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Siemens supports the machine tool industry in utilizing the full potential of data for flexible and sustainable action

Under the theme “Digitalization in Machine Tool Manufacturing — Infinite opportunities from infinite data”, Siemens will demonstrate how the full potential of data can be used for increased productivity during this year’s EMO Milano tradeshow, October 4-9, and during the virtual Siemens Machine Tool Days 2021 event.

The challenges are quite large: the Covid-19 pandemic has significantly accelerated the pace of change in manufacturing markets. Added to this are growing demands of individualization and the urgent need for more sustainability — and these can be achieved with the help of digitalization and automation. Siemens brings together the extremely large volumes of data generated in this process during a continuous cycle between the real and digital worlds. This enables the employees of industrial manufacturers to make the appropriate decisions based upon data and respond more quickly to trends and changes.

Sinumerik One
NEW SINUMERIK ONE Machine Control Panels offer machine tool users intuitive operation, increased efficiency and greater flexibility

SINUMERIK ONE is core element of highlight case with two technologies

During EMO in Milan and the Siemens Machine Tool Days virtual event, Siemens will demonstrate how to react quickly to trends with the new SINUMERIK ONE CNC, which was introduced in the North American market as a digital-native control. To demonstrate this, the focus of the real and virtual Siemens booth is a production line that shows two machines controlled with SINUMERIK ONE — a 5-axis milling center and a robotic-based additive manufacturing machine.

With these two machines, for example, the gears of large gearboxes can be repaired instead of replacing them. Such large gearboxes are used in industries such as wind energy, where they are subject to natural wear-and-tear due to the enormous frictional forces and must be replaced at certain time intervals. Siemens will demonstrate how the gears are initially milled flat in the milling center. Next, a robot is used to rebuild the teeth in an additive manufacturing process. And the final precision grinding takes place at the end again on the 5-axis milling center.

Instead of new production, the repair not only saves material resources, but also approximately 60 percent of energy. SINUMERIK ONE, the first digital-native CNC, represents the core element for the digital transformation of the machine tool industry. Thanks to the Digital Twin known as Create MyVirtual Machine, both machines could be developed, tested and functionally approved simultaneously, long before the real machine was put into operation. This gives machine tool builders the advantage by getting to a better machine faster, while machine tool users can get to the right workpiece even faster.

With the Digital Enterprise portfolio, Siemens supports manufacturers exactly where the current challenges lie. With the help of Digital Twins, such as SINUMERIK ONE, the use of future technologies such as artificial intelligence or industrial edge computing, and the Siemens digitalization portfolio, machine builders and machine users can collect, analyze and understand the data generated and use it in a productive way. This allows them to react quickly and flexibly to challenges, adapt their products and manufacturing processes to new requirements and save resources.


The NEW SINUMERIK ONE is the first-ever digital-native CNC for the machine tool industry
The NEW SINUMERIK ONE is the first-ever digital-native CNC for the machine tool industry

Greater flexibility and innovative technology for machine operation

SINUMERIK ONE offers new functions and technology updates that further increase manufacturing performance, flexibility and modularity. Visitors to the Siemens booth during EMO in Milan, as well as the visitors attending the virtual Siemens Machine Tool Days event, will have the opportunity to see new SINUMERIK ONE Machine Control Panels (MCP) in action.

With the new SINUMERIK ONE MCPs, Siemens brings intuitive machine tool operation to CNC users including more comfort, increased efficiency and greater flexibility. The new ergonomic metal design can be integrated into existing operating concepts and fits 19-inch to 24-inch panels. The new MCPs can even be configured individually for customer-specific requirements.

New functionalities make machine operation even easier. Powerride combines the override switch with the NC start button for easy and efficient machine setup. With the integrated LED scale in Powerride, ACTUAL values can now be visualized. With Powerride, the feed is automatically reset after the end of the set, which makes operation effective and easy. In addition, Powerride provides haptic feedback through short vibration as soon as a defined limit value is exceeded. This increases the perception of these values and supports the blind operation of the panel.

The QWERTY keyboard is provided as standard for the MCPs for the 22-inch and 24-inch variants, so users no longer need an additional keyboard. An integrated RGB LED in the QWERTY keyboard enables customizable color concepts for simplified work. The SINUMERIK ONE MCP can be used in harsh industrial environments thanks to its IP65 protection class rating.

Siemens Industrial Edge — extensions for machine tools

With Industrial Edge, Siemens offers a concept in which both machine tool builders and machine users can flexibly use the advantages of data processing using Edge or Cloud computing as required. Siemens is also expanding its Edge computing portfolio for machine tools that will enable real-time analysis of data on-site during production. During EMO and Siemens Machine Tool Days, the scalability of Edge hardware will be presented with new Industrial PCs IPC 127E and IPC 427E hardware variants.

For specific product information and inquiries, send an e-mail to: cnc.marketing.us@siemens.com   


Contact for journalists:
Siemens
John Meyer
(847) 952-4158                                                       
john.meyer@siemens.com   

Siemens Digital Industries (DI) is an innovation leader in automation and digitalization. Closely collaborating with partners and customers, DI drives the digital transformation in the process and discrete industries. With its Digital Enterprise portfolio, DI provides companies of all sizes with an end-to-end set of products, solutions and services to integrate and digitalize the entire value chain. Optimized for the specific needs of each industry, DI’s unique portfolio supports customers to achieve greater productivity and flexibility. DI is constantly adding innovations to its portfolio to integrate cutting-edge future technologies. Siemens Digital Industries has its global headquarters in Nuremberg, Germany, and has around 75,000 employees internationally.

Siemens Corporation is a U.S. subsidiary of Siemens AG, a global powerhouse focusing on the areas of power generation and distribution, intelligent infrastructure for buildings and distributed energy systems, and automation and digitalization in the process and manufacturing industries. Through the separately managed company Siemens Mobility, a leading supplier of smart mobility solutions for rail and road transport, Siemens is shaping the world market for passenger and freight services. Due to its majority stakes in the publicly listed companies Siemens Healthineers AG and Siemens Gamesa Renewable Energy, Siemens is also a world-leading supplier of medical technology and digital healthcare services as well as environmentally friendly solutions for onshore and offshore wind power generation. For more than 160 years, the company has innovated and invented technologies to support American industry spanning manufacturing, energy, healthcare and infrastructure. In fiscal 2018, Siemens USA reported revenue of $23.7 billion, including $5.0 billion in exports, and employs approximately 50,000 people throughout all 50 states and Puerto Rico.

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Digitalization in Machine Tool Manufacturing — infinite possibilities from infinite data

Siemens to present and demonstrate its SINUMERIK CNC family of CNCs and machine tool digitalization solutions at EASTEC 2021

By combining the real world with the digital world, Siemens will demonstrate how the full potential of data enables machine builders and end-users to be flexible and sustainable in their manufacturing.  

On display in the Siemens booth will be the SINUMERIK family of controls that includes SINUMERIK 828D, SINUMERIK 840D and the new SINUMERIK ONE, the first-ever digital-native CNC.

SINUMERIK 828D is a compact and advanced CNC designed to enable machine tool manufacturers to leverage the full productivity potential of the digital factory in a mid-range control.  With its panel-based design, the 828D can control up to 10 axes and spindles plus two auxiliary axes making it the perfect CNC system for job shop production.

Machine tool builders benefit from the Digital Twin by speeding up development and commissioning times to new levels of quality and efficiency

SINUMERIK 840D sl is the control of choice for modular machine tools used in serial production, 5-axis and multi-tasking machines. The drive-based 840D can control up to 31 axes and spindles, any number of PLC axes and up to 10 machining channels.  It works equally well in a job shop, mid-sized or large production facility. 

Developed from the ground up, the NEW SINUMERIK ONE is the first CNC system to master the challenges of digital transformation in the machine tool industry.  Real-world machining processes and machine tool behavior can now be simulated in the digital world thanks to the Digital Twin

Using Create MyVirtual Machine, machine tool builders can speed up their development and commissioning times to new levels of quality and efficiency.  Machine users can also benefit from a “digital first” strategy for their central processes during production when they use Run MyVirtual Machine.  Programming, production planning and process optimization can be simulated instead of performing them directly at the machine and non-productive times are eliminated.

Create MyVirtual Machine masters the challenges of digital transformation

In addition to the SINUMERIK family of controls, we will present our machine tool digitalization portfolio of software apps that increase the manufacturing productivity and accelerate the business of both machine tool builders and machine users. These include Manage MyMachines, Analyze MyMachine, Analyze MyPerformance, Analyze MyWorkpiece, Adaptive Control and Monitoring, and more.

Siemens technical experts will be in the booth for demonstrations and to answer all questions.  Editors are welcome to stop by. 

For specific product information and inquiries, send an e-mail to: cnc.marketing.us@siemens.com   


Siemens Digital Industries (DI) is an innovation leader in automation and digitalization. Closely collaborating with partners and customers, DI drives the digital transformation in the process and discrete industries. With its Digital Enterprise portfolio, DI provides companies of all sizes with an end-to-end set of products, solutions and services to integrate and digitalize the entire value chain. Optimized for the specific needs of each industry, DI’s unique portfolio supports customers to achieve greater productivity and flexibility. DI is constantly adding innovations to its portfolio to integrate cutting-edge future technologies. Siemens Digital Industries has its global headquarters in Nuremberg, Germany, and has around 75,000 employees internationally.

Siemens Corporation is a U.S. subsidiary of Siemens AG, a global powerhouse focusing on the areas of power generation and distribution, intelligent infrastructure for buildings and distributed energy systems, and automation and digitalization in the process and manufacturing industries. Through the separately managed company Siemens Mobility, a leading supplier of smart mobility solutions for rail and road transport, Siemens is shaping the world market for passenger and freight services. Due to its majority stakes in the publicly listed companies Siemens Healthineers AG and Siemens Gamesa Renewable Energy, Siemens is also a world-leading supplier of medical technology and digital healthcare services as well as environmentally friendly solutions for onshore and offshore wind power generation. For more than 160 years, the company has innovated and invented technologies to support American industry spanning manufacturing, energy, healthcare and infrastructure. In fiscal 2018, Siemens USA reported revenue of $23.7 billion, including $5.0 billion in exports, and employs approximately 50,000 people throughout all 50 states and Puerto Rico.

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New SIMOTICS SD200 Frame Size 440 low-voltage, severe-duty AC motors now with 75-800 hp output

Cast-iron motors meet or exceed NEMA Premium® efficiency standards for oil-and-gas/petrochemical, pulp-and-paper, grain and rock processing, other harsh environments

At this year’s annual EASA Convention and Solutions Expo in Fort Worth, TX, Siemens announces the immediate availability of the SIMOTICS SD200 severe-duty motor in frame size 440 as its latest offering in the low-voltage SIMOTICS motor family.   

Providing high productivity and energy-efficient operation in all torque ranges, these new cast-iron NEMA motors are built to power pumps, fans, compressors, hoists, winders and similar equipment in harsh environments.  With a three-year warranty, the SD200 motors offer 75-800 hp output and feature 444-5013 cast-iron frames for operation in 460V and 575V ranges.  They meet or exceed NEMA Premium® MG1 Table 12-12 efficiencies.  A wide selection of options is offered, including IP56 ingress protection, encoders, brakes, and blowers plus others to suit the applications presented. 

On these motors, the frame, end-shields, fan guard and easy-access, diagonally split, oversized terminal box are all cast-iron.  Complementing this construction are zinc-plated hardware, epoxy paint and stainless-steel nameplates for long life and easy identification in the field.  A unique offset rotor bar provides improved efficiency, while larger bars and end rings reduce resistance.  Each die-cast aluminum rotor assembly is dynamically balanced for extended bearing life and includes a high-strength C1045 carbon steel shaft for maximum performance.  Premium C5-grade steel laminations and copper magnet wire are standard. 

For insulation, the Class-H non-hygroscopic system with NEMA Class B temperature rise provides an extra margin of thermal life.  The insulation system meets or exceeds NEMA MG1 2014 Part 31, making these motors suitable for variable speed drives in constant torque (4:1) and variable torque (20:1).  All windings are tested for Corona Inception Voltage (CIV). 

The Siemens Product Manager for Low-Voltage NEMA Motors, Oscar Palafox, explains, “One of the features of the SD200 is its flexibility in the field, as the motor can be switched from F1 to F2 and F3 orientation with ease.  Plus, the safety features on this new line are unmatched by competition.  Full H-Class conformity provides winding protection, while the swivel hooks are a significant improvement over eyehooks for handling of these heavy units.  In addition, the unique Siemens composite insulation on the SD200 is a cost-saver over the ceramic bearing alternative with ten times the resistance of other solutions in the market.  Finally, the NEMA Premium® efficiency is a guarantee of long performance life with very tight deviation of losses.  Shaft current remains more consistent for better uptime.”  Palafox further notes this new line affords users Division II, Class 1 (gas) and Class 2 (dust) protection. 

Siemens SIMOTICS SD200 frame size 440 low-voltage, severe-duty AC motors will be introduced at EASA 2021.  They are designed for use in the harsh environments of oil-and-gas / petrochemical, grain, rock product, plus food-and-beverage and other markets with Division II, Class 1 and 2 conditions present. 

For more information regarding SIMOTICS SD200 motors, please visit: http://usa.siemens.com/simotics-sd200

Siemens Digital Industries (DI) is an innovation leader in automation and digitalization. Closely collaborating with partners and customers, DI drives the digital transformation in the process and discrete industries. With its Digital Enterprise portfolio, DI provides companies of all sizes with an end-to-end set of products, solutions and services to integrate and digitalize the entire value chain. Optimized for the specific needs of each industry, DI’s unique portfolio supports customers to achieve greater productivity and flexibility. DI is constantly adding innovations to its portfolio to integrate cutting-edge future technologies. Siemens Digital Industries has its global headquarters in Nuremberg, Germany, and has around 75,000 employees internationally.

Siemens Corporation is a U.S. subsidiary of Siemens AG, a global powerhouse focusing on the areas of power generation and distribution, intelligent infrastructure for buildings and distributed energy systems, and automation and digitalization in the process and manufacturing industries. Through the separately managed company Siemens Mobility, a leading supplier of smart mobility solutions for rail and road transport, Siemens is shaping the world market for passenger and freight services. Due to its majority stakes in the publicly listed companies Siemens Healthineers AG and Siemens Gamesa Renewable Energy, Siemens is also a world-leading supplier of medical technology and digital healthcare services as well as environmentally friendly solutions for onshore and offshore wind power generation. For more than 160 years, the company has innovated and invented technologies to support American industry spanning manufacturing, energy, healthcare and infrastructure. In fiscal 2018, Siemens USA reported revenue of $23.7 billion, including $5.0 billion in exports, and employs approximately 50,000 people throughout all 50 states and Puerto Rico.

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New Sinamics G115D distributed drive system specifically designed for conveyor applications

Comprised of the drive, motor and gear box, this new distributed drive system is available as a complete solution for motor-mounted and wall-mounted horizontal motion control conveyor applications.

With its new Sinamics G115D, Siemens is introducing a new, compact and powerful drive system specifically designed for horizontal conveyor applications.  The drive system comprises the motor, drive and gearbox in one unit and is offered in two versions — wall-mounted and motor-mounted.

The Sinamics G115D drive system is characterized by a robust design with a high IP protection class (up to IP66 / UL Type 4X) and is suitable for use in harsh environments.  Thanks to its compact dimensions, the Sinamics G115D can be easily installed in confined areas.  The drive system can also be operated reliably over a wide temperature range of -30 to 55 degrees Celsius (-22 to 131 degrees Fahrenheit), enabling operation in deep freezing applications.

Sinamics G115D is suitable for applications in intra-logistics and airports, as well as in the automotive and food and beverage industries. Its power ranges from 0.37 to 7.5 kilowatts
(1/2 to 10 hp) for wall-mount applications and 0.37 to 4 kilowatts (1/2 to 5 hp) for motor-mounted applications.  The drive system can be put into operation quickly and easily with comprehensive integration into the Totally Integrated Automation (TIA) portal including Startdrive commissioning software or the Sinamics Smart Access Module (SAM) web-server for Wi-Fi setup and diagnostics.

To be prepared for digital transformation and to enable cloud-based analysis, Sinamics G115D is integrated into the entire MindConnect portfolio and is compatible with MindSphere applications such as Analyze MyDrives.

Thanks to Profisafe, the Sinamics G115D has Safety Integrated in the form of STO (Safe Torque Off) SIL2, which standardizes and facilitates the certification process.  For flexibility in terms of installation, service and maintenance, the solution is equipped with a plug-in connector and flexible connection possibilities.  The device is particularly suitable for interaction with Simatic controllers such as the Simatic S7-1200 or Simatic ET200 for motion control. 

Siemens offers warranty extensions for Sinamics G115D through its Service Protect package. As part of this service package, an additional one or two-year warranty extension may be purchased for failure coverage.  The package offers simplified processing under normal warranty conditions for the extended period.

With its new Sinamics G115D, Siemens presents a new, compact, and powerful drive system specifically designed for horizontal conveyor applications.

For more information regarding Sinamics G115D, please visit:
usa.siemens.com/sinamics-g115d

For specific product information and inquiries, send an e-mail to: mc.us@siemens.com   

Siemens Digital Industries (DI) is an innovation leader in automation and digitalization. Closely collaborating with partners and customers, DI drives the digital transformation in the process and discrete industries. With its Digital Enterprise portfolio, DI provides companies of all sizes with an end-to-end set of products, solutions and services to integrate and digitalize the entire value chain. Optimized for the specific needs of each industry, DI’s unique portfolio supports customers to achieve greater productivity and flexibility. DI is constantly adding innovations to its portfolio to integrate cutting-edge future technologies. Siemens Digital Industries has its global headquarters in Nuremberg, Germany, and has around 75,000 employees internationally.

Siemens Corporation is a U.S. subsidiary of Siemens AG, a global powerhouse focusing on the areas of power generation and distribution, intelligent infrastructure for buildings and distributed energy systems, and automation and digitalization in the process and manufacturing industries. Through the separately managed company Siemens Mobility, a leading supplier of smart mobility solutions for rail and road transport, Siemens is shaping the world market for passenger and freight services. Due to its majority stakes in the publicly listed companies Siemens Healthineers AG and Siemens Gamesa Renewable Energy, Siemens is also a world-leading supplier of medical technology and digital healthcare services as well as environmentally friendly solutions for onshore and offshore wind power generation. For more than 160 years, the company has innovated and invented technologies to support American industry spanning manufacturing, energy, healthcare and infrastructure. In fiscal 2018, Siemens USA reported revenue of $23.7 billion, including $5.0 billion in exports, and employs approximately 50,000 people throughout all 50 states and Puerto Rico.

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UL 61800-5-1 – A new UL standard for drives and what you need to know

Below is a whitepaper by Nikunj Shah, Siemens Industry, on the UL 61800-5-1, a new UL standard for drives. It includes information on what you need to know if you are a user, a panel builder, a manufacturer of motor control centers (MCC) or an OEM. 

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Siemens and Ingersoll Machine Tools expanding Digital Enterprise partnership

Robotic fiber placement and 3D printing enable disruptive breakthroughs in today’s manufacturing processes thanks to the advantages promised by Industry 4.0, the Digital Twin, higher robotic intelligence and complex motion control.

Siemens and Ingersoll Machine Tools have expanded their decade-long partnership to support the Rockford, IL-based machine tool company of Camozzi Group on its digital journey of creating digital twins of its products and expanding into new markets. Based upon extensive experience in heavy machine tool building, Siemens cutting-edge technologies in hardware complement Ingersoll Machine Tools’ successful journey into the new market of additive manufacturing and have pushed the boundaries for industrial robots for the aerospace market with its entry-level robotic platforms MasterPrint Robotic™ and MasterPrint Continuous Filament™

For example, Ingersoll developed the mammoth 3D printer MasterPrint™, the world’s largest device that prints with thermoplastics. The MasterPrint  at the University of Maine — included in the Guinness Book of World Records — is able to  3D-print objects up to 100 feet long, 20 feet wide and 10 feet tall. It is designed mainly to make tools for the aerospace, space and marine industry. MasterPrint™ cuts cost and streamlines the manufacturing process. Large parts are printed and then machined to final their shape with the same machine. Manufacturing costs can be reduced by 75% and lead times shortened from months to days.

“As a key supplier of high-tech manufacturing equipment to all the major players of the aerospace industry, Ingersoll has strategic technology goals that push CNC products capabilities and performance beyond their OEMs’ intentions, conception and scope in term of accuracy, reliability, ease of integration and seamless programming experience. Ingersoll has found a CNC and software partner in Siemens who is willing to develop and encompass these advanced capabilities into their products and to enable Ingersoll to achieve its strategic goals and service the needs of our customers by shortening their time-to-market and increasing their profitability”, said Piergiorgio Assandri, Business Director, Ingersoll Machine Tools.

“Ingersoll Machine Tools’ ambitious plans for becoming a leading digital enterprise in the machine tool market are impressive. Their successful additive manufacturing and industrial robot products are a proof point for this. Ingersoll Machine Tools’ entrepreneurial spirit and innovative approach has pushed us to the limits, what our technology is capable of and inspired us to go even further”, said Rajas Sukthankar, Vice-President of Siemens Digital Industries Motion Control Business (US). 

Ingersoll Machine Tools is using cutting-edge CNC automation hardware and software from Siemens to transform their business for the digital age. With the Siemens Virtual NC Kernel (VNCK), the company was able embed the real CNC kernel into a virtual machine, allowing Ingersoll Machine Tools to completely emulate real machine tool control and directly import the commissioning archive of the actual machine. That helped Ingersoll Machine Tools to save time with faster commissioning and to get the machine to their customers faster. From an end-customer perspective, users will be able to simulate the manufacturing of their product and shorten their time-to-market while increasing their production quality.    

“Composite production processes such as the increasingly popular robotic applications can have quite complex machine motions and tight manufacturing tolerances, as well as the ever present need to reduce production times.  Having a virtual version of the CNC kernel directly integrated within the programming and simulation software environment allows a customer to more reliably validate their production processes and timing before physically running anything on the machine.” said John Dreher, Software Engineering Manager, Ingersoll Machine Tools.

To handle the complex machining applications, Ingersoll Machine Tools chose the modular, scalable and open Sinumerik 840D sl CNC system from Siemens, which is considered to be
the control of choice in high-end machining segments like aerospace. High CNC machining performance, along with flexibility and openness, represent the basis for almost every machine tool concept.

Engineers from aerospace and other large-part industries come to Ingersoll Machine Tools
to collaborate on breakthroughs in additive and subtractive manufacturing

The promised advantages of digitalization are being implemented by Ingersoll Machine Tools.
Having removed the boundaries to large-format robotic fiber placement and 3D printing,
expectations now rise toward making breakthrough improvements across the entire part
production process.

Run MyRobot is a key feature on the Siemens Sinumerik 840D sl CNC, bringing precision control to the robotic machines at Ingersoll.


Contact for journalists:

John Meyer
Phone: +1 847 952 4158
E-mail: john.meyer@siemens.com


Follow us on Social Media:
www.twitter.com/siemens_cnc_us            www.facebook.com/Siemens.CNC.US  

Siemens Digital Industries (DI) is an innovation leader in automation and digitalization. Closely collaborating with partners and customers, DI drives the digital transformation in the process and discrete industries. With its Digital Enterprise portfolio, DI provides companies of all sizes with an end-to-end set of products, solutions and services to integrate and digitalize the entire value chain. Optimized for the specific needs of each industry, DI’s unique portfolio supports customers to achieve greater productivity and flexibility. DI is constantly adding innovations to its portfolio to integrate cutting-edge future technologies. Siemens Digital Industries has its global headquarters in Nuremberg, Germany, and has around 75,000 employees internationally.

Siemens Corporation is a U.S. subsidiary of Siemens AG, a global powerhouse focusing on the areas of power generation and distribution, intelligent infrastructure for buildings and distributed energy systems, and automation and digitalization in the process and manufacturing industries. Through the separately managed company Siemens Mobility, a leading supplier of smart mobility solutions for rail and road transport, Siemens is shaping the world market for passenger and freight services. Due to its majority stakes in the publicly listed companies Siemens Healthineers AG and Siemens Gamesa Renewable Energy, Siemens is also a world-leading supplier of medical technology and digital healthcare services as well as environmentally friendly solutions for onshore and offshore wind power generation. For more than 160 years, the company has innovated and invented technologies to support American industry spanning manufacturing, energy, healthcare and infrastructure. In fiscal 2018, Siemens USA reported revenue of $23.7 billion, including $5.0 billion in exports, and employs approximately 50,000 people throughout all 50 states and Puerto Rico.

Ingersoll Machine Tools Inc is a leader in advanced manufacturing processes and a global supplier of additive and subtractive machine tools for the aerospace, defense, energy and all heavy industrial sectors. The Ingersoll product lineup includes MasterMill™, PowerMill™ and SuperProfiler™ for accurate, reliable, high-speed milling and trimming of large, complex-geometry parts made of aluminum, titanium and hard metals; Mongoose™ and Mongoose Hybrid™, for the composite manufacturing of aircrafts’, rockets’ and vessels’ structures; MasterPrint™, the largest existing thermoplastic 3D printer, capable to produce extra-large, hollow, parts in a single piece for the aerospace and the marine sectors. Ingersoll runs these very same machines at its Development Center to manufacture key-components for many aerospace and defense programs. Together with Innse-Berardi (Lombardy, Italy), Ingersoll is part of the Camozzi Machine Tools division of the Camozzi Group. With 30 subsidiaries in 75 countries, 2600 employees, 5 operating divisions and 18 production sites, the Camozzi Group is a global leader in the supply of components and systems for industrial automation and operates in other strategic sectors: Automation, Manufacturing, Digitalization and Textile Machinery

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Kodlin Siemens

Easily creating one-offs

Kodlin Motorcycle customizes motorcycles based upon bikes from the legendary American brand Harley-Davidson. Sophisticated technology and an easy-to-use control system are essential—which is why the company chose the Sinumerik 828D CNC from Siemens.

There is no denying it: the Kodlin family has motorcycles in its blood. Master blacksmith Fred Kodlin gave his son Len his first motocross bike for his fifth birthday. There was never really any question about what Len would do when he grew up. Today, the father-and-son team runs the Fred Kodlin Motorcycle workshop, founded by Fred Kodlin back in 1984, in the small town of Borken in the German state of Hessen.

The company is highly specialized: together, father, son and 10 employees customize Harley-Davidson motorcycles. Up to 50 motorcycles leave their shopfloor each year, to the great excitement of their new owners. Many customers simply want to have their series-produced bikes adjusted to suit them better, or to look more individual. Other customers come to the company looking for bigger modifications, such as the installation of a big front wheel, which has a very striking effect and is popular among Harley-Davidson fans.

The most passionate bikers, however, want their bikes to be completely personalized. “These unique bikes cannot be beaten in terms of exclusivity. When it comes to design and technology, we make the virtually impossible possible,” explains junior manager Len Kodlin. In some of these models, the only thing that’s left is the engine, with its unmistakable Harley-Davidson sound: the rest of the bike is made up of components that have been developed and produced entirely by Kodlin. Customers’ budgets are the only thing limiting their imagination. Enthusiasts pay up to $130,000 for these unique cycles. And then, of course, there are also the technical approval restrictions (TÜV, for example).

Avoiding imitations

When fulfilling a customer’s dream of owning a personalized motorcycle, the customizers at Kodlin Motorcycle not only adapt parts, they also manufacture many individual parts themselves. Various styles of footboards, footpegs, turn-signal trim, air filters, engine covers, hand grips and mirror brackets are manufactured individually or in very small series. Outsourcing production could be cheaper in many cases, but for Kodlin, this is not an option. Len Kodlin explains the reasoning behind the decision. “Unique pieces are the basis of our whole company. The risk of copies appearing is simply too great. Our customers pay for something unique and that’s what we give them. This is why we do everything ourselves, from sheet-metal work and welding to milling, turning, painting and assembly,” Kodlin says.

Kodlin has an extremely large range of manufacturing capabilities to prevent imitations and rival products, thus safeguarding its competitive edge. The company invests heavily in production expertise and machinery. Kodlin even has a world manufacturer identifier. This official designation signals that Kodlin is officially a manufacturer that can build and approve motorcycles.

An integrated process from the design to the machine

Anyone who wants to survive the competition as a small, independent customizer needs top-quality CNC machines. That’s why the core of Kodlin’s production process is a PreMill VL 1000 CNC machining center from MMD Werkzeugmaschinen with a Sinumerik 828D CNC system. Len Kodlin, a trained precision mechanic himself, explains what matters to him and his father, “MMD was extremely cooperative and, with the PreMill VL 1000, gave us a machine that meets our needs perfectly. The price/performance ratio was good and with the Sinumerik 828D control—including the intuitive Sinumerik Operate graphical user interface—our core requirement, namely ease-of-operation, was met to our utmost satisfaction.”

The demands on the machine tool and control system are high and diverse. Many simple parts are programmed directly on the machine. For this type of application, it is important for the shopfloor programming to be as simple as it is reliable and efficient. Jan Rosenkranz, a mechanic on the Kodlin team, gets straight to the point, “The ShopMill menu-based navigation makes everything really quick and easy.” He also appreciates the convenient setup functions.

The production of custom parts, which often involves extremely complex contouring, is entirely different. The junior manager creates the programs for these parts separately at an external CAD/CAM workstation and then transfers them to the machine, using a USB stick. This means the machine can remain in operation while the junior manager can design parts for his spectacular creations, far away from production noise, in peace and quiet. Once the blank is in place, the entire machining process itself goes very quickly. With the help of various Sinumerik CNC cycles, the workpiece and the tool are set up quickly and machining on the PreMill VL 1000 can begin.

Len Kodlin specifically mentions the clearly organized folder structure in Sinumerik Operate, which is designed in a similar way to that found on a traditional PC. Meaningful names—such as “Handlebar1-Customer3”—with up to 28 characters can be assigned to the programs. This improves the ability to maintain an overview and products that have already been made can be clearly identified and accessed again at a later date.

The entire production spectrum covered

In terms of production technology, the PreMill VL 1000 offers everything needed for bike parts. The machine gets extra points for its framework construction, which makes it very stable and easily accessible. The majority of the components are less than 500 mm long. However, there are exceptions, such as long fork tubes. With travel paths of X = 1020 mm, Y = 510 mm, and Z = 560 mm, plus a 1200 x 500 mm clamping table, the machine comprehensively covers the spectrum. The 10-kW milling spindle provides the power needed to quickly and precisely machine the parts, which are usually made of aluminum or steel. The changer can be equipped with up to 30 tools and the linear guides on all three axes ensure utmost precision. According to Jens Bubenheim, a sales consultant at MMD, the PreMill VL 1000 achieves a repeat accuracy of ± 3 µm and a positioning accuracy of ± 5 µm, which means that the desired quality is always guaranteed.

A special feature on the Sinumerik 828D CNC scores additional points for high quality, namely the Sinumerik MDynamics technology package with integrated Advanced Surface motion control. The program sequence can be set or adjusted at any time, ensuring that the machine generates an optimal ratio of speed, accuracy and surface quality. Take the turn signal trim, for example.  In this case, production accuracy is of less significance. Corresponding settings in MDynamics and the activated Advanced Surface therefore ensure that the machine works with a focus on both surface quality and speed of production.


Contact for journalists and product information:

John Meyer
Marketing Communications Manager
Siemens Industry, Inc.
390 Kent Avenue
Elk Grove Village, IL 60007
T: +1 847 640 1595
E: john.meyer@siemens.com
Website: usa.siemens.com/cnc

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Siemens expands its drive portfolio with a new extra-low-voltage drive for 24–48V EC motors. The new Micro-Drive system brings industrial networking and integrated safety to a wide range of applications including battery operated equipment.

Siemens introduces its new Simatic Micro-Drive — the new servo-drive system for extra-low-voltage commercial and manufacturing applications

User benefits include seamless network integration, integrated drive safety, versatility, easy commissioning and servicing  

Siemens expands its drive portfolio with a new extra-low-voltage drive for 24–48V EC motors. The new Micro-Drive system brings industrial networking and integrated safety to a wide range of applications including battery operated equipment.

Siemens is extending its drive portfolio in the safety extra-low-voltage range for 24-48V EC motors by introducing a new servo drive system named Simatic Micro-Drive.  The new system with UL and CE marked components consists of the PDC (Profidrive Control) servo drive in conjunction with a flexible range of motors and connecting cables from product partners.

Simple connectivity to Simatic programmable logic controllers (PLCs) helps significantly reduce the engineering workload, while integration into Siemens automation technology via its TIA Portal makes for simple commissioning and servicing.  Attributes such as smart encoders and one-button tuning add to its plug-and-play startup. Communication takes place over Profinet using Profisafe and Profidrive profiles.  The new Safety Integrated function SLT (Safely Limited Torque) limits torque by monitoring motor current in running operation.

The Simatic Micro-Drive will offer units from 100 watts to 1 kilowatt and allow side-by-side rail mounting.  The Micro-Drive PDC is available in a standard (only hardwired Safe Torque Off (STO)) and fail-safe version.  STO, SS1, SLT, SLS, and SSM Safety Integrated functions are included with the Micro-Drive F variant.  TIA Portal can be used to activate the safety functions with a Fail-safe PLC via PROFIsafe.  Operating data can be transmitted directly to the controller from the Micro-Drive and transferred to Cloud-based platforms such as MindSphere over MindConnect.

To address its customers’ requirements with maximum flexibility, Siemens utilizes product partnerships with companies such as Dunkermotoren, ebm-pabst, Harting and KnorrTec when it comes to the motors and cables used with Micro-Drive.  The servo drive system is suited to a wide range of diverse applications such as precise positioning, shuttles for storage and retrieval machines or warehousing systems, automatic guided vehicle systems (AGVs) and medical technology.

Siemens expands its drive portfolio with a new extra-low-voltage drive for 24–48V EC motors. The new Micro-Drive system brings industrial networking and integrated safety to a wide range of applications including battery operated equipment.

Website:  http://usa.siemens.com/micro-drive

Siemens Digital Industries (DI) is an innovation leader in automation and digitalization. Closely collaborating with partners and customers, DI drives the digital transformation in the process and discrete industries. With its Digital Enterprise portfolio, DI provides companies of all sizes with an end-to-end set of products, solutions and services to integrate and digitalize the entire value chain. Optimized for the specific needs of each industry, DI’s unique portfolio supports customers to achieve greater productivity and flexibility. DI is constantly adding innovations to its portfolio to integrate cutting-edge future technologies. Siemens Digital Industries has its global headquarters in Nuremberg, Germany, and has around 75,000 employees internationally.

Siemens Corporation is a U.S. subsidiary of Siemens AG, a global powerhouse focusing on the areas of power generation and distribution, intelligent infrastructure for buildings and distributed energy systems, and automation and digitalization in the process and manufacturing industries. Through the separately managed company Siemens Mobility, a leading supplier of smart mobility solutions for rail and road transport, Siemens is shaping the world market for passenger and freight services. Due to its majority stakes in the publicly listed companies Siemens Healthineers AG and Siemens Gamesa Renewable Energy, Siemens is also a world-leading supplier of medical technology and digital healthcare services as well as environmentally friendly solutions for onshore and offshore wind power generation. For more than 160 years, the company has innovated and invented technologies to support American industry spanning manufacturing, energy, healthcare and infrastructure. In fiscal 2018, Siemens USA reported revenue of $23.7 billion, including $5.0 billion in exports, and employs approximately 50,000 people throughout all 50 states and Puerto Rico.

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Goss Magnapak Inserter Performance Improves 15% With Siemens Controls

Siemens “Solution Partner” Advanced Industrial Controls provides Goss Magnapak inserting system upgrade together with Enternet Control Systems (ECS) in seven weeks.

In the world of high-speed Newspaper production printing and inserting, the need to remain at peak performance is paramount.  Recently, a leading bindery and newspaper equipment and printing controller supplier, Enternet Control Systems (Glastonbury, Connecticut) was presented the challenge to retrofit a Goss Magnapak newspaper inserting system.  ECS serves many of the largest magazine, catalog, and newspaper printers in the country.

Magnapak inserter underwent a total retrofit on the control hardware and software, including Siemens electrical components, software and HMI.

Turning to its partner on this project, Advanced Industrial Controls (AIC), a St. Louis area Siemens-authorized Solution Partner who specializes in field service and machine retrofits in the printing industry, ECS conducted a joint situation analysis to determine the components and software needed.  It was decided that a complete electrical control and motion upgrade was required, necessitating the replacement of obsolete and tech-incompatible components, software and HMI.   

The obsolete OEM inserter controls on the machine were to be replaced with a new ECS eNews Model 3000 Controller for monitoring and control of the inserter, along with downstream tracking and stacker control.  Interface to the new controller over ProfiNet was required to allow multiple machine components to be interactively linked.  Interface to customer’s existing planning system was provided through the eNews system as well as connectivity to the customers other four (4) existing eNews systems to enable flexibility in production as well as comprehensive reporting. 

As the systems integrator and controls specialist on the project, AIC utilized the industry-proven Siemens Printing Solutions system architecture, which includes all the hardware platforms and software libraries for high usability and standardization.  Having this capability handy drastically reduced the system evaluation and field testing required, from the sensors to the drives, PLCs, motion controller, HMI and wireless data communications hardware, as well as software. 

Padraic Stapleton, project engineering manager from AIC, comments, “Using our experience retrofitting machines across many industries and our in-depth knowledge on the operations on the Magnapak, we first determined what functionality was needed for this machine.  This included high-speed motor synchronization, safety requirements, high-speed signal processing to and from the ECS eNews controller, an ability to recover smoothly from bus failures, elimination of obsolete components, simplified operator controls and the ability for the customer’s maintenance personnel to troubleshoot issues.  We then utilized our experience with the various Siemens product lines and chose the appropriate components and software to meet the requirements.” 

AIC provided all back panel and prewiring construction offsite to reduce install and startup time at the end user location.

Stapleton further noted that an aggressive project schedule was devised to fit the customer’s production requirements.  This schedule comprised pre-engineering and fabrication that were performed at the AIC facility, including testing.  This pre-onsite work allowed AIC to minimize the machine’s downtime and the actual installation was completed in seven days, as planned.  The customer was ready to go online in seven weeks, also per plan.  “This time frame exceeded the customer’s expectations and, overall, the project was completed on time, on budget and without any hiccups,” Stapleton mused. 

An ambitious goal was set for this retrofit, as the result of these component and software upsides. The target for completion of the entire project was only two months, with installation calculated at one week and going back online in seven weeks. 

Functionally, all hardware was powered up, configured and tested at AIC by their personnel, prior to beginning the install. AIC prewired all the hardware and also manufactured the back panels for the hardware, to further reduce install time onsite. At the customer’s location, all installation was indeed accomplished in one work week, performed by AIC technicians, so no other outside contractor costs were incurred, and plant personnel were freed to perform other tasks during the install time. 

All work was performed onsite by AIC technicians, requiring no outside contractors or customer plant personnel.

The startup was indeed completed in seven weeks, including all I/O checks, drive/motor tuning, testing of the entire Siemens motion control system plus training of the operations and maintenance personnel. Every station in the entire line on the Goss Magnapak was revamped, including the PLC enclosures, main drive cabinets, hoppers, releases, master and slave HMI, with wireless Scalance data transmitters provided for flexibility and mobility in the system.

Following restart of the line and over a tracked period of time in production, the end user’s plant has reported an ongoing net production increase of 15%, compared to the line performance before this upgrade and retrofit of the motion control system. Benefits to the end user included the elimination of obsolete components, a substantial increase in reliability with the new Siemens hardware, increased diagnostic capability resulting from the built-in data tracking tools and connectivity on the Sinamics drive system, a decrease in the complexity of the machine functions due to the incorporation of integrated safety functions in the new drives and most notably increased usability and flexible staging possibilities of the eNews controller onboard. At the most basic level, the distributed I/O system is highly scalable and connects seamlessly to the central controller over Profinet.  A plug-and-play scenario is provided, making alterations on-the-fly more practical, faster and requiring less training time for the operators. 

Plant reports a net production increase of 15%, compared to machine performance before the upgrade.

From the safety side, all e-stops, pushbuttons and guard switches are connected to the safety PLC through integrated safety I/O, with Siemens ProfiSafe onboard to control the STO (Safe Torque Off) function to all the drives in the system. 

Device replacement was simplified, as the new devices can be detected and configured via the communication network to allow the replacement of modules without the need for any reconfiguration.  The system automatically addresses and names the replacement modules, saving substantial setup time per station. 

Pre-tested printing solutions from Siemens provide faster startup and operator interface. Increased diagnostics with built-in tools on the controller improve machine troubleshooting and resolution of any performance issues.

With integrally redundant Sinamics drive communication, in the event of one hopper drive or Profinet cable failure, all other hoppers remain operational and the drive can be disabled from the HMI without rewiring. 

Following restart of the line and over a tracked period of time in production, the end user’s plant has reported an ongoing net production increase of 15%, compared to the line performance before this upgrade and retrofit of the motion control system.  Benefits to the end user included:

  • elimination of obsolete components
  • substantial increase in reliability with the new Siemens hardware
  • increased diagnostic capability resulting from the built-in data tracking tools and connectivity on the Sinamics drive system
  • decrease in the complexity of the machine functions due to the incorporation of integrated safety functions in the new drives
  • increased usability and flexible staging possibilities of the eNews controller onboard. 

At the most basic level, the distributed I/O system is now highly scalable and connects seamlessly to the central controller over Profinet.  A plug-and-play scenario is provided, making alterations on-the-fly more practical, faster and requiring less training time for the operators, according to the end user. 

Stapleton concludes, “The Siemens drives were chosen due to multiple reasons, including integrated safety functionality, built-in high speed inputs and outputs that were required for specific machine functions, proven hardware reliability, simplistic overall hardware architecture, proven motion synchronization functionality and the ability to have the drive configuration parameters integrated into one software programming package.” 


AIC is a full-service integrator of electrical and automation systems, working the full suite of Siemens motion control components, robotic, SCADA, networking, power distribution, bar code, RFID and vision systems.  The company further provides turnkey control panel fabrication, field service and parts inventory for customers. 

With over 30 years in the industry, ECS offers its customers a wide range of inline bindery, newspaper, wrapper, mailtube and co-mail control systems for selective pocket feeding and tracking, multi-station inkjet addressing plus integrated camera technology for signature recognition, read and print capability, IMB and bar code verification. 

For more information on this story, please contact: 

Jason Tretter, President
Advanced Industrial Controls
1000 Eleven South
Columbia, IL 62236
618-977-4576
www.advancedindustrialcontrols.com

 OR

Dave Carlos, Sales & Marketing Manager
Enternet Control Systems
21 Sequin Drive
Glastonbury, CT 06033
877-477-1325
www.ecsbindery.com

OR

John Meyer 
Siemens Industry, Inc. 
Digital Industries — General Motion Control
380 Kent Avenue 
Elk Grove Village, IL 60007
Phone:  847-640-1595
www.usa.siemens.com/motioncontrol

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Siemens Engineer Shares Her Experience

Alessandra Da Silva, Siemens Electronic EngineerAlessandra Da Silva has spent the past 12 years working as an electronic engineer for Siemens. Originally from the southern part of Brazil, she graduated with a degree in electrical engineering from Sao Paulo University. Her first job experience came during high school, when she worked as an electronic technician in a Brazilian factory. This was the first time Da Silva was introduced to Siemens products, which she enjoyed using.

Moving to Sao Paulo, Da Silva worked as a software developer and also as an automation engineer and project engineer. She started working for Siemens in the IT department, then moved to product design and software development. Da Silva’s current job title is Head of Artificial Intelligence and Edge Computing Deployment. She works in artificial intelligence and edge computing, as well as participates in R&D to test new projects. While she is very motivated in these areas, Da Silva would like to combine her work in artificial intelligence with robotics, in the next phase of her career.

“A combination of advanced smart technologies, artificial intelligence (AI) empowers machines to perform tasks that were traditionally only possible using human intelligence. Within manufacturing, AI has evolved in its capabilities over the years and found innumerable applications in industrial automation,” Da Silva notes.

The benefits of AI can be divided across product, process and strategic levels of manufacturing. At the product level, AI can be used to deliver end-user benefits, while at the process level, it can be applied to automate and advance operational capabilities. At the more strategic level, AI can be applied to deliver insights that inform decisions made by management. Da Silva says the AI revolution will introduce several capabilities into future automation systems, including improved efficiencies, quicker time to market, increased customization plus reduced manufacturing and operating costs, integrative factories, effective asset management and more. In addition, artificial intelligence helps solve complex issues with minimal or zero human interaction, enhances safety functions by accessing industrial areas that are hazardous to humans and also solves a diverse set of tasks simultaneously. She adds, “Automation systems embedded with AI allow real-time integration such as between a programmable logic controller (PLC) and AI’s data processing capabilities. Because all devices are connected, there is a huge amount of data that is generated. AI further helps manufacturers convert the data into insights that can be used to predict equipment failures and prevent mechanical downtimes.“

Industrial Edge enables intelligent, high-performance data analysis directly within the automation system running on established standards like PLCs, distributed control system (DCS) and supervisory control and data acquisition (SCADA) protocols. With Edge Computing, large volumes of data can be processed locally on the plant floor. It unfolds its full potential in combination with cloud-based analytics on the open Industrial Internet of Things (IIoT) and Siemens Mindsphere, the company’s proprietary cloud-based technology. According to Da Silva, “This greatly reduces storage and transmission costs for users, as large data volumes can be pre-processed and only the relevant data is transferred to a cloud or IT infrastructure. The optimized data points, transferred to the cloud, provide access to more computing power and large storage capacities. With Industrial Edge, users enjoy all the benefits of edge and cloud computing, optimally tailored to a company’s specific requirements.”

Alessandra Da Silva, Siemens Electronic EngineerWhen reflecting on her career as an engineer, Da Silva was always interested in engineering and says she was influenced by her cousin, who went to a technical school. While she didn’t have specific mentors, Da Silva received encouragement from her family and also her boss at the factory who encouraged her to go to the university. During her internship, she was part of the maintenance department, fixing machines and programing PLCs. As a woman in engineering, Da Silva says she was fortunate to have positive experiences in her field of work. Although she says some countries weren’t accustomed to seeing a female engineer, she was treated with respect and appreciation of the competence she brings to her work.

In 5 to 10 years, Da Silva plans to continue working with technology and see how it evolves. The technology that most excites her in the future is artificial intelligence because, since its beginning in the 1950s, there have been constant new developments. Outside of work, Da Silva enjoys playing games, especially the digital kind. She lives in a smart home and always tries to learn more about technology, while she regularly converses with her virtual home “assistant”.


For more information, please contact:
Karen Kasik, Manager of Marketing Communications
Siemens Industry, Factory Automation
Phone: 470-709-3641
Email: Karen.kasik@siemens.com

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