Author Archives: Bernard and Company

Siemens Introduces The New Sinamics V20 Drive for Basic Applications

CHICAGO — Siemens introduced today its new single-axis Sinamics V20 drive for basic applications featuring short commissioning times, easy operation and excellent cost and energy benefits.  The Sinamics V20 comes in four frame sizes covering the performance range from 1/6–20hp and is used to operate pumps, fans, compressors and conveyor systems, and is also used for simple drive tasks in the processing and handling industries.

This compact drive can be connected directly in-line and mounted as a push-through installation in addition to the conventional wall-mounting method.  Since no further modules or add-on options are required for operation, the installation time is minimized.  Additionally, the integrated Basic Operator Panel (BOP) enables trouble-free on-site commissioning and operation.  Besides the universal serial interfaces that allow for easy connection to Simatic PLC controllers, a Modbus interface is also included for communication with third-party controls.  Pre-built connection and application macros are used for facilitating application-specific settings.  For units with power ratings higher than 10hp, a braking resistor can be connected directly to integrated braking chopper.

Operation of the new Sinamics V20 drive is just as easy as its commissioning.  Parameters that have been optimized for one application can easily be transferred to other units using SD or MMC cards via the BOP interface or the battery-operated Parameter Loader — even without powering up the drive. The current firmware can be easily loaded as well.

Tailored inter-connectivity and application macros (i.e. for pumps, fans and compressors) provide the correct settings for the particular application.  The Keep Running Mode automatically adapts the Sinamics V20 drive to the power supply to achieve higher availability when operated on unstable networks.  In this mode, line fluctuations are compensated for internally and error messages are acknowledged autonomously.  Due to the enhanced cooling concept and coated PCBs and electronic components, the Sinamics V20 is extremely rugged, both electrically and mechanically, making the unit reliable even in harsh environments.

The demand-driven regulation of the motor speed also provides increased energy savings even for basic applications. The Sinamics V20 is equipped with an energy-optimized control mode (ECO-mode) for increased energy efficiency.  ECO-mode automatically adapts the magnetic flux in the motor to the optimum operating point.  In addition, the DC link coupling enables efficient energy utilization of drives grouped together.  Further, the Sinamics V20 can be set to hibernation mode, which prolongs the service life of the motor and also reduces system component wear (i.e. pumps). Additionally, by displaying real-time energy consumption on the operator panel display, the operator always has the drive’s energy and cost efficiencies in focus at all times.

For more information about Siemens solutions for the conveyor and material handling industry:

SIEMENS INDUSTRY, INC.
Drive Technologies — Motion Control
390 Kent Avenue
Elk Grove Village, IL  60007
Phone: 847-640-1595 Fax: 847-437-0784
Web:  www.usa.siemens.com/motioncontrol
Email:  SiemensMTBUMarCom.industry@siemens.com
Attention:  John Meyer, Manager, Marketing Communications

 

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NOARK Enters North American Market at AHR 2013, Booth 5700

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James Tool Achieves AS9100 Registration and Completes Facilities Expansion

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New Managing Director for Hunter Asia/Pacific Operations

Mr. Peter Li will assume the new position of Managing Director for all Hunter Asia Pacific Operations, effective February 1, 2013.  Hunter is the world leader in automated matchplate molding machinery and mold handling lines for the foundry industry.

Peter Li’s 16-year career with Hunter has been dedicated to sales and manufacturing management in the Asia Pacific (A/P) territory. He was instrumental in the successful development of the company’s China operation, “Hunter Automated Machinery (Shanghai) Ltd.”  Today, Hunter builds machinery and other equipment in China to serve the A/P market.

Peter will be responsible for A/P marketing and manufacturing programs, including the Shanghai plant, the expansion of our agent network and the integration with new partners where necessary for Hunter to compete effectively in the local markets.

For further information on this announcement, interested parties may contact:

HUNTER AUTOMATED MACHINERY CORPORATION
2222 Hammond Drive Schaumburg, IL 60196
Phone: (847) 397-5110
Fax: (847) 397-8254
Email: info@hunterfoundry.com
Attention:  Bill Hunter, CEO
Web: www.hunterfoundry.com
Connect with Hunter Foundry online:    

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JetSlinger from Hunter

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Oilfield Technology: The Perfect Machining of Threads On Delivery Pipes and Casings

Whether we are talking about North America, Asia or Russia, within the oil and gas industry, there is a spirit of optimism. Geological discoveries have led to a massive increase in the estimated reserves in many countries. Along with these discoveries, the potential for the use of innovative technologies has also increased. According to the expert estimates, oil production in the Gulf of Mexico alone will rise from the present 1.3 million to 1.7 million barrels a day during the next decade, with demands for the highly sophisticated technological equipment required to accomplish it increasing as well. Two examples are delivery pipes and casings.  To create the connection safely and in perfect alignment depends on the threads on the pipe ends. With its USC turning machines, the specialists from EMAG Leipzig have not only created a tool that specializes in this application – and one that has perfected the production sequence for these threads – but also developed complete solutions that guarantee component quality and process integrity.

Economic key performance indicators for suppliers to the oil and natural gas industry change rapidly. An impressive example of this is found in the USA. The USA hopes to reduce its dependence on oil imports and instead invest heavily in new technology. An indicator, for the US, are imports of equipment technology for the American oil and gas industry, which the U.S. Department of Commerce for 2012 show an increase of 33 percent, compared to the previous year. The experts also expect a production boom in South America and Asia. For Brazil, the foreign trade experts at Germany Trade and Invest (GTAI) predict a “high level of growth in new reserves“. And on the other side of the globe, the investment volume in the oil and gas sector of Vietnam alone has reached 40 billion USD, according to GTAI.

The experts at EMAG Leipzig are aware that this extraordinary dynamic has a direct impact on the production of the required technology. For decades, the machine builders at Leipzig have been specializing in the machining of delivery pipes and casings for the oil and gas industry. Many users can no longer do without their special know-how in demanding thread production. Frank Schiffler, Head of Sales, fills us in on the background: “We are talking about a gigantic production output. One steel mill produces up to 2 million metric tons of pipes per annum. Component quality is paramount for these because the pipe threads have to be totally leak-proof and must carry the enormous total weight of pipe and oil during the delivery. The machining centers used must ensure that the quality and efficiency of the threads produced is 100%.”

Flexible solutions for the production of pipes

The USC series from EMAG Leipzig Maschinenfabrik represents an extraordinary, sophisticated solution for this particular production requirement. Flexibility is very important in the construction of these turning machines. Not only do the different machine sizes allow for the complete-machining of different sizes of pipes with external and internal threads to API and GOST standards, they can also cut all proprietary threads. “The larger oil field technology producers have their own thread standards.  We can adjust our machines perfectly to their demands“, explains Mr. Schiffler. For instance, all workholding and centering equipment is configured to suit individual requirements. The same applies to all automation components. As a result, the customer has an extremely fast production solution that automatically loads and unloads the components in 12 to 20 seconds (depending on pipe size and thread type), then carries out the 3-part threading process – from facing to chamfering and finally threadcutting. The output ratio therefore increases enormously, compared with that of traditional turning machines.

However, there are two important factors that must be taken into account when machining threads on delivery pipes and casings: processing quality and process integrity. The quality is guaranteed by a perfectly adjusted machine, with proven EMAG technology and the know-how of the speciality machine builders from Leipzig come together. The whole process benefits from the following important design details:

• The machine base is made with Mineralit (a polymer concrete) and guarantees the stability and the vibration-resistance of all machine components.
• The main drive forms an integral part of the spindle unit. Its frequency-controlled, maintenance-free AC asynchronous motor provides a high torque rate, which allows for the simultaneous machining of both ends of the pipe.
• The pipes are safely clamped in front and rear chucks that – depending on workpiece requirements – can be actuated pneumatically, hydraulically or mechanically.
• The pipe ends are stabilized during the machining process by the insertion of vibration-reducing mandrels, resulting in the highest possible precision.

“This quality is a feature of all our USC series machines,” acknowledges Mr. Schiffler. Depending on the machine used, the max pipe diameter can be any dimension from 2⅜” to 20”.

Complete solutions guarantee process integrity

When faced with high production rates, fast machining processes and expensive pipe blanks, machine downtimes are particularly costly for the manufacturer. For this very reason, the process integrity of these machines is another key development area in Leipzig. “We design complete solutions for our customers, who – in turn – benefit from the quality of the EMAG components“, explains Mr. Schiffler. “In addition to that, we integrate, for instance, measuring stations, crack detection equipment, embossing and plating units and, of course, a monitoring system that covers all components. At the end, what we supply is a production system that guarantees the greatest possible degree of process integrity.“ Of similar importance in this context is the worldwide service presence of the specialists. Not only are both user and maintenance staff trained to perfection, a 24-hour 365-day telephone service is also available. This ensures that possible machine downtimes are reduced to an absolute minimum.

Projects from A to Z

How do the special machine manufacturers assess their market opportunities over the next few years? Mr. Schiffler’s judgement on the market’s dynamic is a positive one: “We already are the market leader in machines for the threading of oil and gas pipes; and we intend to further extend this position.“ One formula for success in this field is the famous “Made in Germany“ – which is a sign for quality. Over 70 percent of the machine components are made and assembled at EMAG in Germany. Every customer comes to Leipzig for the machine acceptance, where the first test run, using the actual pipe blanks, is carried out. Only then will the machine be installed at the production site. “Our particular quality of service kicks in long before the machine is built, or the central claim made by EMAG Leipzig would not be a valid one. Our name stands for projects that are carried through to perfection from A to Z, and that represent all-round solutions.“

See the USC series in action HERE.

For more information:

Kristal Kilgore
EMAG LLC
38800 Grand River Avenue
Farmington Hills, MI 48335
Tel: (248) 875-0313
Fax: (248) 477-7784
E-mail: kkilgore@emag.com
Web: www.emag.com

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New 1:4 Speed Multipliers from Heimatec

24,000 RPM max. styles available for all popular machine tools

Heimatec, a world leader in live tools, angle heads and multi-spindle drill heads, announces immediate availability of its newest development, a line of 1:4 live tool speed multipliers in 24,000 RPM max. styles, available for all popular live tool lathes currently on the market.

These speed multipliers are provided as axial or radial drilling and milling heads, with either external or internal coolant design, and mounting configurations to suit virtually any machine tool turret set-up, including all VDI and BMT sizes.

Speed multipliers for Haas and Nakamura machines are now in stock with others in production for short lead time deliveries.

According to Heimatec President Preben Hansen, “As our presence in the American machine tool market continues to expand, so does our product line.  These speed multipliers are a great addition to our line.  They give us more to offer the job shop and large production departments, through our growing network of reps and distributors, serving the market here.”

For further information and literature, or to arrange a demo on this new line, please contact:

Preben Hansen, President
HEIMATEC INC.
16 E. Piper Lane Suite 129
Prospect Heights, IL 60070
Phone:  847-749-0633
Fax:  847-749-2445
Email: info@heimatecinc.com
Website: www.heimatecinc.com

Connect with Heimatec Inc:  

—

Heimatec is an international tooling manufacturer, based in Renchen, Germany. Its experienced staff is dedicated to providing customers the most innovative tooling technology possible. In 2010, the company opened Heimatec Inc. in Prospect Heights, IL, near Chicago, to serve its growing North American customer base with sales and service, plus an extensive inventory of products. Heimatec serves the auto, aero, medical, off-highway, rail, energy, woodworking, composites and other industries, as well as an ever-increasing number of machine tool OEM’s worldwide.

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Floor-level Cabinet Oven from Grieve

No. 981 is a 350ºF, electrically-heated floor-level cabinet oven from Grieve, currently used for curing flat urethane sheets at the customer’s facility.  Workspace dimensions of this oven measure 48” W x 48” D x 60” H.   18KW are installed in Nichrome wire elements to heat the oven chamber, while 2000 CFM, 2-HP recirculating blowers provide horizontal airflow to the workload.

This Grieve oven has 4” insulated walls, 2” insulated floor, top-mounted heating chamber, Type 304, 2B stainless steel interior, stainless steel exterior with #4 brushed finish, double doors front and rear, plus a special sealing flange to allow the oven to seal into a wall between a cleanroom and the fabrication area in the customer’s facility.

Controls on No. 981 include a digital indicating temperature controller, manual reset excess temperature controller with separate contactors, recirculating blower airflow safety switch and a 30-hour shutdown timer.

For more information, please contact: THE GRIEVE CORPORATION, 500 Hart

Road, Round Lake, Illinois 60073-2835 USA.  Phone: (847) 546-8225.  Fax: (847) 546-

9210.  Web: www.grievecorp.com. Email: sales@grievecorp.com. Attention: Frank

Calabrese.

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Small Grinding Center Offers Big Productivity Boost

Automobile manufacturers all over the world were able to enjoy an increase in their sales figures, this year! The biggest increases were experienced in the USA, China, India and Russia. However, the rapidly increasing number of vehicles built also brought some production challenges – for instance, the sub-contractors must deal with the increasing output levels and also need to ensure that process safety and component quality do not suffer. In fact, even the smallest components with complex geometries must be produced with increasing levels of precision.  In the development of the VLC 100 G Vertical Grinding Center from EMAG, our grinding specialists have made sure that the machine concept offers efficient, error-free machining processes for the production of small chucked components.

Small chucked components are typically produced in large quantities. The demand for components, such as gearwheels, planetary gears, chain gears and flanged components for cars, for instance, have necessary quantities that typically go into the millions; and short cycle times in the production of these components have become mandatory. For instance, the internal contour of a gearwheel must be ground in the shortest possible time and the machine’s workholding unit must be loaded with a new workpiece just as quickly. In many production environments, this represents a critical moment, because the idle time is commonly a decisive factor in establishing the economic viability of the whole process.

Automatic loading scores heavily

High output levels – short cycle times. This is exactly why the VLC 100 G Vertical Grinding Center from EMAG, for small chucked components with a maximum diameter of 100 mm, was developed. The machine utilizes its onboard pick-up system to load itself. And while one workpiece is being machined, the operator – or the automation system – is putting the raw-parts on the conveyor belt. This reduces idle time and increases output rates. Another benefit is the vertical machining concept; the design ensures that the grinding sludge falls to the bottom of the machine unhindered, where it is then transported out of the machine. (Click HERE for a video detailing the VLC 100 G Vertical Grinding Center)

Quality control is integrated

Measuring processes can also be integrated into the machine, making quality control an integral part of the whole process. The measuring probe is located between the machining area and pick-up station, where it is protected from contamination.

In use are two different grinding wheels

An important feature of the VLC 100 G is that it offers the possibility to use two grinding spindles, which can be used to perform different grinding operations, or to handle both rough- and finish-grinding work.  In other words, the first wheel performs the “rough” job of removing excess material from the raw-part at high feedrates (the CBN wheel is specially designed to absorb the necessary forces), while the second wheel (with different specifications) takes over the finishing work to guarantee a perfect surface finish on even the most challenging geometries. With the help of this intelligent tooling combination, EMAG design engineers have succeeded in drastically reducing the grinding time of even very complex components. “For the removal of large amounts, two wheels offer a shorter cycle time than one, with the first wheel designed to do the rough-grinding and the second one in charge of finish-grinding work,” explains Dr. Guido Hegener,  Managing Director of EMAG Salach Maschinenfabrik GmbH in Germany.

A convincing machine concept

The combination of fast loading and efficient grinding processes leads to a very compelling machine concept. The VLC 100 G works very well with the dynamic developments in automotive production. Now, with the rapid increase in required quantities, the demand is for new machine concepts that can be integrated into existing production without any problem. With the VLC 100 G, two features enable it to be integrated without any problems. “Programming the workpieces with our new EMAG NAVIGATOR software is simple and intuitive, saving valuable setup time. For many production environments, this is an advantage that should not be underrated,“ confirms Dr. Hegener. Furthermore, the exceptionally small footprint for the VLC 100 G should make the work of every production planner easier. The stand-alone machine occupies about 4.5 square meters (48 square feet), making sure that the growth of a production facility of this kind will not be limited by floor space requirements.

The advantages of the VLC 100 G

• Compact grinder with the highest precision
• The machine can accommodate both internal and external grinding spindles.
• Integral automation, short travel times = short chip-to-chip times
• Vertical machining = unhindered chip flow, with the grinding sludge falling to the bottom
• Optimal access = fast setups
• Great process safety through the use of an optional measuring probe

For more information:

Kristal Kilgore
EMAG LLC
38800 Grand River Avenue
Farmington Hills, MI 48335
Tel: (248) 875-0313
Fax: (248) 477-7784
E-mail: kkilgore@emag.com
Web: www.emag.com

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Bretting Develops New Controls Platform for Napkin, Interfold Towel and Tissue Machine Lines

Planning and partnerships lead to success on export machine series

C.G. Bretting Manufacturing Company Inc. has been in business for over 120 years, serving the OEM paper converting industry and providing contract manufacturing services for more than 60 years. Bretting is located in Ashland, Wisconsin on the southern shores of Lake Superior. The fourth generation of the Bretting family leads the business today, while the fifth generation is currently on deck.

OEM paper converting equipment converts rolls of paper into folded and rolled paper products such as napkins, interfolded napkins, singlefold facial tissue, multifold paper toweling, kitchen towel rolls and bathroom tissue rolls.  Bretting is an industry leader in global sales and service of OEM paper converting equipment. Machines are designed, manufactured, assembled and tested at the Ashland factory, prior to shipping to the customer’s site for set-up and commissioning.

Bretting recently delivered its first paper converting machine controlled entirely by Siemens hardware and software.  The project was a major undertaking for Bretting, Siemens and Standard Electric (local Siemens distributor) and was deemed a great success, according to Dave Vedder, director of engineering, C.G. Bretting.  “Planning and partnerships with our vendors were keys to our success on this first 41-axis Siemens-controlled machine.  We planned for success and achieved it. The project started more than 24 months prior to delivery of the machine to the customer.”

Vedder continued to explain the process.

“The project started with listening to our customers, who had been requesting Siemens automation on our equipment for some time. Meeting customer needs is a Bretting strength. We realized it was time to act.  The Bretting Leadership Team commissioned an effort to provide an acceptable solution. That solution comprised Sinamics drives, Simatic PLC and Simotion motion controllers.”

The purchasing department then met with the local distributor, Standard Electric. Meetings were organized with Standard Electric, Siemens and Bretting within several weeks.  Planning for the first Siemens machine was initiated.   It was determined the products and software available would satisfy the full range of Bretting machine functionality and other requirements. Initial planning included:

• The establishment of partnerships, along with clarification of pricing, delivery, support and inventory levels
• Small dedicated R&D lab for training, programming and testing
• Training for field service, hardware engineers and software programmers
• First Machine Support for engineering, programming, build, startup and full commissioning in the field

A formal customer inquiry for a new machine followed about six months later.  The inquiry included a requirement for a full Siemens automation solution on the customer’s new paper converting machine.  Bretting, Siemens and Standard Electric were now well prepared and ready to respond, Vedder explained. Proposals for the machine with full Siemens automation solutions were shared with the customer.  A new set of planning protocols was started, one that focused specifically on the first Bretting paper converting machine to be equipped entirely with the new vendor’s products and software onboard.

First machine planning included-

• Siemens hardware and software engineering coaching
• Bill of Material reviews
• Schedules for parts ordering and delivery
• Machine build support
• Machine startup support
• Machine installation in the field support
• Warranty and field issue support process

The customer ordered the machine approximately six months after the initial inquiry.  The plans for the first machine were approved and authorized for production. Some checks and adjustments were required during the machine engineering and build process. “The combined talents of Siemens, Standard Electric and Bretting addressed and resolved any issues as they occurred,” Dave Vedder explained. “The customer approved the machine during the Final Machine Checkout process. The time from Order to Checkout was similar to other machines we’ve produced during recent years.”

The machine was then disassembled and shipped to the customer’s site in Europe. The reassembly, startup and final commissioning proceeded without issue.  The machine is currently running successfully in the field, with no significant service issues reported, according to Vedder.

Planning and partnership were key to the success of this first export paper converting machine with Siemens automation onboard, all made possible by the combined efforts of the machine builder, the controls supplier and the local value-adding electrical distributor.

Bretting is an ISO9001:2008 Certified manufacturer with sales representatives worldwide.

For further information on this story, please contact:

C.G. BRETTING MANUFACTURING INC.
3401 Lake Park Road
Ashland, WI 54806
Phone: 715-682-5231
Web: www.bretting.com
Attention: David Vedder, Director of Engineering

or

SIEMENS INDUSTRY, INC.
Drive Technologies — Motion Control
390 Kent Avenue
Elk Grove Village, IL  60007
Phone: 847-640-1595 Fax: 847-437-0784
Web:  www.usa.siemens.com/motioncontrol
Email:  SiemensMTBUMarCom.industry@siemens.com
Attention:  John Meyer, Manager, Marketing Communications

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