Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
At both the AIST Iron & Steel Show and the Forge Fair, Advanced Machine & Engineering will be displaying their carbide circular sawing systems.
AMSAW® high-speed, production saw machines are specifically designed to use carbide blades to improve the cutting speed of ferrous and non-ferrous material, bars or billets, rails, profiles, pipes and tubes. Standard design features include:
Options include: stock size measuring, automated length measuring systems, bar manipulating systems, infeed and outfeed systems and stackers.
Also displayed will be various chip conveyors, safety devices and machine enclosures offered by AME and its sister division, Hennig.
Advanced Machine & Engineering Co., is a manufacturer located in Rockford, IL, serving the Machine Tool Industry with precision components and accessories, including spindle interface components, workholding devices, and, through our sister company, Hennig, machine enclosures, chip removal and filtration systems. The Fluid Power – Safety markets are served with cylinder rod locks and safety catcher devises; and the Production Saw market with our Amsaw carbide saw machines and Speedcut blade products. AME has manufacturing partners and customers around the world and across the U.S. To learn more, visit www.ame.com.
Hennig, Inc. design and produces custom machine protection and chip/coolant management products for state-of-the-art machine tools. Hennig products are designed to protect against corrosion, debris and common workplace contaminants. Manufacturing facilities located in the U.S., Germany, Brazil, India, Japan, China and South Korea. Repair centers are located in Machesney Park, IL; Chandler, OK; Livonia, MI; Blue Ash, OH; Mexico City, Mexico and Saltillo, Mexico. To learn more, visit www.hennigworldwide.com.
For more information, contact:
Tim Waterman
ADVANCED MACHINE & ENGINEERING CO.
2500 Latham St.
Rockford, IL 61103
Phone: 815-316-5277
Fax: 815-962-6483
E-mail: info@ame.com
Connect with AME online: 
Practical Operation
The SCHÖMA machine factory opted for a cycle turning machine with Sinumerik 840D solution line CNC for the manufacturing of individual parts and small batches of locomotive wheels; this machine also features Siemens ShopTurn with Manual Machine function. This hardware and software solution combines the flexibility and benefits of conventional machining with the productivity and efficiency of a CNC and this is what tipped the balance in its favor for one customer.
Christoph Schöttler Maschinenfabrik GmbH (SCHÖMA) is based in Diepholz, Germany. The company specializes in the development and production of diesel-engine locomotives. The model range includes tunnel and shunting locomotives; service, field and narrow-gauge locomotives; handcars, passenger carriages and gang cars. Around 90 percent of the locomotives produced each year at SCHÖMA are destined for use in tunnel construction.
Each construction project brings its own specific requirements and each country through which the locomotives travel has different environmental and safety legislation. SCHÖMA uses a modular system to meet a diverse range of customer requirements and the resulting need for a variety of equipment and product versions. One of the tasks facing the company is working out how to equip the locomotives for transportation by rail on differing track widths. Another requirement is locomotives with driving wheels featuring diameters between 600 mm and 900 mm, depending on local track usage.
The right decision
Faced with even more demanding requirements in terms of production capacity and flexibility, SCHÖMA’s Managing Director, Christoph Schöttler, last year decided to add a cycle-control Seiger Record LC 1400 lathe to his inventory of machines. “We opted for a head turning machine, as we do not need a tailstock to produce driving wheels, axle bearing housings and gear wheels. It is working just as we envisioned, so we obviously made the right decision,” says Schöttler.
SCHÖMA constructs around 120 locomotives each year, which equates to 480 wheels. In addition, there are also repair orders, which increase the workload to between 560 and 600 driving wheels per year. These wheels are produced in two mountings from forged blanks on the cycle turning machine. The first mounting is used to machine the wheel flange on the reverse side and the wheel hub. The shaft locating bore is pre-turned. In the second mounting, the first task is to pre-turn the driving wheel profile, then the rolling circle level and the wheel shaft locating bore are finished.
Careful approach
The cycle turning machine is controlled by a Siemens Sinumerik 840D sl CNC, equipped with the ShopTurn software package with Manual Machine feature. If required, ShopTurn programming can be performed on a separate PC as part of an operator’s work planning, without interrupting the work sequences on the machine. The programs are routed to the machine via the network, where they are called up as required, depending on the workpieces to be produced. The Sinumerik CNC is used for both numerically controlled machining and manual operation with the ShopTurn’s Manual Machine functions. In manual mode with electronic handwheels, the machine behaves just like a conventional lathe with an actual value display.
During face and longitudinal turning, the process operates with the entered feed and spindle speed. The real highlight of the system is that every cycle can be used straightaway, without having to create a custom program. At SCHÖMA, the option for manual intervention is used for setting the zero point or for simple contours. Diameters are determined manually, if driving wheels have been newly profiled or if driving wheel profiles require resurfacing. The wheel profiles abrade as a result of the high loads experienced in heavy-duty operation or on poor-quality tracks or as a result of the driven wheels skidding.
“With a machine that uses only CNC, it is difficult to rework the driving wheels, as it is not possible to determine how much material needs to be removed. With this optional manual mode, however, users can adopt a careful approach. This sums up the ease of control,” explains Walter Horstmann, head of mechanical production and wheel set construction at SCHÖMA.
Siemens ShopTurn with Manual Machine for the job shop
After machine start-up, the basic MANUAL screen is immediately displayed and offers direct access to choosing machining options without having to create a parts program.
Machining procedures such as “taper turning” and “straight line face and longitudinal turning” can be executed immediately. The operator simply selects tool, feed speed, spindle speed and orientation, plus, if required, machining angle, then presses “Start”. The active direction is graphically displayed in the basic screen, using a compass rose symbol. All machining steps such as entry, thread grinding and drilling can also be started in manual mode.
For additional product information and inquirie, contact:
SIEMENS MACHINE TOOL BUSINESS
John Meyer
Manager, Marketing Communications
Siemens Industry, Inc.
(847) 640-1595
www.usa.siemens.com/cnc
SiemensMTBUMarCom.industry@siemens.com
Follow us on Facebook: www.facebook.com/SiemensCNC or Twitter: www.twitter.com/siemens_cnc_us.
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Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit. For more information, visit http://www.usa.siemens.com/industry.
The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability. For more information, visit http://www.usa.siemens.com/drivetechnologies.
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Grenzebach automates new High-Speed Stacker with Siemens SIMOTION motion control and SIMATIC PLCs fully integrated into one system, for increased throughput, reduced production costs, better finished glass quality and improved safety.
The float glass industry is facing multiple challenges, not the least of which is a growing array of applications requiring a broader offering of products and sizes, and competition from offshore producers.
The need for more flexibility and speed in the production process has never been so important. Similarly, the necessity to reduce production costs and optimize profit margins has never been so critical. Smart glass producers are finding that replacing manual functions with streamlined automation is not only meeting these objectives, but also has become a requirement for long-term stability and success.
Of all the functions on the float glass line, stacking remains the most labor intensive, and therefore a key target for automation. Glass producers have been looking for a more efficient, reliable and cost-effective method to stack the expanding selection of glass sizes they manufacture. Some producers have automated their stacking, but have experienced difficulties with speed of throughput, because of glass stacking displacement causing breakage.
But many more float glass producers are still handling stacking manually without the aid of any controls automation.
Fully automated cold-end line
Effectively streamlining the uniformity and quality in the making of plate glass – a new generation of glass-handling equipment has emerged, which is destined to change the landscape of cold-end line process efficiencies. Developed by Grenzebach, in tandem with Siemens, a new line of glass-handling equipment is being released featuring integrated controls systems that provide a fully automated solution to the handling of finished float glass. Every function of the cold-end line is being integrated into one controls automation platform – including take-over of the glass from the lehr, cutting the glass ribbon into sheets of optimum size, glass snapping, rejection of faulty glass sheets, sorting according to size and quality, and stacking into glass racks with robotics.
The cold-end line requires that multiple, continuously-operating functions be precisely and sequentially connected. Grenzebach and Siemens have effectively brought each of these functions into one complete and totally integrated automation controls system, with the net effect of reducing production costs and increasing throughput. This package of automation controls is equally applicable to individual machines in the line, so additional line equipment can easily be added to the system at the discretion of the plant.
Grenzebach
Grenzebach is a pioneer in float glass cold-end equipment. In 1974, the company developed the world’s first processing systems for automated float glass production. In addition to machines for transport and handling operations, and cutting and breaking lines, systems for identifying flaws, glass quality control and optimization of material yield have also been created.
Grenzebach Corporation is the U.S. subsidiary of Grenzebach Maschinenbau GmbH of Hamlar, Germany, which is a global manufacturer of production equipment for the flat glass and construction material industries. It is recognized as an international mechanical engineering company, with development and production facilities in Germany, the United States and China. Worldwide, the Grenzebach Group has some 1,400 employees.
High-Speed Stacker
The first piece of Grenzebach equipment to exclusively utilize this advanced automation technology is the company’s new High-Speed Stacker. Designed to increase glass manufacturer’s efficiency and flexibility, it was developed for stacking small glass formats with high cycle times, and is currently the only device which can stack glass sheets in less than a one-second cycle. The new system is the world’s most flexible glass stacker.
It is a robot-assisted float glass stacker, which reaches its speed from quickly forming sub-packs of glass and achieves its flexibility by stacking the sub-packs with a robot. The system improves employee working conditions and stacking accuracy and efficiency, while decreasing product damage and ultimately costs. The High Speed Stacker is an ideal answer to today’s flexibility and speed demands in the glass manufacturing industry.
The High-Speed Stacker stacks glass formats from 12” x 18” up to 73” x 97”, and then transports glass sheets by a suction belt into a packet frame, where each sheet is placed successively until a sub-pack has been created. Next the packet is transported to a robot for take-off, either from above or from the side, to be stored on a glass rack that is used to transport the product to other facility locations or to end customers.
The system’s six-axis robots are capable of correcting the stacking alignment and creating precise glass stacks. For small glass sheets, two packets are built up and stacked parallel. Using this production method, up to 80 glass plates per minute can be taken off and stacked. The robots have a payload capacity of up to 220 lbs. and also feature integrated energy supply systems to reduce floor space.
The stacker can stack multiple sizes of glass with varying orientation – landscape or portrait, tin side in or tin side out with accuracy and speed. The High-Speed Stacker offers manufacturers the flexibility to adapt to product variations and rack and equipment changes. Feeding can be performed in a double stream, so that two packets are built up and stacked in parallel. It can be integrated into existing side-legs, but also demonstrates its stacking qualities in off-line cutting operations.
High-Speed Stackers can automate the entire packing capacity of a typical float glass production line, and can completely eliminate manual packing of glass.
Ideally, the angle of the glass rack is known and accurate. Since glass is heavy and the racks are being exposed to rough handling during regular operations, this angle can change over time compromising the structural integrity of the rack. As a result, a conventional stacker would not stack the glass in an optimal manner and glass breakage could occur. The robot of the Grenzebach High-Speed Stacker scans the rack for dimensional and angular discrepancies and adjusts its stacking program according to the actual geometry of the rack.
“Our customers have been demanding a better solution for stacking the many different glass sizes that they manufacture,” says Gerald Haas with Grenzebach Corporation. “Until now, they have had to rely on manual labor for their stacking operations. With the High-Speed Stacker, not only do they improve their employee’s working conditions, but they increase their operational efficiency and flexibility.”
Totally Integrated Automation
Grenzebach’s totally automated cold-end line, and specific application to the High-Speed Stacker, is functionally based on Siemens’ concept of Totally Integrated Automation (TIA). TIA is characterized by its unique continuity. It provides maximum transparency at all levels with reduced interfacing requirements. It encompasses the field level and production control level, up to the corporate management level.
It also provides maximum interoperability, covering the controller, HMI and drives, up to the process control system. This reduces the complexity of the automation solution in the plant.
Motion Control, PLCs and Tech functions in one system
Central to Siemens’ TIA system in place with the Grenzebach line and High-Speed Stacker is SIMOTION®, Siemens latest generation of motion controller. SIMOTION, which includes a palate of high-tech control system components which are optimally harmonized.
Most machines require motion control (positioning, synchronous operation), PLC functionality and technology tasks (i.e. pressure control and temperature control).
The fusion of these functions into one system – as with SIMOTION – has a number of advantages, such as lower engineering costs, higher machine performance, the elimination of time-critical interfaces between individual components and simple, uniform and transparent programming and diagnostics for the entire machine with a single tool. The focus here is placed on a simple and flexible solution for numerous motion control tasks.
The motion controller, the drives and the motors encompass the scope of the Grenzebach cold-end line needs. This was a very big step forward technologically for Grenzebach, in terms of the wiring, drive integration and motion control. Taking standard, off-the-shelf Siemens technologies and applying them to a machine solution presented significant advantages to Grenzebach as an OEM.
Integrated with SIMOTION is Siemens SIMATIC® S7-300 automation system. Applicable for centralized and distributed configurations, it has the ability to integrate powerful CPUs with Industrial Ethernet/PROFINET interface. It can be set up in a modular configuration without the need for slot rules with I/O modules.
The Siemens SIMOTION motion control and SIMATIC controller provide a fusion of motion control, PLC and technology functions in one unit. This means that the new sophisticated stacking robots in use with the High-Speed Stacker can now be more easily controlled and operated.
Improved safety
A critical requirement of machine manufacturers and operators is seamless safety between humans and machines.
A truly safety-integrated system is a complete and consistent safety portfolio, which covers all tasks to be accomplished in the field of safety technology – ranging from detecting through evaluating, to reacting. In float glass production, safety is a critical concern. The automation built into the Grenzebach system greatly increases safety with handling sheet glass, resulting in far less accidents and injuries.
The Siemens S7 controllers are SIMATIC Safety Integrated, which provide the highest level of safety for humans, machines and environ¬ment. They are used to prevent accidents and damage resulting from a fault or mal¬function. The safety SIMATIC controllers monitor themselves, detect faults autonomously and immediately change into or remain in a safe mode when a fault occurs. They are optimized for use in production engineering and provide air-tight safety for all operations.
Fail-safe CPUs have been exercised for safety-oriented applications with the Grenzebach High-Speed Stacker and all other equipment on the cold-end line. The PROFIsafe profile for safe communication via PROFIBUS and PROFINET allows the integration of safety-related functions into standard automation environments.
Automation for a changing market
“We are making the SIMOTION and SIMATIC technology available to float glass producers so they can benefit from its system-wide controls capability and streamline their cold-end line production,” says Chad Shaffer with Siemens.
“This totally-integrated solution has been successfully applied to many other industries, but it is quite unique to float glass production until now.”
“Siemens has teamed with Grenzebach to help effect production efficiencies in the glass industry,” continues Shaffer. “More efficient equipment, safer production systems and a better bottom line for glass producers are our objectives.”
As glass producers deal with the influence of an increase in cheaper off-shore glass being imported and a more diverse product mix, production automation is more important than ever before. With new equipment providing better solutions, like the High-Speed Stacker equipped with a truly integrated controls package, glass fabricators stand in a much better position to operate their plants more efficiency and maintain a more competitive stature in the market.
Grenzebach Corporation can be reached by contacting: www.grenzebach.com
Grenzebach is a pioneer in float glass cold-end equipment. In 1974, the company developed the world’s first processing systems for automated float glass production. In addition to machines for transport and handling operations, and cutting and breaking lines, systems for identifying flaws, glass quality control and optimization of material yield have also been created.
The first piece of Grenzebach equipment to exclusively utilize this advanced automation technology is the company’s new High-Speed Stacker. Designed to increase glass manufacturer’s efficiency and flexibility, it was developed for stacking small glass formats with high cycle times, and is currently the only device which can stack glass sheets in less than a one-second cycle.
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
HAN-KWANG INTRODUCES THREE NEW LASERS
Korean giant enters U.S. market with big splash at recent FABTECH show
PL Machine
At the recent FABTECH show in Chicago, the largest builder of laser machines in Korea introduced three new CO2 lasers for metal fabrication, including two plate/sheetmetal machines and one tube/pipe cutter. Reaction from the attendees was very positive and interest quite high, as all three machines ran continuously throughout the show.
Details on the machines follow here:
Han-Kwang takes the next step in its technology development with the introduction of the Series PL laser system. Incorporating our unique Beam Radius Control (BRC) and Constant Beam Delivery System (CBDS), Series PL also features the newest Han-Kwang laser technology, our S5 High-Speed Cutting Head, which significantly increases the cutting speeds on all sheet metals, up to 1120 IPM for 20ga mild steel and 790 IPM for 16ga stainless. In addition, the practical machine design and highly functional, ergonomic controls make the Series PL the new benchmark in long gantry laser systems.
Features
• BRC-Beam Radius Control
Through optimizing the beam diameter for each different material and thickness, cut quality is greatly increased.
• CBDS-Constant Beam Delivery System
By keeping the entire length of the beam delivery constant over the work area, beam quality at the cutting focal point is enhanced.
• S5 High Speed Cutting Head
Adopting the new generation of the sensing board and the cutting head means cutting speeds for sheet metals such as mild steel, stainless and aluminum are dramatically increased.
• PMU-Plasma Monitoring Unit
Constantly monitors cut error such as plasma and restart with faster piercing and more stable cutting quality.
• LCS-Lens Crack Sensor
Built-in LCS monitors the status of lens contamination to give maintenance personnel instant alerts for replacement.
• Rotary axis for tube cutting
Cuts tubes up to 12” OD to give your operation substantial flexibility in work strategies
• Siemens SINUMERIK 840D with 15” touch screen
Use of the highest powered CNC, with open architecture and simplified set-up with plain language commands, plus full interface to your shop programming/monitoring network, means greater productivity at the machine and overall in your operation
• Onboard high-efficiency air filter & dehumidifier with monitoring window
Utilizing its own power supply, this unique Han-Kwang system guarantees contamination-free cutting and unmatched consistency.
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PS Machine
Han-Kwang takes the next step in its technology development with the introduction of the Series PS laser system. Incorporating our unique Beam Radius Control (BRC) and Constant Beam Delivery System (CBDS), Series PS also features the newest Han-Kwang laser technology, our S5 High-Speed Cutting Head, which significantly increases the cutting speeds on all sheet metals, up to 1120 IPM for 20ga mild steel and 790 IPM for 16ga stainless. In addition, the practical machine design and highly functional, ergonomic controls make the Series PS the new benchmark in short gantry laser systems.
Features
• BRC-Beam Radius Control
Through optimizing the beam diameter for each different material and thickness, cut quality is greatly increased.
• CBDS-Constant Beam Delivery System
By keeping the entire length of the beam delivery constant over the work area, beam quality at the cutting focal point is enhanced.
• S5 High Speed Cutting Head
Adopting the new generation of the sensing board and the cutting head means cutting speeds for sheet metals such as mild steel, stainless and aluminum are dramatically increased.
• PMU-Plasma Monitoring Unit
Constantly monitors cut error such as plasma and restart with faster piercing and more stable cutting quality.
• LCS-Lens Crack Sensor
Built-in LCS monitors the status of lens contamination to give maintenance personnel instant alerts for replacement.
•Siemens SINUMERIK 840D with 15” touch screen
Use of the highest powered CNC, with open architecture and simplified set-up with plain language commands, plus full interface to your shop programming/monitoring network, means greater productivity at the machine and overall in your operation
• Onboard high-efficiency air filter & dehumidifier with monitoring window
Utilizing its own power supply, this unique Han-Kwang system guarantees contamination-free cutting and unmatched consistency.
—————————————————————–
Han-Kwang takes the next step forward in fully automated tube cutting systems with the introduction of the new Series TL. All our experience in tube cutting technology has joined with our expertise in the design and engineering of materials handling systems to offer users a very affordable yet superior quality and highly flexible system for virtually non-stop production of tubes and shapes. Coupled with our exclusive Han-Kwang ProDesign 3D CAM/CAM software and fully controlled by a single CNC workstation, Series PL will provide unmatched productivity to your operation.
Highlight of the Series TL is our highly advanced S5 cutting head, which combines superior measurement and sensing mechanisms to change from signal size to pulse monitoring, resulting in optimum cutting conditions. This new cutting head design is further enhanced by Han-Kwang’s quick piercing nitrogen-injection technology. Smaller holes, quicker ambient area cooling and a substantial reduction in hole-to-hole cutting time will all benefit your production and your bottom line.
Features
• BRC-Beam Radius Control
• CBDS-Constant Beam Delivery System
• Magazine-fed bundle tube loading system
• Tube V-support system
• Rotary chucking system
• Completely enclosed safety workstation with automatic doors and light barrier system
• Panasonic 2500W resonator
• Cutting capability to 21’ long x 6” diameter
• Material thicknesses to 0.25” mild steel and 0.2” stainless
• Siemens SINUMERIK 840D, the highest-powered CNC on the market for maintaining complete processing cycle control by a single operator, using touchscreen and simple language commands
• ProDesign 3D CAD/CAM enabling fast adjustments to the production scheduling to yield maximum productivity from the system
• Unique Han-Kwang air filtration and dehumidifying system for cleaner cuts and more operator-friendly environment
For more information on this emerging new player in the laser machine market, please contact:
Robert Won, Director/North American Sales
HANKWANG USA, INC. Web: www.hankwang.com
Agency contact: Tim Daro Bernard & Company www.bernardandcompany.com
Fine tuning equipment at Joa
Seamless integration of Siemens drives, automation and controls products enabled faster startups and improved system productivity with Curt G. Joa, Inc. production machines in the nonwovens industry.
by Bill Gilbert, Application Engineer with Siemens Energy and Automation
In the market of baby diapers and personal hygiene products, competition runs high. Major players in this market know that the slightest changes in product features can yield huge profits for those manufactures that are first to reach the market with a more absorbent, comfortable or easier to use product. Behind this high-stakes competition, however, is another player, Curt G. Joa, Inc., one of the world’s leading manufacturers of machinery for the production of disposable products including baby diapers, sanitary napkins, incontinent pads and related single-use items. Before these products can come to market the production machines that make them need to be designed or retooled. The machine re-design process is frequent as product changes are ongoing. Additionally, there is tight security surrounding these machine design developments. In a first-ever move, however, Joa has allowed a rare glimpse into its manufacturing facility, spotlighting machine automation and a solution developed in concert with Siemens Energy & Automation, Inc.
Since 1932, Curt G. Joa, Inc. (Joa) has earned a worldwide reputation for leadership in the design and manufacture of quality equipment for converting non-woven’s, plastics, paper, films, foil, tape and elastics. The company has machinery operating in over 55 countries throughout the world.
It has created an engineering environment that provides the utmost confidentiality and personalized service. The company maintains a fully-staffed team of mechanical and electrical design engineers representing a complete range of machine-building disciplines. SolidEdge, AutoCAD and EPlan are the drawing standards it uses. The company builds machines to meet a variety of worldwide codes and standards.
Joa goes beyond process design, however, providing rapid prototyping of complete manufacturing processes. Using a broad array of existing converting modules, it builds, tests and verifies the processes for its clients. The company’s multiple test stands are capable of performing a wide variety of web processes at speeds of more than 450 mpm. Its machines can be configured to slit raw materials, apply adhesives, weld web layers, apply discrete patches of one material onto another and perform complex product folding. With this approach, Joa can efficiently provide shortened machine delivery schedules and validated process concepts to its clients.
From engineering and design through installation, Joa provides a complete web manufacturing solution to its clients for new systems and equipment upgrades and improvements. It is one of few global designers in the industry that does not outsource key manufacturing and assembly operations. It does, however, closely collaborate with qualified solution providers, such as Siemens on machine controls automation.
The company’s machines feature modular designs that reduce product changeover times and make future upgrades simple. The modular design drives the configuration of automation, human interface, operations and maintenance. Optional process features permit high-speed production of a wide array of product configurations. Depending on product type and machine design, maximum process speeds can range up to 1200 products produced per minute. Projects can range in technology from a simple rotary cut-off unit to major converting machines over 50 meters long, each using upwards of 150 servo axes.
Product testing at Joa
“A disposable products manufacturer recently contacted us about customizing a piece of equipment to go into its primary production line,” says Kevin Zeinemann, manager of Electrical Engineering with Joa, “The company was adding a new feature into one of its existing products. We began building a 8-meter machine section for them at our location. We were having some difficulty translating their machine’s existing program because we were attempting to cut and paste our new functionality into our client’s existing machine core functionality. Since this was not working we decided to put a stand-alone Siemens PLC into our machine section, bringing in Siemens techs to guide us through the process.”
“It worked out so well that when it was time to marry up the new machine section with our client’s existing machine at their location, they decided to move all of the information out of their main PLC and put it into the Siemens PLC that we had built,” continued Zeinemann. “The Siemens controller slated for use on the new 25-foot machine section, started as a tag-along and then eventually took over full ownership of the entire machine process because it had better functionality.”
The PLC that Joa integrated was Siemens SIMATIC® S7-400. An established platform, the S7-400 controller provides the highest performance in the Siemens SIMATIC S7 family.
A strong feature of the S7-400 is its modularity that is optimized for high-performance machine and factory automation, facilitating integrated and economical system solutions in centralized and distributed architectures. It has a CPU with integral I/O and integrated technology functions and integrated communications interfaces which create efficient processing speed for short machine cycle times.
“Our clients have different control configurations in place, and different comfort levels and preferences with their automation systems,” adds Zeinemann. “So, we work within their control specifications. I will say, however, that Siemens PLCs have excellent speed and performance. Our client has been quite happy with their functionality as well.”
“The Siemens processor also has an embedded safety functionality,” Zeinemann says. “Instead of having hard wired devices we were able to do a lot of safety interlocking via the PLC itself, and then network to our many different devices with a simple ProfiNet connection.”
The S7-400 controllers with safety integration provide the highest level of safety for humans, machines and the environment. They are used to prevent accidents and damage resulting from improper operation. The safety integrated controllers monitor themselves, detecting faults automatically and immediately.
Single Master Drive with Cascading Motion Commands
For the drives, one of the features uniquely designed into the system is the Siemens FM458 drive controller module within the S7-400 PLC. This controls a single master drive that cascades multiple virtual masters to control subsequent groups of drives. Instead of making a synchronized speed change, gear ratio correction or phase advance to each virtual drive, just one change to the master is needed, and every drive in that group will follow.
“Our client also needed 34 additional servo drives to be installed into their new 25-foot machine module,” continues Zeinemann. “They already were using 300 to 400 Siemens Masterdrive® servo motors on the equipment in their plant, so we specified Masterdrives into our new section as well for compatibility.”
The Masterdrives offload much of the performance that the PLC would normally have to handle. It puts it into the drive enabling the processor to pick up speed. The S7-400 PLC communicates to all 34 of servo drives and parameterizes them to send information back and forth. The drives follow at whatever speed they are told to run.
Siemens Masterdrive servo motors are ideal where high dynamic performance and intelligent motion control functions are required. They can handle the most complex motion sequences.
Joa and Siemens’ technicians setting up a machine on site.
High-Speed Communications Link Improves Performance
As the demand for performance increases, automation networks used to control drive systems have become a limitation to quality and throughput. While open networks have been developed to control, configure and parameterize drives, they are limited by the overhead required to carry out non-control functions. To remedy this, Siemens developed SIMOLINK® designed to be a 100 percent control bus with none of the bandwidth stealing functions that could be carried out over a standard fieldbus.
Integrated into the Siemens control systems used on Joa machines, SIMOLINK provides the high-speed communications link required to synchronize set points from a single external master. It enables peer to peer data transfers between drives, and synchronizes the processor time slices of multiple drives and controllers. While operating at 11 megabits per second with very little overhead, 100 pieces of 32 bit data can be transmitted in 0.63 milliseconds. A high-speed synchronization pulse ensures that the data is acted upon in every drive at the same time. SIMOLINK provides Joa equipment with the high-speed communications required to reduce process variance and increase quality.
Totally Integrated Controls Automation – Faster Start-Ups and Improved Productivity
The Siemens automation solution that Joa employed is based on a concept called Totally Integrated Automation (TIA). TIA is characterized by its unique continuity, providing maximum transparency at all levels with reduced interfacing requirements. Its influence covers everything from the field level and production control level, up to the corporate management level. It also provides maximum interoperability, including everything from the controller, HMI and drives, to the process control system. This reduces the complexity of the automation solution in the plant.
Working closely together, Joa engineers and Siemens were able to develop this project in only a couple weeks. The commissioning was extremely short. Joa sent the machine over to its client and it operated flawlessly when it arrived at the plant. This was one of eight similar machine kits that Siemens jointly produced for this particular Joa client.
“Siemens was closely involved with us on this project from beginning through the final installation,” says Zeinemann. “They spent many hours with us on location, training us and ensuring we were comfortable with the system and their infrastructure and architecture. With Siemens programming assistance, we were able to do the initial bench testing. Additionally, when the project was installed, Siemens was with us at our client’s site working to ensure the installation went smoothly.”
The net result of the project was reduced machine design time and lowered total project costs, realized through faster startup and commissioning, as well as thorough testing, diagnostics and debugging prior to shipment. After observing the results of the first machine, the end user requested that eight other machines in its plant also be upgraded to match this solution design.
Machines in this aspect of the converting industry are very complex, requiring a comprehensive solution. Siemens and Joa were able to deliver a total controls automation solution, providing seamless integration of drives, automation and control products that enabled faster startups and improved system productivity.
To find our more about Curt G. Joa, Inc. visit its website at www.joa.com.
About Siemens
Siemens Industry, Inc., Drives Technologies, Motion Control is a division of the Siemens operating company in the U.S. Headquartered in the Atlanta suburb of Alpharetta, Ga., Siemens Industry, Inc. manufactures and markets one of the world’s broadest ranges of electrical and electronic products, systems and services to industrial and construction market customers. Its technologies range from circuit protection and energy management systems to process control, industrial software and totally integrated automation solutions. The company also has expertise in systems integration, technical services and turnkey industrial systems.
Siemens AG (NYSE:SI) is a global powerhouse in electrical engineering and electronics, focusing on the three key sectors of healthcare, industry and energy. Founded 160 years ago in Germany, Siemens AG reported sales of $96.6 billion in fiscal year 2007 (ended September 30). Siemens today employs more than 470,000 people in some 190 countries. In the United States alone, Siemens had sales of over $25 billion (including export sales), fueled largely by infrastructure projects and innovative solutions in the industry areas of medical, automation and control, power, transportation and lighting. Headquartered in New York City, Siemens in the U.S. employs nearly 72,000 people in all 50 states and Puerto Rico. The U.S. is also home to the global headquarters of nine of Siemens’ worldwide businesses. For more information on Siemens in the United States, go to www.usa.siemens.com.
For more information
SIEMENS INDUSTRY, INC.
GENERAL MOTION CONTROL
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Fax: 847-437-0784
Web: www.usa.siemens.com/simotion
Email: SiemensMTBUMarCom.sea@siemens.com
Attention: John Meyer, Manager, Marketing Communications
by Bill Gilbert, Application Engineer with Siemens Energy and Automation.
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Production boost of 20% reported by Amgraph on food packages
At 30 years old and approximately 75-feet long, the Black-Clawson two station Extrusion Laminator dominates Amgraph’s (Versaille, Conn.) production floor like a dinosaur lining up at a bone yard. As customer requirements surpassed the capabilities of this aging behemoth, Amgraph, which supplies flexible packaging solutions for the food industry, had several choices. It could spend millions on a new machine, settle for lower productivity and product diversity or retrofit the equipment for the 21st century. Instead of scrapping their investment and spending millions on new machines to meet new product, productivity, and customer requirements, Amgraph’s Senior Management decided to prepare their equipment for the needs of tomorrow by upgrading the analog control system to high-efficiency Siemens motors, Sinamics S120 digital drives and newer control systems.
As a result of the retrofit, Amgraph can now produce a wider variety of coated plastic and foil flexible food packages, cut material expenditures and improve throughput, while boosting productivity.
Improved Web Tension
Siemens Solutions Partner, Circonix, located in Ringwood, N.J., knew that by upgrading the machine’s analog drives and discrete controls to the latest Siemens motors and Sinamics S120 digital drives, Amgraph could accommodate new materials, manufacture packages with thicker coatings, achieve uptime of 95 percent or better, and increase throughput by 20 percent or more.
“Initially, the machine had four different motors with analog drives and controls, each with their own wiring harness and relay logic, which really made the machines a challenge to maintain,” explained Circonix Vice President of Engineering Andrew Alaya. “Only one of the sections was capable of tension control, which forced Amgraph to operate the extrusion machine in draw mode. This meant that the machine could only handle certain types of coatings without breaking the web and going down. Improving that uptime through better tension control was the main goal of the project.”
Circonix engineers decided to retrofit the Extruder’s four existing analog drives with Siemens motors and Sinamics S120 drives, while adding four load cells inline, and a new Fulton Machinery dancer to the machine’s two unwind spindles. Also, two Vetaphone treaters were added inline as part of the retrofit. These effectively eliminated the need for the primer coater, and served as pull stations for the machine, which were driven by Siemens motors and drives. These modifications allowed the machine to work in closed-loop tension control mode. By changing values on the HMI and PLC, Amgraph’s Production Manager, David Rand, could now precisely control the speed and thickness of the web, turn various systems such as treaters, laminators, and tension control systems on or off, and apply either thinner coatings to package materials without worrying about additional web breaks and downtime, or thicker coatings to meet special customer needs.
“Now that we have more control of the system, we’re looking at replacing thicker films that we used to purchase from other vendors with extruded materials we make ourselves, which saves us money,” says Amgraph’s Rand. “Our initial trials have been successful.”
The new motors, upgraded digital drives and new controls also increased the extrusion machine’s uptime, throughput and productivity. The high bandwidth of the Sinamics S120 digital drives allows for improved speed regulation and faster response, both of which are key to improving tension control. Amgraph set aggressive goals of 95 percent uptime for the retrofitted extrusion machine. “We’ve had some success since the machine was installed in January,” says Amgraph’s Rand. “We spent a few months fine-tuning operations, [but] recently, we’re starting to see [uptime] benefits. We should have some firm numbers in the next few months.”
In addition to increasing uptime and the number of products the machine can handle, Rand says the retrofit has increased throughput by up to 20 percent, depending on the product line. “We’ve definitely increased production speeds,” he said. “We’re happy where we are now, but we still have opportunities to improve throughput.”
On time, Within Budget
Retrofitting large production machinery like Amgraph’s Black-Clawson extrusion laminator machine rarely comes in as scheduled because changing a machine from discrete analog to digital control systems with the latest energy-saving AC induction motors presents significant electronic and mechanical engineering challenges.
Customers may also want to use specific equipment providers for certain systems. In this case, Amgraph was familiar with third-party HMI and PLC technology, which meant Circonix needed to interface the Sinamics S120 drives with third-party systems. However, thanks to Circonix’s close partnership with Siemens as an official Siemens Solutions Provider, Siemens’ STARTER drive engineering/commissioning software and the easy integration of the Sinamics S120 drives using the electronic name plate capabilities of Drive-Cliq for the motors and drive components, the project was delivered to Amgraph on time and within budget.
“We used Profibus to tie the drives together and an SST module in the PLC to talk to the Siemens drives,” Alaya explains. “It was easy to meet Amgraph’s development schedule. With Siemens DC bus line up, all the drives fit in a single cabinet that was smaller than the space of one of the previous motor control systems. We were able to eliminate the wiring mess and relay logic that came with the older analog controls, which significantly simplified maintenance and troubleshooting for the customer while improving performance and uptime.”
Circonix started engineering development for the system in July of 2008, and just six months later, installed and commissioned the retrofits.
“We gave them a pretty intense schedule,” says Amgraph’s Rand. “What’s remarkable about this project is that it was done on-time. We have some machines that came in before we did this project and they’re still not up and running.”
For specific product information and inquiries, call (800) 879-8079 ext. Marketing Communications or send an e-mail to: SiemensMTBUMarCom.industry@siemens.com.
Continue readingI had a speaking engagement today where I spoke about Social Media to a Human Resource association. I was discussing how Twitter, blogging and YouTube work best when they go hand-in-hand with each other. This topic came up here at work recently and this is how I put it into perspective:
When you develop a great video presentation and bring it to a trade-show or conference, you don’t just set it up on a table and leave it playing in a loop all by itself. You don’t just start the presentation and leave it unattended do you? Instead, you are there ready to greet people who show any interest in the presentation you are running. You are there to answer questions, make conversation and interact with others. As we all know, this is called networking. Likewise social media, when used correctly establishes this same type of interaction. Videos on YouTube need to be associated with a website, or a blog where someone interested can go and interact and ask questions. Once a connection is made and a conversation is started, it is just like you are standing together at the trade-show, or in the conference room. Here, in the discussion that evolves, whether it be virtual or in person, you will decide whether continuing a business relationship or not is in your best interest. So in both scenarios (virtual or in person) the same objective is being met.
Likewise, it’s important that once you post something on YouTube you have methods in place to draw traffic to the video. This is where your website, Facebook, Twitter and blog will play their part in this dance of getting your online presence noticed. Social Media needs to work together and be in harmony with each other. Working together is the key to the success of your social media campaign as well as your overall marketing plan.
We have a client who posts videos on YouTube, at the end of their Print Ads in the trade magazines we print: “see our videos on YouTube”… how is that for the evolution of the ad/PR world? We now have our traditional print ads referring potential clients (and anyone else who is interested) to our client’s online presence. At least for right now, it seems you can’t effectively have one without the other.
-Wendy
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I have seen many businesses that looked at social media as a passing phase… at least they were crossing their fingers and hoping it was. Others felt it wasn’t relevant to their type of business. This way of thinking has led to them simply “dabbling” in social media. Ultimately, they end up neglecting it and concluding “it doesn’t work”. When a business chooses to simply dabble or chooses to outsource social media negative results are almost always a certainty.
It is very common for us to hear “My son (or daughter) set up our Facebook page (twitter account, blog etc) but nothing ever came of it.” You cannot have an “if you build it, they will come” mentality when it comes to social media.
Your online presence needs to be built, given life and then it needs to be nurtured so it stays alive and grows bigger and stronger.
Twitter or posting a blog once in a while. It’s not about someone who already has a full time job at your company spending a few minutes each week, “checking things out“. Here is the truth about social media: the beginning, the setting it up is actually the least time consuming and the easiest part. Why? because no one has found you yet and no one has started to communicate and interact with you yet. You are also not developing content, researching what’s being said and what are good, relevant things for you to be talking about. Getting content out into the world takes time. What are people interested in and talking about? How do you or your clients contribute to that conversation? This is not about selling products it is about participating in a conversation so you become the “go to” person for information and guidance in the world that your business is part of. I hear people say all the time, “what’s the big deal? I’ll just throw some things up on twitter once in a while and blog once in a while.” Sure, that is great if you want to use social media as an outlet for your daily ponderings… but if you want to get paying clients out of it, it’s a whole different ball-game.
In the PR/ad world, we need to maintain this knowledge for our business to grow, but we also need to be a source and knowledge base for our clients so they can to look to us for expertise and guidance. How do we do this? We need to know about, speak about and write about anything and everything that is relevant to our world as well as theirs. We also need to know where our clients need to have a presence in order for social media to work for them. They look to us for knowledge and guidance and as their ad/PR agency; we better know what we are talking about.
Fryer Easy Turn Combination Lathe with Siemens SINUMERIK 840D sl CNC lets operators at Continental Machine program, set-up and run faster; critical for one-off operations
By definition, says Josh Johnson, vice-president, Continental Machine, Rockford, Illinois, his prototype and short-run production shop must constantly run lean. There can be no tolerating excessive programming, set-up or machining time of any kind, otherwise the shop loses and, in this economy, Johnson notes, that is simply unacceptable.
Continental Machine is a seven-person, 13,000 square-foot facility that houses a variety of CNC milling, turning, wire EDM, hole popping and grinding machines, as well as various sheetmetal and plastic injection molding machinery. Therefore, the shop is well positioned to produce a wide variety of metal and plastic prototypes used by its diverse customer base, which spans markets such as window hardware, bicycle components, automotive parts, chemical processing, medical devices and foodservice equipment. Materials processed here are just as wide-ranging, including aluminum, CRS, tool steels such as A2 and D2, zinc, brass, copper, bronze, titanium and a variety of engineered plastics such as glass-filled Delrin.
Recently, this job shop purchased a Fryer Easy Turn-21 CNC Combination Lathe, controlled by a Siemens SINUMERIK 840D sl numerical control. The two operators responsible for this machine upgrade at Continental had limited experience with CNC and none whatsoever with the Siemens protocol, as this was the first of its kind at the shop.
The Easy Turn-21 was particularly appealing to Josh Johnson, who comments, “The set-up is extremely easy. Teaching the tools, altering the lengths and diameters is kept very simple. After the initial learning curve, which took only a few days, the operators picked up on the conversational programming, right away. Also, one of the best features on the machine was that you could still turn the parts by using the electronic handwheel and just one function, such as hogging off material automatically or putting on a tapered thread.” He noted this feature was not only more comfortable for the operators, but it also allowed them to quickly and efficiently prove out part programs. Johnson commented that this would not have been possible on previous machines, owing to the flexibility of the control onboard the Fryer. The result has been a minimum 20% improvement in the overall cycle time on most part programs run at Continental. For this primarily prototype job shop, that fact translates into a substantial increase in the work product possible here.
Echoing this sentiment, Sue Ostrander, sales manager, Fryer Machine Systems, explained the process that led her company to select the SINUMERIK 840D sl numerical control for all its milling and turning machines, a move that was recently formalized by the company and announced to the trade.
“Since its inception 26 years ago, family-owned Fryer Machine Systems has based its operation on three core principles: build a quality product, price it fairly and provide quality service. This philosophy has allowed Fryer’s business to grow even in challenging times,” she said.
Fryer manufactures a diverse line of over 50 models of high-quality CNC machine tools in its 50,000 square-foot facility in Patterson, New York. Over the years, Fryer has become well-respected for its quality and innovation, throughout the job shop and production machining market segments.
“Moving to the Siemens 840D sl platform was the next step in Fryer’s ongoing commitment to provide our customers with the most innovative machine tools available in the market today,” Ostrander continued. “The Siemens solution allows machine tool end-users to achieve higher productivity through easy and intuitive features and step-by-step, on-screen programming. This enables them to dramatically reduce set-up, programming, and tooling times, while significantly increasing output.”
“The SINUMERIK 840D sl modular design allows us to take full advantage of the superior mechanical features in our machines,” continued Larry Fryer, president and CEO, Fryer Machine Systems. “Fryer has always been known for our easy conversational controls and the move to Siemens has allowed us to greatly enhance this feature,” Fryer noted. “The 840D sl menu-driven system combines an advanced geometry calculator that displays the part while the operator is programming it. Sophisticated solid model graphics allow the operator to verify the part program with more clarity than ever before,” he said.
Larry Fryer has also been impressed with the automatic tool set-up and easy part set-up, made possible by the Siemens CNC. Fryer explained that auto-run mode is where many operators experience difficulty. Siemens and Fryer Machine Systems worked together to create an electronic handwheel run mode that gives the operator a safer way to prove out program execution, both forward and backward, using a standard electronic handwheel.
Fryer further stated, “Siemens provides us with a highly flexible solution that is critical to our ability to meet the specific needs of each customer. Our enhanced capability to offer the same control for both turning and milling gives Fryer machines a unified platform that is very important to customers both in the short-term and for long range expansion. Coupled with Siemens quality and reliability, they are invaluable to us in competing in today’s aggressive marketplace.”
Johnson added this comment on the service and training received by his operators at Continental. “Siemens has been helpful and very thorough in their training and after-sale service. The ShopTurn program, being integral to the control, now enables us to accurately determine tool path, potential collisions, tool changes and real world run time. This makes our operators’ jobs much easier, with the added benefit of allowing us to estimate much more accurately than ever.” Johnson further noted the CNC has substantial hard drive space, thus allowing most programs to be stored directly on the machine, though the company does maintain a back-up system.
For more information on this story, please contact:
CONTINENTAL MACHINE CO.
Email: conmach@onecommail.com
FRYER MACHINE SYSTEMS, INC.
Web: www.fryermachine.com
SIEMENS MACHINE TOOL BUSINESS
John Meyer
Manager, Marketing Communications
Siemens Industry, Inc.
(847) 640-1595
www.usa.siemens.com/cnc
SiemensMTBUMarCom.industry@siemens.com
Follow us on Facebook: www.facebook.com/SiemensCNC or Twitter: www.twitter.com/siemens_cnc_us.
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Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit. For more information, visit http://www.usa.siemens.com/industry.
The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability. For more information, visit http://www.usa.siemens.com/drivetechnologies.
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In this struggling economy, we have clients who’ve actually gone back to Marketing 101 and decided that tough times require more aggressive presence in the market.
Old customers and prospective new ones are being courted more often, both in print ads, direct mail (making a nice comeback as it’s now unique!) and online via blast email, regular newsletters and the inexpensive if rather impersonal vid conference.
The impact of such activity has had the collateral if unintended consequence of making our agency quite busy, this year. So thanks for that, clients!
Much more important is the fundamental tenet of marketing being applied here. They can’t buy from you if they don’t know you’re on the planet, to be blunt.
And, whether they’re currently buying or not, the ones who’ll stay in business are the targets of our messages for clients.
Having lived through four major recessions in business in my time, the theory has been proven true, time and again. Namely, companies who continue to maintain a presence in their market, by whatever means, come back faster and stronger than those who don’t. This is a fact and we have the evidence to prove it, for anyone interested.
TD