it must be noted that the actual number 

of measures is not significant. The deciding factor 

is to consider which types of data collection or 

networking measures are sensible for your own 

company and how large quantities of data are 

processed in a productive way. 

Let yourself be inspired while reading the 

current issue. 

Manfred Weber 

m.weber@vfmz.de 

Editorial board: 

Winfried Bauer (Editor-in-chief), 

E-mail: w.bauer@vfmz.de 

Nicole Steinicke (Editor-in-chief), 

E-mail: s.steinicke@vfmz.de 

Manfred Weber, 

E-mail: m.weber@vfmz.de 

Managing editor: 

Winfried Bauer 

Assistant editors: 

Petra Weidt, Melanie Lerch, Angelina Haas, 

Ulla Winter, Doris Buchenau 

Design/Layout: 

Anna Schätzlein, Sonja Daniel, 

Anette Fröder, Mario Wüst 

E-paper designer: 

Anna Schätzlein 

Publishing house: 

Vereinigte Fachverlage GmbH 

Lise-Meitner-Str. 2, 55129 Mainz, Germany 

Commercial register No.: 

HRB 2270, District Court of Mainz 

VAT-ID: 

DE149063659 

Privacy statement: 

ds-vfv.vfmz.de 

Managing director: 

Dr. Olaf Theisen 

Publishing director: 

Dr. Michael Werner, E-mail: m.werner@vfmz.de 

Correspondent India: 

Sushen Haresh Doshi M.Sc. 

Advertising sales director: 

Beatrice Thomas-Meyer, 

E-mail: b.thomas-meyer@vfmz.de 

Advertising sales manager: 

Oliver Jennen, E-mail: o.jennen@vfmz.de 

Andreas Zepig, E-mail: a.zepig@vfmz.de 

Sales representatives 

Austria: 

Heinz-Joachim Greiner, 

E-mail: verlagsbuero-greiner@vfmz.de 

Denmark, Sweden, Finland, Norway: 

Malte Mezger, 

E-mail: verlagsbuero-mezger@vfmz.de 

France: 

Marc Jouanny, 

E-mail: marc-jouanny@wanadoo.fr 

Great Britain, Ireland: 

Rob Brewer, 

E-mail: rob.brewer1@btinternet.com 

Italy: 

Edgar Mäder, E-Mail: publications@emtrad.it 

Switzerland: 

Hermann Jordi, 

E-mail: info@jordipublipress.de 

USA, Canada, Mexico: 

Patrick Venezia Jr, 

E-mail: verlagsbuero-venezia@vfmz.de 

Advertising disposition: 

Isabell Faß, E-Mail: i.fass@vfmz.de 

Brigitte Glückler, E-Mail: b.glueckler@vfmz.de 

Nevenka Islamovic, E-mail: n.islamovic@vfmz.de 

Heike Rauschkolb, E-mail: h.rauschkolb@vfmz.de 

In cooperation with: 

Hannover Fairs International GmbH, 

Messegelände, 30521 Hannover, Germany 

Internet: 


WORLD OF INDUSTRIES 2020 3

TABLE OF CONTENT 

08 

14 

18 

12 

10 

NEWS AND MARKETS 

03 EDITORIAL 

05 NEWS AND MARKETS 

AUTOMATION 

06 DATA MANAGEMENT IN 

THE INDUSTRIAL INTERNET 

OF THINGS 

08 SWISS PRECISION PLUS 

10 10 CAMERAS TO TEST 10 MILLION 

SOCKET COVER PLATES 

LOGISTICS 

16 COVER STORY DOUBLE HOIST 

UNIT SOLUTION PROVIDES 

ADDITIONAL FLEXIBILITY AND 

IMPROVES HANDLING RATES 

18 OPTIMAL SPARE PARTS SUPPLY 

MOTION AND DRIVES 

12 FOR EFFICIENT MACHINES: 

TRIBO-POLYMERS INCREASE 

SERVICE LIFE 

14 EVERYTHING OF A PIECE 

COVER 

Demag Cranes 

& Components, 

Wetter, Germany 

4 WORLD OF INDUSTRIES 2020

W RLDWIDE NEWS 

New Vice President Sales & Marketing 

at TTControl 

TTControl, a provider of high-end electronic control systems, 

operator interfaces and IoT solutions for mobile machines, 

appoints Markus Plankensteiner as Vice President Sales & 

Marketing. In this position, he will be responsible to intensify 

and expand TTControl’s customer relationships around 

controllers, displays and entire machine 

architectures, as well as on innovative 

industry-specific solutions for 

autonomous operation, smart 

farming, cloud services and IoT. 

Plankensteiner brings in about 

20 years of experience in executive 

positions in the field of sales and 

marketing. 

“Markus Plankensteiner is an experienced 

manager, who combines a deep 

technological understanding with outstanding 

sales and marketing expertise,” says Manfred Prammer, 

Managing Director at TTControl. “He is well-connected in the 

world of mobile machines and a valuable addition to the 

existing management and leadership team. His background 

and know-how will be highly valuable for TTControl. We’re 

thrilled to welcome Markus to the team.” 

Phoenix Contact places key 

importance on digital quality 

Along with product quality, Phoenix 

Contact also places high demands 

on quality within the digitalization 

process. This is evidenced, 

for example, by the appointment 

of a new Chief Digital 

Officer (CDO). The electronic 

and automated data 

exchange happens using 

eCl@ss, the globally 

recognized and standardcompliant 

standard for 

Industry 4.0. eCl@ss enables 

the cross-industry standardized 

classification and clear 

description of products and 

services throughout the entire value 

chain, often across companies. This 

makes it easier for customers to gain an 

overview of their processes, such as production. 

Working together with business partners is made more efficient. 

www.phoenixcontact.com 

www.ttcontrol.com 

Securing the industry of tomorrow 

Iuno, the German national reference project for IT security 

in Industry 4.0, returns with a second iteration under the 

name of Iuno2Pakt, new goals, and partners to offer a vast 

range of solutions meant to counter the cyber challenges 

Germany and the global community are facing on the cusp 

of the digital industrial revolution. Fraunhofer IOSB, 

Hilscher, Weidmueller and Wibu-Systems. Wibu-Systems 

has adhered to the consortium with a commitment to 

harnessing the power of certificates for safer industrial 

communication. Digital certificates provide the most 

desperately needed currency in these transactions: trust. 

Assigned by a trustworthy Certification Authority, certificates 

can act as proof of identity in machine-tomachine 

communication and smart 

factories, where appli cations, 

machines, and business 

systems need to be able to 

identify and communicate 

with each other. Wibu- 

Systems is enveloping this 

entire process with a novel 

addition to its CodeMeter 

security and protection 

universe: CodeMeter 

Certificate Vault. 

COVERING THE 4TH INDUSTRIAL REVOLUTION 

COVERING THE 4TH INDUSTRIAL REVOLUTION 

Discover the 

EXCELLENCE OF TECHNOLOGY 

with a click! 


www.wibu.com 

WORLD OF INDUSTRIES 2020 5 

WIN_EA_Go_Global_2018_01.indd 6 18.09.2018 10:17:36

Data Management in 

the Industrial Internet 

of Things 

AUTOMATION 

Industrial Ethernet, the most widely used 

communication standard, allows for the simple 

connection to control levels while also ensuring good 

communication between localised field devices and 

the control system. With its new managed switches 

in the Advanced Line, Weidmüller is providing a 

guaranteed future-proof infrastructure with high 

levels of availability, reliability and transparency. 

The Advanced Line managed switches can increase network 

availability by means of redundancy and control mechanisms, 

and also offer a range of diagnostic options for sophisticated 

automation networks. They support common protocols such as 

STP/RSTP or SNMP and can be intuitively configured via a browsersupported 

web interface. With model variants for Fast Ethernet, 

Gigabit and PoE as well as versions fitted with between 5 and 

24 ports, the switches also ensure high levels of flexibility. The large 

temperature range means that the switches can be used in challenging 

environments such as production applications or in the 

field. The Advanced Line product line ranges from Full Managed 

switches for complex applications such as those with port monitoring, 

to Lite Managed switches for simple tasks within a network 

representing very good value for money. 

High level of operational reliability thanks 

to quick redundancy mechanisms 

Ring redundancy is used as standard in today’s Industrial Ethernet 

networks. This ring redundancy method increases the availability of 

automation networks and reduces downtimes while also optimising 

configurability and operability within the network. The 

Weidmüller Advanced Line switches support the combination of 

ring and line redundancy, involving the interlinking of multiple 

Ethernet switches in a line network. The configuration of the head 

switch and the tail switch at the outer ends of the chain incorporates 

the two ends into the network. Using the ring and line redundancy 

method allows administrators to create redundant topologies 

with a high level of flexibility in each network segment. When 

The ring redundancy method increases the 

availability of automation networks and reduces 

downtimes while also optimising configurability 

and operability within the network 

using the Weidmüller Advanced Line switches, a back-up path is 

created if one of the network segments fails, meaning that the 

network is restored in just 30 ms in a setup with up to 250 switches. 

This increases network availability while reducing cost-intensive 

downtimes. 

Easy to integrate into different automation 

landscapes 

The Advanced Line switches support common protocols such as 

STP, RSTP or SNMP, making them particularly easy to integrate into 

different automation landscapes. The web-based configuration of 

the Advanced Line switches is performed using a simple and intuitive 

user interface. As a result, users are able to benefit from direct 

access to all status information and operational functions of the 

switches within their familiar software environment. 


Weidmüller also offers an external Backup and Restore module for 

smooth operation even in the event of errors. This module provides 

a backup of the device configuration, making sure that reconfiguration 

can be performed directly on the device if required. This means 

that the configuration can be backed up without a network or a 

computer. A replacement device can therefore be put back into 

operation directly on site. 

A high level of flexibility 

Model variants for Fast Ethernet, Gigabit and PoE (Power over 

Ethernet – for the remote supply of the periphery) as well as the 

options to have between 5 and 24 ports ensure a high level of flexibility, 

meaning that there is the perfect device for every application. 

Partner in industrial connectivity 

As experienced experts we support our customers and 

partners around the world with products, solutions and 

services in the industrial environment of power, signal and 

data. We are at home in their industries and markets and 

know the technological challenges of tomorrow. We are 

therefore continuously developing innovative, sustainable 

and useful solutions for their individual needs. Together we 

set standards in Industrial Connectivity. The Weidmüller 

Group owns manufacturing plants, sales companies and 

representatives in more than 80 countries. 

All Ethernet switches have an industrial IP30 metal enclosure with 

integrated clip-in base for easy installation on the terminal rail 

(TS35). In addition to its simple installation, the switch is also characterised 

by its large temperature range. The switches can be used 

in environments from –40 to +75 °C. This allows for operation both 

within production and in the field. 

The right solution for every application 

Depending on the particular version, the switches are fitted with a 

number of combinable copper or fibre-optic interfaces, meaning that 

different media can be used and large distances covered. Whether 

multi-mode or single-mode, 500 metre or anywhere up to 20 km – the 

SFP slots help to guarantee flexible use. With the modular port assembly, 

the transceiver simply needs to be plugged in. It is therefore 

also possible to change the technology at a later point in time. 

For simple or complex tasks 

The Advanced Line switches are available in the “Full Managed” 

and “Lite Managed” versions. The Full Managed switches are particularly 

well-suited for use in networks with complex tasks and 

particular requirements regarding redundancy, secured data transfer 

or the monitoring of individual ports. The Lite Managed switches 

are the economical alternative for simple tasks in networks with 

little demand for managed processes. 

Photos: Lead stock.adobe.com/elenabsl, product image Weidmueller 

www.weidmueller.com 

smart plastics 

Avoid unplanned downtime 

Industry 4.0: smart plastics eliminate downtimes 

Intelligent products give a maintenance alert ahead of time and can be integrated into 

standard predicitve maintenance; smart plastics allow your equipment to run continously 

as well as reducing maintenance costs. 

Video "Industry 4.0 - predictive maintenance" at igus.eu/smartplastics 

plastics for longer life ® 

Tel. +49-2203-9649-800 info@igus.eu 

EU-1131-smart plastics 185x130.indd 1 10.03.20 08:57 


Rotary tilting table on 

the milling center 

Swiss Precision Plus 

The Swiss maker GF Machining Solutions has equipped its 5-axis high-performance 

machining centers with the versatile IO-Link communication interface. Users will now 

profit from simpler handling as well as never before availability of process data for 

configuration, diagnostic and service purposes. 

Author: Wolfgang Zosel, 

freelance industry journalist, 

Reutlingen, Germany 

AUTOMATION 

The IO-Link technology is a communication system for connecting 

intelligent sensors and actuators to an automation system. 

In addition to simple handling, this also shortens the installation 

and start-up phase and makes it easier to meet individual customer 

requirements for cables and tool management. For this reason, the 

Swiss manufacturer GF Machining Solutions (GFMS) has equipped 

its 5-axis high-performance machining centers with the versatile 

IO-Link communication interface. The new Mikron MILL P 500 U 

thus meets the highest precision requirements and IO-Link has established 

itself at GFML as a real push technology for digitized and 

networked system concepts. 

Highest precision with accuracies 

of +/- 2 micrometers 

Stefan Fahrni, Milling Product Manager, puts in a nutshell what 

customers appreciate about GFMS machining centers: “With accuracies 

of +/- 2 micrometers we meet the requirements for the highest 

precision and consistently high quality. In order to ensure thermal 

stability, the machine bed is made of an especially heavy duty 

mineral casting. We use water-cooled components to ensure that 

heat sources cannot have an effect on the customer’s product.” As a 

member of GF Machining Solutions, Mikron Agie Charmilles AG 

with headquarters in Nidau near Biel is a globally active manufacturer 

of machines, automation solutions for mold and tool making 

as well as for the manufacturing of precision parts. 

The new Mill P 500 U is a 5-axis high performance machine for both 

precision part manufacturers active in the aerospace, machinery 

and defense industries, general mechanic industries and precision 

mold makers active in industries such as automotive and home appliance. 

The core of the machine is a base module for top or front 

loading. Depending on the customer requirement either partly or 

fully automated feed mechanisms as well as differently dimensioned 

tool magazines are available. 

The “Integral Connectivity 4” project 

The first stages of development of the Mill P 500 U go back several 

years. Most of the focus was on what customer requirements would 

look like in the future. Long before the term Industry 4.0 became an 

IO-Link by Balluff makes high-performance 

milling machine ready for Industry 4.0 

electrifying metaphor for an entire sector, the developers at GFMS 

had recognized the significance of increasing digitization and networking 

including the associated opportunities. “In addition to 

simple position values, intelligent sensors today offer a variety of 

process data right where the action is taking place. The question is 


how to use this in an uncomplicated and efficient 

way for process optimization. What changes with respect 

to equipment handling? How does the customer 

benefit, what changes for us as a manufacturer,” 

summarizes Konrad Meier, Head of 

Electronic Design. 

This was a reason for the company in 2014 

to create the “Integral Connectivity 4” 

project: GF Machining Solutions used 

this to pursue the goal of implementing 

more functional security in the 

controller, modular electronic concepts with 

decentralized linking of the peripherals, as 

well as a simple, thorough communication 

solution between the command level and the 

sensor/actuator level. No more cumbersome 

multi-pin wiring; the installation, assembly and maintenance 

effort was to be drastically reduced and the diagnostic capability 

increased. 

01 Mill P 500 U highperformance 

milling center with its 

versatile and simply programmable 

IO-Link SmartLight stack light 

02 8 x ProfiNet/IO-Link master 

and IO-Link sensor/actuator hub 

from Balluff (right); the cables are 

installed via plug-and-play without 

the need for tools 

Development of an integrated IO-Link concept 

“In spring of 2014 we had an opportunity to present the IO-Link 

communication standard, which at that time was hardly known at 

GF Machining Solutions. Two of the engineers quickly recognized 

that this bidirectional interface would provide answers to a variety 

of questions. A short time later we got the order to work with GF 

Machining Solutions to develop an integrated IO-Link concept for 

the planned Mill P 500,” recalls Thomas Zumbrunn, sales engineer 

with the Swiss Balluff subsidiary. As a globally standardized IO 

standard (IEC 61131-9) IO-Link enables uncomplicated data exchange 

between sensors/actuators and the master/control level - 

using just the familiar standard 3-conductor cable and M12 connector! 

This efficient point-to-point connection is not a fieldbus, 

but rather a logical continuation of the previous connection technology 

for sensors and actuators. 

In addition to many different sensors for position and object detection, 

valve terminals and pressure sensors on the rotary index 

table including RFID tool management, the Mill P 500 U with its 

various feed mechanisms organizes dozens of signals. IO-Link is 

in contact with the Siemens and Heidenhain controllers in the 

system via Profinet IO-Link masters. “IO-Link offers a previously 

unknown simplification from the conception to the installation 

and commissioning phase thanks to its standardization. Installation 

with IO-Link means error-free plug-in instead of error-prone 

wiring. Shielded special cables and expensive plug-in cards are 

passé, drag chains undergo drastic reduction, and equipment 

with IO-Link guarantees high EMC stability. 

Advantages of IO-Link in use 

IO-Link really shows its strengths in customer application: a simple 

to use central recipe management system allows users to reconfigure 

entire sensor groups in seconds from the master or controller 

level. The threshold value of a pressure sensor is no longer set on 

the device, but rather centrally by the master or from the HMI. Replacing 

a defective sensor no longer involves a long system stoppage: 

just a few seconds after plugging in the cable the device receives 

its relevant values from the central location and resumes its 

intended task. 

Intelligent sensors are able to transmit a wealth of parameter and 

status data in real time, thus creating a comprehensive picture of 

the status of things on the process level. This opens up new diagnostic 

and predictive maintenance approaches: the milling tool 

equipped with an RFID chip sends its specific product and use data 

03 Valve terminal plugs connect decentralized valve terminals to the 

control level via IO-Link 

to the controller and prompts a sharpening date ahead of time. 

When a lens gets dirty a photoelectric sensor sends a notification 

that performance is being degraded and prompts intervention. A 

drive tells the system that a defined temperature limit has been 

exceeded. Service and maintenance actions are possible remotely 

down to the sensor/actuator level while meeting the operator’s 

safety specifications. 

Easily visualize every conceivable status 

Part of the IO-Link portfolio equipping the new Mill P 500 U is the 

SmartLight from Balluff: the IO-Link stack light is freely and easily 

programmable, with options for stack light, level, run light and flexi 

modes with a broad color spectrum range. “This allows us to easily 

visualize every conceivable status, warning message or prompt for 

action. And mainly we only need to stock a single, universally 

adaptable light type,” emphasizes Konrad Meier. 

By using IO-Link GF Machining Solutions and Balluff have shown 

that an amazingly simple technology can further refine an essentially 

highly precise and reliable process. “Balluff was not just a 

parts supplier, but rather a valuable consultant and equal level 

project partner. Which is why “IO-Link by Balluff” will be a fixed 

part of our offering in the future as well,” summarizes Stefan Fahrni. 

Photos: Balluff 

www.balluff.com 


10 cameras to test 

millions of socket cover plates 

How do you carry out quality inspections on ten million plastic parts per year? Until 

recently this was done manually, but now it has become an automated process thanks 

to the smart inspection system by Aumo. The automation specialist relies on ten 

Baumer CX cameras working as the “eyes” of the machine. 

Author: Nicole Marofsky, 

Marketing Communication 

at Vision Competence Center 

by Baumer 

AUTOMATION 

It all starts with a blank sheet of paper. Next, the customer outlines 

what is needed; a quality inspection system, an automated assembly 

machine, or any other specific installation. The Aumo engineers 

elaborate on a concept and design and at the end of the 

process is the final all-in package, including system, servicing, commissioning 

and maintenance. “We only build individual solutions,” 

says Ben Rösler, project and sales manager and son of René Rösler, 

who founded the company in its present form in 1990, and has been 

the CEO ever since. Their main customers are in the automotive 

and supplier industry, aerospace, and plastics processing but also 

can be found in mechanical engineering, medical technology, and 

the semiconductor industry. 

Simple parts, yet complex inspection 

SchoPlast, a German state-owned company in the early 1970s and 

re-founded in 1992, delivers decades of experience. Being a wellestablished 

manufacturer of mainly thermosetting plastic parts for 

electrical installations, they asked Aumo to develop a quality in- 

spection system for socket plates. Dozens of them can be found in 

everybody’s home today. The socket cover, attached fully visible 

outside the wall, is manufactured in large quantities and must undergo 

complex inspection, since the premium customer SchoPlast 

has extraordinarily high demands on quality. Quality requirements 

refer to dimensions and precise outer contours. Identifying even 

the smallest defects such as scratches and surface imperfections is 

particularly demanding. SchoPlast produces ten million socket 

plates per year, with all-manual inspection so far – a giant effort, 

which was the spark that got things moving to take the load off the 

people and automate the task. So SchoPlast approached Aumo to 

learn if they could make it an automated process. 

Change into an automated process 

Aumo could. Within the system than has been in operation at Scho- 

Plast since April 2018, two socket plates per cycle are picked from 

the bin and placed next to each other on a complex conveying system. 

In the next step, the plates pass several inspection stations. All 


The background image shows the second test box which hosts the 

angularly arranged cameras and illumination system. Any irregularities 

on the plate surface are revealed by the cast shadow. The product image 

shows the CX series cameras with GigE, USB 3.0 and cutting-edge Global 

and Rolling Shutter CMOS sensors for cross-industry applications 

inspections tasks are image-based, except for two tactile operations 

to measure material thickness and so-called pot size. To do so, there 

are four measuring boxes hosting ten cameras in total and illumination 

units with ring lights as incident or transmitted light for surface 

illumination. Passing the boxes, the cover plates are automatically 

turned and positioned for backside inspection. As the final step in 

the inspection process, the socket plates are sorted according to 

good parts or defect type. 

Open system architecture preferred 

The ten Baumer cameras are integral to this successful automation 

solution. In which way? The first benefit is quite unspectacular: 

From the Baumer Vision Competence Center to Aumo, it’s only 25 

minutes by car. Baumer has been using Aumo profile systems and 

components for the design of production and inspection stations, 

so they have known and trusted each other. But that is only half of 

the story. “We were looking for an open system with standardized 

lens connection and data interface to output gray images,” says 

Rösler. “Other manufacturers only offered complete systems which 

we found insufficient in terms of flexibility.” 

The Baumer camera VCXU-53M with USB 3.0, lens connection 

35 mm and 1.4 aperture was the perfect match. Integrating ON 

Semiconductor Python 5.3 Megapixel Global Shutter sensors, the 

cameras deliver excellent image quality with up to 73 fps. In the 

SchoPlast application, the cameras acquire an image every 3.67 

seconds at exposure times between 0.125 and 0.5 milliseconds. The 

camera data are delivered to two industrial PCs, which in parallel 

control illumination. The computers run specific Aumo-developed 

evaluation software. The results directly enter the SchoPlast quality 

management system. Results can be retrieved even years later for 

reasons of traceability in the event of frequent error occurrence at 

later points in time. 

Aumo does not only use the Baumer VCXU-53M cameras for the 

SchoPlast inspection application. Baumer cameras do their jobs – 

contour inspections on objects – in two more applications at other 

customers. “We chose this camera because it has exactly what we 

need,” says Rösler. 

Temperature under control 

Among other features, the cameras have excellent temperature 

management capabilities. Prior to commissioning, there was concern 

about the cameras heating up too much and probably exceeding 

the maximum permissible operating temperature of 65 °C when 

being exposed to the “flash light inferno” inside the measuring 

boxes. However, the all-clear was given by the diagnostics of the 

continuously transmitted operating data of each camera. The maximum 

temperature reached was 56 °C. This eliminates the need for 

active cooling, which would have made the system even more complex 

and expensive. 

“The SchoPlast project manager was very pleased and astonished 

by our clever solution,” says Rösler, and solves the secret behind it: 

“We don’t just want to sell our solution; we always look at the customer’s 

requirements from his point of view”. 

Photos: Background Aumo, product image Baumer 

www.baumer.com 

MY INVERTER 

IS FROM NORD! 

THE NEW NORDAC PRO 

Integrated multi-protocol 

Ethernet interface 

Multi-encoder interface 

for multiple axis operation 

Mains voltage-free 

parameterisation via USB port 

GEAR UNIT + MOTOR + DRIVE ELECTRONIC = DER ANTRIEB. 

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

WORLD OF INDUSTRIES 2020 11 

www.nord.com

Igus offers a large selection 

of self-lubricating polymer 

plain bearings 

For efficient machines: 

tribo-polymers increase service life 


Tribo-polymers from igus display their advantages in 

maintenance-free and lubrication-free iglidur bearing 

technology. 

Anyone who wants to be relaxed about a future with Industry 4.0 

goes a long way towards getting things right by keeping a close 

eye on costs. A consideration of service life must take account of all 

those costs that are incurred over the long term, in addition to the 

costs of purchase, procurement and installation of a machine. Operation, 

maintenance and repair are examples of what can lead to 

such costs. The use of wear-resistant materials and low-maintenance 

components reduces not only costs but also the risk of unscheduled 

shutdowns and extensive maintenance work. Motion 

plastics specialist igus has many years of experience and knowledge 

in the development and production of wear-resistant solutions 

made of tribo-polymers, and also keeps a large database in its own 

test laboratory – all of which makes the company the ideal supplier 

for mechanical engineers. The reason is that machines today are often 

utilised all day long in three shifts. In the light of the growing 

challenges, searching for the tribologically optimised component is 

time well spent for every mechanical engineer. 

The combination is the secret 

Design engineers know all about looking for and finding the right 

material. Users often find that the best tribologically optimised 

component for them is to be obtained from the Cologne-based 

plastics specialist. This is because igus develops polymers specifically 

for dry operation. Use is made of base polymers, solid lubricants 

and, last but not least, strengtheners in order to develop even 

better materials for increasingly challenging applications and to 

achieve better wear results. 

Continuous development based on experience 

Whereas some of these materials are developed specifically on behalf 

of individual customers who indicate special requirements, 

others become part of the catalogue portfolio. In more than 12,000 

wear tests per year on over 450 test stands, the engineers from igus 

analyse wear behaviour systematically. In this context, more than 

135 trillion test movements take place. The large number of tests is 

due to the different ambient conditions that are considered, such as 

temperature, humidity, the type of movement and the contact materials. 

All these factors have an effect on the wear patterns in the 

individual scenarios and have to be taken into account. The analysis 

is used not only to evaluate the materials generally but also to create 

the basis for a service that is unique throughout the industry: namely, 

calculation of the service life of components in any application. 

The test laboratory as a reflection of 

industrial reality 

This large number of parameters alone, shows how much work is 

involved in the acquisition of research results that are essential for 


the successful development of high-strength polymer components. 

This is why plastics specialist igus operates a test laboratory covering 

an area of 3,800 square metres. The tribological quality of the 

polymers is tested here with linear, rotating and flexing types of motion 

as well as in combination with other materials. But it is not just 

the mechanical properties that are important for the generation of 

relevant information and the continuous improvement of customer 

solutions; igus components are used in different branches of industry 

and, accordingly, must be able to withstand different external 

influences. Examples of the latter are, on the one hand, classical 

manufacturing equipment and methods involving a normal degree 

of dirt and, on the other, extremely dirty environments or the presence 

of aggressive chemicals. This is the case when components 

made of tribo-polymers are used in the area of agriculture, the 

building industry or offshore installations. Other branches, other 

challenges. And this is exactly why the tests in the igus laboratory 

are so important. 

Diverse influences have an effect on the 

polymer products 

In meadows and fields there is always a lot of dust, while ambient 

conditions tend to be aggressive in the building materials industry 

due to chemicals or in the offshore area due to salt water. Components 

that are used in cleanrooms of the pharmaceutical industry 

or in environments where they come into contact with food have to 

cope with other conditions. Here, hygienic design is of utmost importance. 

In the igus laboratory, the engineers are very well prepared 

for all the challenges they encounter, from tests underwater 

to the simulation of very dirty environments. Of course, such a large 

variety of test environments also includes the use of different temperatures 

and tests in a cold chamber. All this has resulted in products 

such as iglidur plain bearings, drylin linear bearings, xiros ball 

bearings, energy chains and cables whose polymers have the best 

tribological properties for almost any application. 

A continually growing database 

Year after year, the laboratory’s test databases are supplemented 

with more research data on the basis of which new materials are 

created, whose technical performance today is already at the level 

of what customers will not be looking for until tomorrow. Just how 

closely and effectively the igus engineers focus on the future is also 

shown by the fact that, thanks to the huge amount of recorded test 

data, the service life of a product can be calculated in an expert system 

specially developed for this purpose. This service, which is 

unique throughout the industry, is a significant benefit for the customer, 

especially when it comes to bearing technology products 

that are of central importance for the operational readiness of machines 

and installations. What is also important is that the consequences 

of a bad choice of material can be devastating. 

Tribologically optimised polymers ensuring 

the smooth operation of bearings 

Anyone who wants a safe and reliable production process on a large 

scale should first think of the small things, namely the bearing. This 

component should be as wear-resistant as possible so that everything 

operates smoothly and also for a long time. There are many 

different types of bearing such as rolling bearings, linear bearings 

and plain bearings. The latter are supplied by igus as lubricationfree 

polymer bearings. A product range with over 8,500 catalogue 

dimensions and specialist parts according to customer specifications 

made of more than 60 different tribologically optimised materials 

offers the user a wide range of choices. Simply the fact that no 

lubrication is needed reduces the customer’s costs. Maintenance 

work is also reduced. igus polymers are corrosion-free and even 

able to withstand high loads. In addition to the classical plain bearings, 

igus supplies a wide range of polymer slewing ring bearings 

(iglidur PRT). Last but not least, the tribologically optimised xiros 

polymer ball bearings are the result of intensive research. In many 

places today, they are the first choice of mechanical engineers for 

whom classical ball bearings made of metal are inadequate. For 

customers who are looking for more freedom in the design of lubrication-free 

spherical bearings, it is worthwhile looking at the igubal 

series of bearings. The complete system of self-adjusting bearing 

elements has the best tribological properties and consists of a wide 

range of swivel heads, clevis joints, flange bearings, spherical bearings 

and pillow block bearings. 

Tribo-polymers: a good option for 

do-it-yourselfers as well 

Customers who love creating as much as they do freedom, can obtain 

iglidur sold by the metre, which is a type of bar stock that offers 

many possibilities of design. iglidur bar stock is a good choice for 

the creation of test samples, very small series and, last but not least, 

complicated prototypes, which often entail searching for the right 

material. 

Where durability is more of a concern than design, the tribological 

properties of lead screw systems, trapezoidal threads or high 

helix threads from igus are more important. This is because the 

functioning of such products and therefore process reliability, depends 

on an abrasion-resistant surface structure. In the drylin series, 

mechanical engineers can find polymer solutions that do their 

job reliably and without fault, even under very stressful conditions. 

igus is able to say this for each of its products because of the tests it 

carries out in its own laboratory. Today, tomorrow, the day after 

tomorrow and even the day after that. 

Photos: igus 

www.igus.de 

01 Igus engages in 

research and continually 

develops new tribocompounds 

01 02 

02 The origin of every 

motion plastics product: 

igus tribologically 

optimised polymers 


Everything 

of a piece 


Whether it’s a gearbox or crankcase, structural 

components such as A-pillars or doors and tailgates: 

when it comes to aluminum die-casting, numerous 

well-known automobile manufacturers rely on the 

moulds produced by toolmaking specialist 

Heck+Becker. Sophisticated temperature management 

ensures the outstanding precision of the cast parts 

– and requires a large number of hose lines. 

The aluminum alloy is heated to temperatures of up to 700 °C and 

can be poured into the man-sized mould at speeds of up to 

5 m/s. The molten metal is then post-compacted at up to 1,000 bar. 

The mould filling process is completed in a few milliseconds and 

then the solidification of the component begins. This can produce a 

gearbox housing with a highly complex structure in a very short 

time. During the entire casting process a hydraulically generated 

clamping force of over 3,000 t ensures that both halves of the mould 

fit accurately together. The mould is opened hydraulically and a robot 

removes the completely solidified casting. A second robot cools 

the mould with a water-based release agent and prepares it for the 

next part to be cast. The casting process is repeated fully automatically 

every 90 seconds. And that 7 days a week, 24 hours a day. 

It’s all a question of temperature 

But how does the company achieve this outstanding precision in 

die-casting, which in addition to reproducing intricate details, also 

allows the forming of drill holes into which only the thread has to be 


01 Up to 200 m of hose in different sizes can be installed on a single 

mould 

02 In addition to supplying complete workshop equipment, Hansa-Flex 

supports the mould specialist by offering appropriate training in hose 

production 

cut later? “An optimum result requires optimum temperature control 

of the casting mould”, explains Ralf Fett, Production Manager at 

Heck+Becker GmbH. This is because the temperature conditions in 

the mould have to be managed in such a way that it can be completely 

filled without the aluminium already beginning to solidify 

during the filling process. A regulated heating and cooling circuit 

ensures that the required temperature is maintained in each area of 

the mould throughout the entire casting process. Depending on the 

application, oil and water are used for heating or cooling. The media 

flow through hose lines that connect the numerous inputs and 

outputs of the mould to the temperature control units. 

Engineering meets experience 

Heck+Becker develops the moulds in close cooperation with its 

customers. The moulds are constructed virtually using a 3D CAD 

model. The temperature conditions within the mould are also calculated 

and simulated in advance on the model. “The question of 

where and how to heat and where and how to cool can’t, however, 

be answered conclusively in theory. There are simply too many different 

parameters involved,” reports Fett. The optimisation of the 

mould also takes place in practical operations. First the shape is 

milled from a specially alloyed hardened tool steel on the basis of 

the design data and using CNC technology. Next the patterning – 

i.e. the test castings – takes place, for which Heck+Becker has its 

own fully automated casting cell. The cast components are then 

precisely measured and compared with the strict quality specifications 

of the customer. “Even the slightest changes to the temperature 

controls can have a noticeable effect. However, a mathematical 

model is no longer the answer here – on the contrary, what is required 

at this stage is simply our many years of experience,” says 

Fett in summing up the challenge. 

Hose lines manufactured in-house 

Changes to the temperature controls often require adjustments to 

the hose lines of the heating and cooling circuit. Heck+Becker manufactures 

these hose lines itself, together with the hydraulic lines 

and the supply for the water-wax mixture used as a separating 

agent, in the process relying on HANSA-FLEX components: “Long 

service life is a matter of course for us and our customers. Due to the 

media used as well as the high temperatures and pressures, we 

can’t afford any compromises in terms of quality,” reports Ullrich 

Graul, who is in charge of moulded tubing. Heck+Becker relies almost 

throughout on multiple reinforced Teflon hoses. And there is 

no shortage of these, because up to 200 m of hose in different sizes 

can be installed on a single mould. In addition to supplying 

complete workshop equipment, HANSA-FLEX supports the mould 

specialist by offering appropriate training in hose production. 

Right on the spot 

The close proximity to the HANSA-FLEX branch – only a few hundred 

metres separate the two companies in Dautphetal, Germany 

– enables Heck+Becker to dispense with extensive stock keeping. “It 

is often only directly at the mould that it becomes clear what diameter 

will enable the right heating conditions. We really appreciate 

the fact that we can obtain what we need quickly,” explains Graul. 

The branch itself ensures continuous supply capability: “It’s not uncommon 

for us to take delivery of 5,000 m of hoses in a single day,” 

says Dennis Heinold, a member of the depot team. However, the 

cooperation is not limited to the supply of materials: “Together we 

discuss what customer-specific requirements we can best cover 

with what material”. 

Fast support 

In addition to manufacturing, Heck+Becker also carries out the 

maintenance and repair of die-casting moulds for many of its customers. 

When order backlogs develop due to predetermined time 

windows, the mould specialist falls back on HANSA-FLEX’s Rapid 

Hydraulic Service. “We are supported around the clock not only in 

mould making, but also in the maintenance of our own production 

machinery,” sums up Fett. “Whether it’s material procurement, 

consulting or on-site deployment: we benefit in a number of ways 

from the uncomplicated cooperation between our companies” 

www.hansa-flex.com 


Double hoist unit solution provides 

additional flexibility and improves 

handling rates 

LOGISTICS 

The paper industry is a key sector for process crane 

technology. The corresponding cranes and hoists have 

to perform a wide range of tasks, from precise 

positioning of paper machine rollers to fully 

automated stores for paper rolls. Laakirchen Papier AG 

is a good example of the potential that can be 

achieved. 

Laakirchen Papier AG is an important part of the local economy 

in the Laakirchen municipality in Upper Austria. As part of the 

Heinzel Group, the company produces paper for packing and publication 

purposes on the two PM 10 and PM 11 paper machines at 

this location. Following the conversion and modernisation work, 

paper machine PM 10 specialises in the production of lightweight 

corrugated base paper made from waste paper for environmentally 

friendly packaging solutions. This provides a not inconsiderable 

increase in its production capacity. At the same time, the company 

has extended its production capacity for SC paper used for magazines, 

catalogues and printed advertising material on paper machine 

PM 11. The resulting investment in a new paper-roll shipping 

store is an important part of the growth strategy pursued by Heinzel 

Group, which has set itself the goal of becoming the most competitive 

and eco-friendly paper factory in Europe. 

Loading times cut by 30 per cent 

Two process cranes (33 m spans) supplied by Demag handle the 

rolls of paper in the shipping store. The store can accommodate 

some 8,870 tons of paper when filled to a capacity of 80 per cent. 

The store is filled around the clock in 24/7 operation. Besides the 

limited area for storage of the paper rolls, the loading times, which 

are limited to five working days, also posed a challenge. Particularly 

at the beginning of the week, when the roll store is largely full, the 

trucks that collect the product need to be served very quickly. “To 

clear the order peaks in the paper store, we initially placed emphasis 

on reducing the number of crane travel operations. This was 

achieved by installing two crabs on each crane”, explains Markus 

Otto, Demag Process Cranes Sales Director. 

The open winch units are equipped with vacuum lifting devices, 

which can be used to store and retrieve the unpacked rolls of paper 


The concept with two process cranes 

operating on one crane runway, each 

fitted with two open winch crabs that can 

travel independently of each other, 

is an example of Demag expertise 

Winfried Bauer, editor-in-chief 

World of Industries 

quickly and, above all, gently. Each crane is designed in such a way 

that it can handle rolls with a maximum diameter of 1,500 mm, 

widths up to 3,300 mm and a maximum weight of 4,5 tons in pairs or 

individually. Using the new technology, the system can perform 104 

roll-handling movements per hour. Otto explains: “These performance 

figures were also achieved by combining the fast travel and 

lifting speeds of our process cranes with this double-crab solution.” 

The cranes, which feature dual channels for all safety-relevant 

features, are precisely positioned at the points specified by the 

warehouse management system by means of laser position measuring 

systems. The vacuum lifting device needs less than a second to 

connect to the rolls of paper by suction. Lifting and lowering speeds 

of up to 78 m/min are achieved with a load and 120 m/min without 

a load. The cranes place the paper roll products in dedicated stacks 

measuring up to 15,05 m in height in an area measuring 2,700 m². 

“With our new fully automated crane store, we can load approx. five 

trucks per hour. Compared to a manually controlled store, we have 

cut loading times by some 30 per cent”, explains Dr. Thomas Welt, 

CEO of Laakirchen Papier AG. 

The Demag warehouse management system also contributes significantly 

towards system performance. “The software can flexibly 

assign the travel areas to both of the cranes, optimises utilisation of 

the storage locations and prepares any scheduled retrieval operations”, 

explains Gerhard Lange, Demag Senior Project Manager Process 

Cranes for the paper industry. 

The two process cranes utilise benefits for handling rolls and for 

power consumption: electric power generated during the lowering 

and braking operations is fed back into the power supply by power 

recovery units. In this way, the company’s energy footprint is further 

improved. 

Co-operation going forward 

The investments in the paper machines and cranes have paid off 

for the customer. During a visit to the site, work on a third area of 

the paper roll shipping store was well underway. The additional capacity 

is also urgently needed because the operating speeds of 

PM 10 and PM 11 are to be gradually increased to 1,600 and 

1,800 m/min, respectively. Since both process cranes were specified 

for future requirements, the additional loads will be no problem 

for the installations. 

WB 

Photos: Demag, f+h 

www.demagcranes.com 

ROBA ® -brake-checker: 

Intelligent safety 

Permanent brake monitoring of switching 

condition, temperature and wear 

ON / OFF 

ON / OFF 

www.mayr.com 


Optimal spare parts supply 

Airport 

Logistics operator 

Sparrow 

Virtual 

Parts 

Pool 

E-commerce 

SEW Stock 

Beumer Stock 

With its digital marketplace, the start-up Sparrow 

Networks ensures that the participants are supplied 

with the appropriate spare part as quickly as possible 

in the event a component in their systems fails. 

Sparrow connects the stock of the system operators 

with each other. Thanks to the network, a suitable 

supplier can always be found quickly. This prevents 

long downtimes and expensive storage costs. Beumer 

Group supports founder Lars Meir Veisberg, bringing 

digital projects into its corporate group. 

tory and buy components from other members. “We created a huge 

virtual warehouse”, says Veisberg. “We enable members to share 

components.” They receive the required spare part quickly; long 

downtimes are a thing of the past. 

The founder receives extensive support from the Berlin-based, 

autonomous company builder Beam, a spin-off of Beumer Group. 

“We try to solve unique problems in logistics together with the startup 

teams”, explains Managing Director Robert Bach. “My task is to 

find young entrepreneurs with business ideas that are relevant to 

us. For this we are planning on founding three start-ups per year 

and transfer them, consolidated under Beam, into a separate company. 

This now includes Sparrow Networks.” Beumer Group wants 

to open up new business areas in logistics with these companies. 

Spare parts for all 

LOGISTICS 

“We were missing a sensor. One simple part that would have cost 

500 euros. In the end, the failure cost us several hundred thousand 

euros”, says a logistics service provider. “This is a common problem”, 

says Meir Veisberg. “Time and again it happens that in the event of 

a failure the right components are not in stock.” And it takes time for 

the suppliers to deliver them – too much time which can be very 

expensive. He has worked out an efficient solution together with his 

start-up Sparrow Networks: he provides a digital marketplace 

where the participants can offer components from their own inven- 

“In discussions with Beumer experts, suppliers, and customers, I 

found out that small and medium-sized companies often aren’t big 

enough to maintain a huge parts stock. And when they do, they do 

not always have the components they need”, says Veisberg. If an employee 

accidentally hits the sortation system with a forklift, damaging 

a motor that is not stocked as a spare part, this can result in long 

downtime. The question for companies is: Which spare parts should 

they store and in what quantity? Depending on the components 

required, the associated costs can be very high. But if they are not 


needed, they are dead capital. Delivery times can be quite long. 

Moreover, suppliers are usually unaware of their customers’ stocks. 

Planning production is therefore often not easy for them. 

Members of the new platform benefit from an almost unlimited 

pool of spare parts. Thanks to the high availability, their systems 

experience significantly less downtime, they can reduce their own 

stock and keep fewer parts in stock in the future. These are significant 

cost savings. And due to the constant exchange, older parts are 

always replaced by new ones. 

Motivation and at least two years of experience 

“Not everyone is suitable to be a founder”, says Beam Managing 

Director Bach. “We require at least two years of start-up experience 

or very good knowledge of the logistics sector.” Veisberg has been 

living in Berlin for some time now. “What I did before? I worked as 

a product manager for a long time – until I got to know Beam and 

Robert Bach. Since September, you can access our digital marketplace 

under www.sparrow.parts”, says Veisberg. The founder manages 

the data exchange and ensures the quality of the inventory. 

Every registered potential buyer can offer their own stock on the 

online marketplace. “Sparrow lives on this. The participants provide 

as many spare parts as possible”, Veisberg describes, “but the 

participants only upload the quantity they want.” After all, no company 

should find itself in the unpleasant situation of no longer being 

able to access a spare part that is suddenly needed in an emergency. 

“Data security plays a very important role for us”, says the 

founder. Customer data is always protected. Once the deal is closed, 

Sparrow takes care of the delivery. 

Optimize the supply chain 

“By participating, the customer benefits from a very large pool of 

spare parts”, promises Bach. This pool is also the first step in improving 

supply chains: System operators who need the spare parts 

can network with each other to cover their parts requirements. 

“Now, if suppliers and system integrators are provided with the 

necessary data and kept constantly informed about requirements, 

they are able to optimally plan their production and avoid long delivery 

times. There is a great deal of optimization potential here”, the 

Beam Managing Director is certain. 

With the start-up, Beumer Group can successfully pursue its goal 

of bringing digital solutions into the corporate group. For example, 

in urgent cases, the system provider can now provide its customers 

with even better support, strengthening its position on the 

market. And Sparrow Networks? “I benefit from the cooperation 

with Beumer Group in the form of generous start-up financing, an 

extensive network of experts and customers, and a great deal of 

know-how”, Veisberg says happily. “My company is now part of the 

Beumer family.” 

Photos: Beumer Group 

www.beumer.com 


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Phone: 0049/6131/992-245 

c.nawrath@vfmz.de

WORLD OF INDUSTRIES 2/2020

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