PROGRESS: LAZY MEN LOOKING FOR EASY WAYS TO DO THINGS · komm-ma Kommunikation und Marketing Uschi...

PROGRESS: LAZY MEN LOOKING FOREASY WAYS TO DO THINGS

W W W. C N C C L E A R C U T. C O . Z A

JULY/AUGUST 2017 Volume 26 No. 4

Machine Tool Market®

Machine Tool Market – July/August 2017 1

Proprietors and Publishers: MTM Publications (Pty) Ltd Reg No. 2005/030589/07

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SaWing 6

nEWS – inTERnaTiOnaL 24PREDiCTiVE MainTEnanCE SaVES LOTS OF MOnEY 24UPBEaT MinDSET in THE inDian ECOnOMY 27inDUSTRY 4.0 REQUiRES MORE OPEnnESS 30$40 BiLLiOn OF nEW COMMERCiaL aiRCRaFT ORDERS 32nEaRLY 35,000 aiRCRaFT REQUiRED 32CECiMO annOUnCES POSiTiVE FORECaSTS FOR 2017 34WORLD’S LaRgEST FLOaTing PHOTOVOLTaiC POWER PLanT TEST-BED 36THE FUTURE OF TRanSPORT iS MagnETiC 38

nEWS – LOCaL 40SaEFa COnFiDEnT PaRTiES Can STiLL aVOiD EnginEERing SECTOR STRiKES 40STEEL inDUSTRY nEgOTiaTiOnS – MiSinFORMaTiOn BY nUMSa 41HigH-PROFiLE DiaLOgUE FOR EMBaTTLED STEEL anD EnginEERing SECTOR 41RiSing UnEMPLOYMEnT SHOWS an ECOnOMY in TROUBLE 42

CUTTing TOOL FaCTS 48

RESEaRCH 52EVERY DRiLL BiT COUnTS 52nEW SaFETY TECHnOLOgY EnaBLES TEaMWORK 53

TRaDE FaiRS 54

• CONTENTS •

JULY/aUgUST 2017 Vol. 26 – no. 4

CNC CLEAR CUT

WORLD CLASS PLASMA TABLES

CNC CLEAR CNC CLEAR

Tel: (012) 541-0552 • Fax: 086 684 6813Email: [email protected]

www.cncclearcut.co.za

PROGRESS: LAZY

MEN LOOKING FOR

EASY WAYS TO DO THINGS

12 Fairwood Road, Rosslyn East 0200



Simple, inexpensive, compact• Variety of materials • Enhanced productivity in thin sheets • Low investment and operating costs • Simple to operate • Simple design and short installation time

FIBER LASERS

AD-R PRESS BRAKESFast, stronger, accurate with new design

PLASMA CUTTERSSHEARS IRON WORKER PUNCH/LASERPLATE ROLLING MACHINE SECTION ROLLERS BANDSAW

Local: 08600 DURMA (38762)International: +27 11 865 4090

[email protected] | Byron 083 231 1955www.durma.co.za

THE WINNING FORCE

Other machines available:

• CNC punching machines

• Variable rake swing beam and mechanical shears

• CNC plasma cutting systems

• L angle processing centers

• Plate roll benders

• Profile benders

• Iron workers

• Bandsaws

• Corner notchers

• Laser and Plasma Consumables • Press Brake Tooling • Eccentric Presses • Press Feeding Equipment and CompressorsWe are an authorised service centre for

PRECITEC Laser Heads

Sheet Metal Solutions

We are a distributor for

MTM®

PLASMA & LASER CUTTING CONSUMABLES

PRESS BRAKE TOOLING

CUTTING PRODUCTS, SYSTEMS &SOFTWARE

COMPRESSORS

Authorized Partner

One source your best sourceDurma South Africa have made it easier and faster to get just what you need - your forming and fabricating source for machines, consumables, accessories

and systems

Just cut, bend and fabricate it!!

Main Screen

Manual Mode screen switch button

Auto Mode screen switch button

Alarm screen switch button

Settings screen switch button

Diagnostic screen switch button


Just cut, bend and fabricate it!!


DCB-S-560 Double Column Semi-Automatic Bandsaw

THE FUTURE IS FORMED BY OUR MACHINES

CNC TURRET PUNCH PRESSES, CNC LASER CUTTERS, CNC PRESSBRAKES, NC HYDRAULIC/MECHANICAL SHEARS, SOFTWARE, BANDSAWS,

BANDSAW BLADES, SALES & SERVICE.

THE SAWING SOLUTION

MTM®

GAUTENGTel: (011) 453-5459 • Fax: (011) 453-5442 Cell: 082 465 5924 (Rick) • E-mail: [email protected] TOWN DURBANTel: (021) 706-0502 • Fax: (021) 706-0503 Tel: (031) 700-5070 • Fax: (031) 700-5077

GAUTENGTel: (011) 453-5459 • Fax: (011) 453-5442 Cell: 082 465 5924 (Rick) • E-mail: [email protected] TOWN DURBANTel: (021) 706-0502 • Fax: (021) 706-0503 Tel: (031) 700-5070 • Fax: (031) 700-5077

®

Amada’s bandsawing technology allows you to play an active role in material processing with its extensive range of bandsawing machinery which enables you to turn the impossible into the possible. To get a cut above the rest call us at ...(011) 453-5459 and join the circle of satisfaction.

Amada’s bandsawing technology allows you to play an active role in material processing with its extensive range of bandsawing machinery which enables you to turn the impossible into the possible. To get a cut above the rest call us at ...(011) 453-5459 and join the circle of satisfaction.

“BAND SAW CUTTING” ... A fundamental concept in material processing, and one in which AMADA can apply the world’s most advanced techniques with it’s many years of experience. It is well known that the cutting process has a great deal of influence in both product dimensional accuracy and manufacturing economy. At the same time, this fundamental process of cutting becomes the cornerstone of profit in manufacturing.

“BAND SAW CUTTING” ... A fundamental concept in material processing, and one in which AMADA can apply the world’s most advanced techniques with it’s many years of experience. It is well known that the cutting process has a great deal of influence in both product dimensional accuracy and manufacturing economy. At the same time, this fundamental process of cutting becomes the cornerstone of profit in manufacturing.

Machine Tool Market – July/August 20176

SawingTHE SPECIALIST FOR LONGITUDINAL CUTTINGThe KASTOvertical semi-automatic vertical band sawing machine manufactured by the metal sawing specialist KASTO is an excellent solution for companies that focus on toolmaking, steel processing and special machining tasks. Its ability to make longitudinal cuts allows one to saw square or flat materials with different cross sections from small rolled blocks or rolled plates. The machine is also ideal for efficient cutting of test strips.

The KaSTOvertical has a cutting depth of up to 680mm and a cutting height of 600mm. The maximum cutting length is 1,260mm. it can efficiently saw all commonly used materials, including those that are very hard to machine, at a high level of quality. its robust welded structure ensures quiet operation and precision. The saw has a movable material support table with a height of 1,150mm, allowing fast and safe handling of bulky workpieces with weights of up to two tonnes. in contrast to conventional machines for making longitudinal cuts, which have stationary tables and a moving saw head, the KaSTOvertical has a movable material support table.

Thanks to this special feature, users can position, align and anchor the material outside the machine’s working area, and these tasks can be done safely, easily and quickly. The table and its guide have a cast-iron structure to cope with the rough conditions encountered in everyday operation. Support rails with T-slots allow quick and secure clamping of workpieces, and they are suitable for a wide range of clamping and fastening devices. Linear guides with zero-play carriages guide the material support table on the machine bed. They are driven by a ball screw spindle with servomotor, which comes as standard.

The KASTOvertical has an amply dimensioned frequency-controlled saw band drive. The cutting speed and saw feed rate are infinitely variable. For this purpose the KASTOvertical is equipped with KASTO BasicControl, an intelligent controller with easy touchscreen

operation. A swivel-mounted operating panel allows users to keep their eyes on the workpiece and saw blade from any position.

In addition, KASTO offers an extensive range of saw accessories. A wide range of measuring stops are available for aligning blocks and plates. The simplest version is a manually adjustable clamp-on measuring stop. For longer materials there is also a stop bar which extends the entire length of the table and can be adjusted by means of a hand wheel with a digital display. Alternatively, this stop can be moved by means of an electric motor. The KASTOvertical is a powerful, compact sawing machine with outstanding value for money.

For more information, please contact Retecon – Tel: 011 976-8600.

The KASTOvertical semi-automatic vertical band sawing machine is for sawing square or flat materials with different cross sections from small rolled blocks or rolled plates.

The saw, which is designed for longitudinal cutting, has a movable material support table that permits fast and safe handling

of bulky workpieces with weights of up to two tonnes.

A durable, low-maintenance ball screw spindle moves the saw with

very high precision.

Storage systems for bar and sheets

Large production and plate saws

Economic sawing and storing of metal

No compromises

Contact Marc Edwards

Tel: 011 976 8600 • Cell: 083 383 7796 • [email protected]

Cape Town: 021 555 2270/1 • Port Elizabeth: 041 453 2720 • Durban: 031 701 8149

RETECON (PTY) LTDYour Partner in Metal Working

PRODUCTIVITY | RELIABILITY | QUALITY

Small and versatile, band saws and circular sawsSmall and versatile, band saws and circular sawsSmall and versatile, band saws and circular sawsSmall and versatile, band saws and circular saws


Sawing

For more information, please contact Retecon – Tel: 011 976-8600.

PRECISE HIGH-PERFORMANCE BAND SAW REDUCES CUTTING TIMES BY UP TO 50 PERCENTThe metal sawing and storage technology specialist KaSTO has brought out a new high-performance band saw, the KaSTOwin pro aC 5.6. Users will appreciate its short cutting times, long tool life and intuitive operation. The fully automatic machine is optimized for bimetallic and carbide blades and can be applied in areas such as the steel trade, steel production, forging mills, machine manufacturing and the automotive industry. Besides helping to reduce tool costs, it significantly increases production speed and efficiency. Depending on the type of blade, cutting times can be reduced by 50 percent and more.

The KASTOwin pro AC 5.6 is designed for a wide range of applications and delivers top performance with both carbide and bimetallic saw blades. An important feature is its innovative feed system, which is controlled by means of two ball screw spindles, each with a servo drive for precise, infinitely variable control. The KASTOwin pro also has a retraction unit on each side for lifting the band from the surface when the saw head moves back. This makes for particularly efficient, exact sawing with minimal tool wear.

The KASTOwin pro AC 5.6 is driven by an

11-kilowatt frequency-controlled motor, which provides plenty of capacity for use with carbide blades. The cutting range is 560 millimetres and the smallest dimension to be cut is 25 x 25 millimetres. The shortest residual length is ten millimetres for individual offcuts and 35 millimetres for automatic operation, enabling operators to reduce waste to a minimum. Two electrically driven plastic brushes keep the band free of chips. They are easy to replace and are automatically adjusted throughout their service life. The sawing unit has a heavy, torsionally rigid welded structure with vibration-optimized ribbing, ensuring quiet operation with shorter cutting times and a long tool life.

The KASTOwin pro AC 5.6 also has a powerful coolant pump and a large coolant reservoir so that difficult-to-machine materials can be cut with minimal tool wear. In addition, this fully automatic saw comes with EasyControl, a high-performance control unit. It is easy to use and reduces idle times in automatic operation for maximum cutting performance. All parameters can be optimized to match the type of blade being used.

The KASTOwin pro is noteworthy for its cutting times, long tool life and intuitive operation.

The fully automatic machine is optimised for bimetallic and carbide blades and can be applied in areas such as the steel trade, steel production, forging mills, machine

manufacturing and the automotive industry.

From machinery and equipment fi nance to cash fl ow requirements, our complete offering of solutions and expertise focuses on making a real difference to the success of your business. Let us be your partner for growth on this continent we call home.

*Terms and conditions apply.

standardbank.co.za/business

“What can I do to make my manufacturing

business go forward?”“Talk to us.”

Authorised fi nancial services and registered credit provider (NCRCP15).The Standard Bank of South Africa Limited (Reg. No. 1962/000738/06). Moving Forward is a trademark of The Standard Bank of South Africa Limited SBSA 213213 06/16.


Sawing

The high-performance automatic circular saw KASTOspeed C 9 has been specially designed for economic series production.

For more information, please contact Retecon –

Tel: 011 976-8600.

HIGH-PERFORMANCE CIRCULAR SAW WITH OUTSTANDING AUTOMATION POTENTIALWhether in press shops or forging plants, at manufacturers of fittings or electrical parts, at steel stockholders or automotive industry suppliers: in countless industries, there is a demand for sawing solutions that combine high cutting performance with efficiency and precision. With KASTOspeed C 9, the sawing specialist KASTO has just such a solution in its portfolio. The high-performance automatic circular saw has been specially designed for economic series production and can be integrated in a controlled, end-to-end material flow by means of the KASTOsort robot interface.

The KaSTOspeed C 9 is suitable for sawing steel and has a cutting range of up to 90 millimetres for round material and 80 millimetres for square material. The automatic circular saw helps minimize cycle times and makes it possible to produce millions of high precision cut parts every year when operated for two or three shifts per day. Thanks to its outstanding reliability and precision in continuous operation, KaSTOspeed is one of the most frequently purchased high-volume circular saws in the world.

The KASTOspeed C 9 uses carbide-tipped saw blades. The optimum positioning of the saw drive, and the four-point workpiece clamping arrangement, enable an extremely short saw stroke. The robust machine construction with helical gearbox, combined with a hydraulically damped measuring stop and a bar pusher that can be moved rapidly into position, permits accurate cutting and very high output.

What is more, the KASTOspeed C 9 offers many different ways of improving efficiency. The KASTOsort robot interface makes it possible to automate upstream and downstream production processes and integrate these in a controlled, end-to-end material flow that includes the sawing operation itself. Industrial robots are able to remove the cut parts automatically and accomplish numerous other tasks, from deburring and chamfering, through centring, tapping, marking and printing and on to sorting, stacking and picking. This robot-saw solution can be further integrated with a container management or driverless transport system.

Depending on the customer’s requirements, KASTO integrates the robot controller into the saw controller, its own KASTOlogic Warehouse Management System or in an existing ERP system. As a result, the user can control and monitor all the processes over a single interface and benefits from a perfectly harmonized process chain. A number of different magazine variants are available to allow large quantities of raw material to be stored upstream of the machine. This means that companies can run the system fully unattended even for long periods when required.

Operational range with adjustable saw blade guide (patented), measuring stop and outfeed conveyor for cut-off pieces

(optional accessory).

Bar pusher carriage with linear guide system and material guide rail.


Sawing

For more information, please contact First Cut – Tel: 011 614-1112.

EVERISING P-SERIES – THE SOLUTION TO HIGH SPEED CUTTING, REDUCED COST PER CUT AND FULL AUTOMATIONFirst Cut, South African sole agent for Taiwan-based Everising Machine Company introduced Everising’s comprehensive range of bandsaw machines because of its offering of maximum productivity at minimum cost.

The P-series also has a user friendly touch screen, with very clear graphics. All the cutting parameters are represented on the touch screen controller. This includes a self-diagnostic function for on-screen troubleshooting, so that problems can be detected and resolved immediately.

The gear transmission driver provides high efficiency and consistent cutting speed and the carbide guide pads are used to strengthen the rigidity of the saw blades, which means not only accuracy, but the life of the saw blade is extended.

Recently, installing the new and improved P100 at one of First Cut’s customers who required minimum wastage and a faster cutting time was achieved by adding a third vise which resulted in a 15mm remnant piece and an indexing capability of 1000mm.

A new addition to the P-Series family is the unrivaled P230. The new evolved and uniquely adapted P-230B can cut up to an impressive 230mm in diameter. In addition to reliability and affordability, the Everising P-230B

Series CNC cutting machine brings a new level of speed and accuracy to the user.

Key features of the P-series include the requirement of only one operator to set and load the machine, with no supervision thereafter, machine sorting of remnant pieces into a separate bin and a space saving potential of +/-60m² if 5-6 bandsaw machines would be replaced. Add to this a milling cutter finish with a tolerance of 0.02mm and the ability to cut a 50mm round bar in 8 seconds.

“With our national footprint, we guarantee fast and reliable deliveries, including installation and thorough training on the range of machines offered. While our highly skilled technicians install, service and maintain all machines offered, our call center is available to assist with machine related queries, booking of services and scheduling maintenance contracts. Last not least we have full spares back up for all our machines” concludes Van Wyk.

This machine is ex-stock, while stocks last.

a specialist in medium to large band saws since 1982, Everising derives its technological innovation from customer requests. “This is very much in line with the First Cut philosophy of finding niche solutions to customer application requirements in order to provide long-term sustainability and productivity, while at the same time reducing maintenance and downtime,” says First Cut Director Steve Van Wyk.

“Everising bandsaw and circular sawing machines are ISO accredited, and are among the finest in the world, renowned for their extraordinary rigidity and accuracy, while exhibiting the most advanced cutting tool technology,” says Van Wyk.

The P-series CNC machines are equipped with some outstanding features, such as automatic loading tables which support a large number of work pieces. This allows for automatic feeding of bar stock during cutting operations, resulting in continuous output. This range of machines can cut round, square, hollow, tube and flat bar.


Sawing

For more information, please contact First Cut – Tel: 011 614-1112.

NEW TECHNOLOGY WIKUS SKALAR® BANDSAW BLADEWhile WIKUS analyzes in detail all parameters, which influence the cost per cut, this rigorous evaluation of the cutting process is a key factor in achieving reduced cutting costs and with its product portfolio, WIKUS offers highly efficient, long-lasting solutions for any cutting task.

Cutting times and cutting costs can easily be reduced, blade lifetimes increased and additional capacities obtained through highly efficient tool performance. Moreover, innovative top-quality WiKUS bandsaw blades give an excellent finish to any cut, a factor which reduces the number of subsequent process steps. The results are increased efficiency and productivity, reduced cost per cut as well as the realisation of potential savings.

SKALAR® precision metal cutting bandsaw blade

WIKUS introduced the newly developed SKALAR bandsaw blade to the bimetal product family. This high-tech bandsaw blade meets the highest standards in metal cutting.

In developing the SKALAR® blade, Wikus especially took customer requirements into account. The bandsaw blade has many new features resulting from cooperation

between Wikus’s Research and Development and Technical Support departments. The SKALAR® blade performs exceptionally well in terms of blade-life when cutting difficult special materials such as stainless- and acid-resistant-steels, while achieving an excellent finish to the cut surfaces. A series of successful internal and external cutting trials verified the performance of this new high-quality blade.

The blade’s ground tooth technology allows high performance cutting of many special steels and metals, namely stainless and acid-resistant steels (ferritic), nitriding and high-speed steels, cast iron, tool steels, hardening steels, spring and ball-bearing steels, carbon and heat-treated steels, construction, deep-drawing and cutting steels, non-ferrous metals and aluminium / aluminium alloys.

ParaMaster 3.0 – online cutting data program

This software application has been designed for the optimization of the cutting process, taking into account the materials that need to be cut and the customer’s requirements.

With the online ParaMaster 3.0 cutting software, registered users can enter the parameters for a specific cutting task and receive the appropriate specifications regarding the best choice of bandsaw blade and the particular cutting parameters for the job in hand. This simple, useful tool is available through First Cut on the WIKUS website.

KANEFUSA COLD SAW™ TECHNOLOGYKanefusa is Japan’s largest manufacturer of high-quality industrial tools used in the metalworking industry. Their saw blades, cutters and machine knives are engineered to the highest industrial standards and available in South africa from First Cut.

Kanefusa’s V-tech™ PCD saw blade, FM Cold Saw™ technology and advanced material technology coating on cutting edges are demonstrations of their innovative strength. Satisfied users all around the world testify to the reliability of Kanefusa’s products.

Kanefusa’s FM (Ferro Max) cold saw blades (single use) cut on average three times faster than a conventional bandsaw or metal saw, which means one machine can do the job of three. Less energy is needed to power the machines, less oil mist is generated and less space is required.

FM cold saw blades such as the Ferro Max Speed can outlast a conventional saw blade by up to 10 times. In the same period, a conventional saw blade must be reground nine times. This process produces a lot of sludge that requires costly disposal and each time a blade needs regrinding there are associated pickup and delivery costs nine times over. FM cold saw blades also allow for a thinner kerf than resharpened blades, which leads to a better material utilization and less swarf that must be either disposed of or recycled.

Every Kanefusa blade provides a constant cut quality and durability, providing absolute excellence and reliability blade after blade, a factor which is key to timeous and efficient production.

HARP ACCURL CNC HYDRAULIC PRESS BRAKE

Size range from 40Ton to 450Ton

HARP WAYTRAIN HORIZONTAL BANDSAW

UE-712A1 / UE-916A / UE-918S / UE-250 / UE-330

HORIZONTAL BANDSAWHORIZONTAL BANDSAW

UE-918S / UE-250 / UE-330

HORIZONTAL BANDSAWHORIZONTAL BANDSAW

UE-918S / UE-250 / UE-330HARP SMTCL DOUBLE

COLUMN HORIZONTAL BANDSAW

DBS280 / DBS350 / DBS280NC / DBS350NC

MTM®

• TEL: (011) 918-5138 • FAX: (011) 918-5139 • •161 DORMEHL ROAD, ANDERBOLT, BOKSBURG NORTH • PO BOX 2698 BENONI 1500 •

Monday-Thursday 08:00-17:00 • Friday 08:00-14:00 | Saturday by appointment Friday 08:00-14:00 | Saturday by appointment

Harp Machine Toolswww.harp.co.zae-mail: [email protected]

FINANCE FACILITIES AVAILABLE - ONLY 24 HOURS FOR APPROVAL

Size range from 40Ton to 450Ton

Harp Quality never lets you down

HARP ACCURL CNC HYDRAULIC HARP ACCURL CNC HYDRAULIC

HARP SMTCL CENTRE LATHE Size range from 1000mm To 4000mm

HARP SMTCL RADIAL DRILLZ3032x10/1 / Z3050x16/1 /

Z3063x20/1 / Z3080x25

HARP SMTCL SURFACE GRINDERSGA3063AHD / SGA4080AHD / SGA40100AHD

KINGRICH BED TYPE MILLKR-B4V

HARP SMTCL HORIZONTAL BORING MILL

TPX6113/2 (130mm) / TPX6111B/3 (110mm)

HARP ACCURL CNC HYDRAULIC GUILLOTINE

Size range from 4mm to 20mm

KINGRICH TURRET MILLKR-V2000 / KR-V3000 /

KR-V3000SL

HarpHarp QualityQualityQuality

BAOJI CENTRE LATHESize range from 1000mm

to 3000mm

NEW STOCK

ARRIVING


Sawing

For more information, please contact F&H Machine

Tools – Tel: 011 397-4050.

COSEN CNC-430 PERFORMANCE BANDSAW The Cosen CNC-430 performance bandsaw machine features world-class design with technology to cut faster and smarter, while saving the user money.

Anti-Vibration Quick Approach Device

Robust Guide Arms

Dual Powered Chip Brushes

Servo Motor Driven Ball Screw

Adjustable Control Panel

Cast Iron Saw Frame

Dual Vibration Dampener

Directly drive motor and Spur Gear Box

Chip Conveyor

Hard material like inconel, titanium and stainless steel are expensive to cut due to extensive time consumption, tool costs and demand for an experienced operator. With the Cosen CnC-430 customers are in full control by cutting hard material faster, extending blade life and eliminating guesswork or operator error.

With the CNC-430 blades and work orders can be managed from the office, while cutting with recommended rates storing favourite parameters.

The CNC-430 features a cast iron saw frame, 4 oversized linear rails, large cast iron wheels with reinforcement arms, dual vibration dampeners and extra large/wide guide arms, while a V-Drive further acts to remove harmonics and vibration.

The dual vibration dampeners enhance cutting performance by suppressing the maximum amount of blade vibration.

The heavy duty and rugged cast iron saw frame stabilizes downfeed movement; there-by ensuring the performance and accuracy of the cut and also extending blade life.

Cosen produce metal cutting band saws from the smallest versions up to CNC machines. It is an ideal tool for the machine shop, maintenance shop, metal fabricating shop, school and limited run production work. Its solid construction ensures many years of accurate and reliable performance.

+27 (0)11 397 4050 | [email protected]

Proud Member of

Ÿ Ultra Wide A-Shaped Column DesignŸ Full Support Base DesignŸ Ultra-Wide Y-Axis DesignŸ Best Supporting BESSEL Point DesignŸ One-Piece Coolant Collect Frame DesignŸ 3 Axis Direct Coupled Servo MotorsŸ 3 Axis Pretensioned Ball ScrewsŸ Large Size Heavy Duty Working TableŸ Robust Cast Iron HeadstockŸ Built-in Screw Type Chip Conveyor

SUPERIOR STRUCTURE DESIGN

Double Column and Five Axis Machines also available


Sawing

All mechanical and hydraulic systems of HB and DCB series Durma bandsaws are designed by experienced Durmazlar engineers in the R&D centre by using parametric 3D technology. Electric and electronic systems are designed in-house by computer and mechatronics engineers, while prototypes are forwarded to serial production after numerous tests.

DURMA HB, DCB series bandsaws feature a strong and heavy body design combined with high motor power and fast cutting ability; add to this longer blade life and a low sound level.

Hydraulic movements are facilitated by Rexroth valves, while all electrical control components are selected from Siemens and Schneider.

Standard features include a hydraulic vice, electric cutting speed adjustment with inverter, a bimetal bandsaw and cooling system and a bearing and carbide type blade housing. The

NC control system, chip brush and a roller table complete the lineup. Extra tables can be put together to support longer materials.

Optional equipment includes a motorized chip-brush, chip conveyor, a laser marking system and hydraulic top clamping. A micro spray cooling system, automatic cutting pressure control and an extra roller table, measuring 1500mm length is also available.

DURMA DOUBLE COLUMN AUTOMATIC BANDSAWToday, bandsaws are the easiest, the fastest and the best way to cut metal. They are used in cutting iron, copper compounds, aluminium compounds, production steel, carbon steel, hot-cold work tool steel, reform steel, pattern steel, nickel chrome compound steel, bearing steel, stainless steel, titanium compounds, foundries, construction steels and non-ferrous metals straight or angular.

For more information, contact: Durmazlar – Tel: 011 865-4090.

DCB-A 1100 Durma Double Column Automatic Bandsaw

it can cut one by one and also multiple. as bandsaws are fast and inexpensive, they are used commonly in steel plants, craft, aircraft, automotive industries and manufacturing, construction and aluminium sectors.

Hydraulic Vice

Bimetal Bandsaw and Cooling System

Bearing and Carbide Type Blade Housing


Sawing

AMADA – ON THE CUTTING-EDGE OF BANDSAW TECHNOLOGY

The history of amada cutting-edge bandsaw technology dates back to 1946; ever since our goals have been to provide customers with increased productivity and reliability. While technology evolved, we embraced CnC automation as a core strength, thus improving throughput. Today we are uniquely positioned to help customers expand production capabilities and growing their business.

No two customers’ needs are exactly alike. Finding the right solution means thoroughly understanding objectives and configuring a solution that matches them precisely. Our engineers have decades of industry experience which promote achieving specified goals with a process that fits and enhances a customer’s work flow.

From the early beginnings of bandsaw machinery produced by Amada, (many of which are still running today), Amada has strived to offer machines that not only meet customers’ needs, but exceed them by offering features that were once considered impossible.

The technology of the bandsaw demonstrates the ability and limitations of the blade. As blades advance in technology, so do the machines utilizing them. Amada, as a proud manufacturer of both the machines and the blades, continues to research these developments and incorporates customer feedback to produce constantly evolving solutions.

Amada supplies bandsaw machinery and blades, such as the HK / HD series for mitre cutting, the semi-automatic H series, fully automatic HA / HFA series and the VM vertical series. The latest bandsaw technology is reflected in models such as the Dynasaw 430, the PCSAW with pulse cutting technology and CMB high speed circular saws.

Some features include out of square cutting detection, motion detectors to monitor the blade for jamming or breakage while cutting and quick approach arms. Add to this no work limit switches and work lights, hydraulic blade tensioning, variable blade speed control, vice pressure control units and positively driven wire brushes. 9 times feed for cutting long lengths and cut-off counters

ensure the correct number of cuts. All these features, assist semi-skilled workers in the operation of the machines.

Certain models can be left to run unmanned on larger batch runs, thus allowing staff to do other important jobs at the same time. Take-up conveyors and tripod stands are available making material handling simple during the loading and cutting process.

Models available start with the entry level of 250mm capacity, which are highly popular and favourably priced. With larger steel suppliers all utilizing Amada bandsaws daily, testimony is given to their accuracy, reliability and longevity. Cutting accuracies are obtained right down to 0,2mm. With such accuracies, the need for secondary machining processes is greatly reduced and in some cases eliminated.

The latest additions to the Amada bandsaw range is the PCSAW, with either single pulse cutting action or double pulse cutting action. The PCSAW series is designed to offer high cutting rates, high precision, low noise and long blade life.

Vibration has always been an unwanted characteristic of metal sawing when cutting too fast. It leads to decreased blade life, noise and uneven or inaccurate cutting. By introducing a controlled pulsating motion to the blade through either an induction motor or a servo motor, all unwanted vibrations are eliminated and most efficient metal cutting is achieved. Blade temperature is reduced considerably during the process, and this together with positive chip removal through a twin wire brush system and a large area chip conveyor all enhance blade life and reduce running costs. All PCSAW bandsaws are operated through the on-board user-friendly CNC control.

The HPSaw (High Performance Saw) is possibly the fastest bandsaw in its class with the latest in cutting speed innovation and the ability to cut at up to 1.5 times faster than the high speed circular saws.

The specially designed AXCELA HP1 blade for this machine also reduces material wastage by up to 60% and guarantees accurate cutting.

Circular sawing machines are the optimal technology for realizing reduction in cycle time and high-precision cutting needed for steel bar cutting at high speed. An automatic loading table for continued cutting operation is supported by a CNC powered cut-in control for ease of operation. In perfecting functionality of these machines, Amada has developed a unique carbide tip

By Barry Page

angle encoders linear encoders contouring controls digital readouts length gauges rotary encoders

Can a numerical control be far-sighted?

MAFEMA SALES SERVICES CCTel +2711 314 4416, Fax +2711 314 2289http:/www.heidenhain.co.zaE-Mail: [email protected]

To come to your destination safely, you need to look far ahead. That’s why a numerical control from HEIDENHAIN is the ideal companion for high speed milling. Because it can keep its balance. For absolute reliability and precision.TNC320 numerical control can be used for Point-to-Point and contouring milling.Most Manual operated machines can be retrofitted to a Point-to-Point or contouring milling/boring machines.Local distributors in your area: Electronic Specialities Tel (031) 267 1423, Specialised Machine Tool ServicesTel (041) 453 4206, Coastal Machine Tool Support CC Tel (021) 891 9805


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circular blade that cuts cleanly, generating virtually no burrs.

A full range of bi-metal bandsaw blades are produced by Amada to compliment machine technology. As mentioned previously, a bandsaw demonstrates the ability and limitations of a blade. This means that a machine is only as good as the blade being used. Amada blades have earned the reputation of extreme reliability and longevity. All blades are manufactured in Japan to the most stringent quality standards and utilizing

the latest in electron beam welding methods. These measures ensure that premature blade breakage is almost unheard of. The comprehensive range of blades available is tailor-made for all types of cutting conditions on all types of steels and profiles.

For more information, please contact Amada –

Tel: 011 453-5459.

Robustness of Amada machinery, combined with longevity of Amada blades and a highly dedicated backup policy provide Amada customers, with total peace of mind.

angle encoders linear encoders contouring controls digital readouts length gauges rotary encoders

Can a numerical control be far-sighted?

MAFEMA SALES SERVICES CCTel +2711 314 4416, Fax +2711 314 2289http:/www.heidenhain.co.zaE-Mail: [email protected]

To come to your destination safely, you need to look far ahead. That’s why a numerical control from HEIDENHAIN is the ideal companion for high speed milling. Because it can keep its balance. For absolute reliability and precision.TNC320 numerical control can be used for Point-to-Point and contouring milling.Most Manual operated machines can be retrofitted to a Point-to-Point or contouring milling/boring machines.Local distributors in your area: Electronic Specialities Tel (031) 267 1423, Specialised Machine Tool ServicesTel (041) 453 4206, Coastal Machine Tool Support CC Tel (021) 891 9805


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TUBE CUTTING WITH CHAMFERING AND DEBURRING SYSTEM AUTOMATION CELLS

SOCO offers solutions for chamfering and deburring after cutting.

The Sa-78nCE high tensile steel tube cutting line together with the DEF-Fa/76-V chamfering system can connect to the SOCO BDB-70 deburring system by an automation cell, covering loading, cutting, end-finishing, washing, length measuring and stacking.

Cutting lines with deburring system

In general, the deburring method has been more widely used within the tubing industry. Using wire brushes, the operator can easily remove the burrs at the end of the tubes through manual and automatic systems and for single or double tube ends.

The brushes are able to reach the entire surface, both internal and external through different movements that are perpendicular to the tube, as well as remove burrs on the face of the tube. Variations of this process may include different types of brushes for specific applications, as caused by requirements such as deeper burr removal depths, tube material and deburring cycle time. Further automating existing cutting processes, SOCO offers the SA-78NCE high speed cutting line together with the SOCO BDB-70 double tube ends deburring machine. This powerful combination is capable of cutting and deburring various tube shapes and profiles such as round, rectangular, square and oval tubing

Cutting lines with chamfering system

Tube chamfering usually involves a set of tooling made to size, clamping the part while the chamfering head moves in and out of the tube ends.

It is able to form an exact chamfering angle,

allowing the tube to fit into other parts for future processing. It may also chamfer the external and internal parts of the tube, while creating a smoothened surface. It can also be executed with one or two sides of the tube at the same time. Since the stroke of the chamfering head may sometimes be controlled, so can the tube length after cutting and chamfering, as well as the chamfering depth. In SOCO, besides the standard functions of SA-76NC, the SA-76NC in-line may also be a part of complete Automation Cells for tubing. The working process includes loading, feeding, cutting, chamfering, deburring , air clearing and tube collecting. It brings time saving as well as higher throughput and performance.

Co-existing solutions

Until recent years, the deburring process through wire brushes has been the preferred method due to its encompassing range and in general, it also required less set-up time. However, as production requirements changed, and through new developments in the chamfering field, the deburring systems

have been gradually replaced by chamfering machines in high production environments for different reasons and needs.

Overall, both end finishing processes will continue to co-exist in the global market for different requirements and needs, but it is up to each company to decide and choose the most suitable and efficient method for their production environment.

For more information, contact: PIM – Tel: 011 022-4648

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SA-78NCE




SA-78NCE Cutting Highlight BDB-70 Highlight

The SA-78NCe high tensile steel tube cutting line together with the DeF-FA/76-V chamfering system can connect to the SOCO BDB-70 deburring system by an automation cell, covering loading, cutting, end-finishing, washing, length measuring and stacking.



The brushes are able to reach the entire surface, both internal and external through different movements that are perpendicular to the tube, as well as remove burrs on the face of the tube. Variations of this process may include different types of brushes for specific applications, as caused by requirements such as deeper burr removal depths, tube material and deburring cycle time. Further automating

existing cutting processes, SOCO offers the SA-78NCE high speed cutting line together with the SOCO BDB-70 double tube ends deburring machine. This powerful combination is capable of cutting and deburring various tube shapes and profiles such as round, rectangular, square and oval tubing



It is able to form an exact chamfering angle, allowing the tube to fit into other parts for future processing. It may also chamfer the external and internal parts of the tube, while creating a smoothened surface. It can also be executed with one or two sides of the tube at the same time. Since the stroke of the chamfering head may sometimes be controlled, so can the tube length after cutting and chamfering, as well as the chamfering depth. In SOCO, besides the standard functions of SA-76NC,

the SA-76NC in-line may also be a part of complete Automation Cells for tubing. The working process includes loading, feeding, cutting, chamfering, deburring , air clearing and tube collecting. It brings time saving as well as higher throughput and performance.


Until recent years, the deburring process through wire brushes has been the preferred method due to its encompassing range and in general, it also required less set-up time. However, as production requirements changed, and through new developments in the chamfering field, the deburring systems have been gradually replaced by chamfering machines in high production environments for different reasons and needs.


SA-78NCE

For more information, contact: PIM – Tel: (011) 022-4648

FM-76V Chamfering and Length Measuring

Sawing

138 Pretoria Road, Rynfield, BenoniP.O.Box 17624, Benoni West, 1503Tel: 011 022 4648 | Fax: 086 576 8797www.industrialmachinery.co.za

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NEWSInternational

PREDICTIVE MAINTENANCE SAVES LOTS OF MONEY – SOLUTIONS AT EMO HANNOVER 2017

Production scientists of the Fraunhofer Institute for Production Systems and Design Technology (IPK) are able to foresee the future of machine tools a lot more clearly and accurately with the aid of predictive maintenance: it helps its users to identify the optimum juncture for maintenance work, to avoid lost production, and to optimise the processes involved. In our interview, Eckhard Hohwieler, Head of Production Machines and Line Management and Claudio Geisert, both from the Fraunhofer Institute for Production Systems and Design Technology (IPK) in Berlin, report on the salient considerations and the role EMO Hannover 2017 plays in their work.

To quote Eckhard Hohwieler, Department Manager Production Machines and Line

Management, “perhaps at EMO Hannover 2017 someone will already be presenting the

Machine Tool 4.0, which tweets on Twitter and lets visitors communicate with it on

their smartphones.” Photo: IPK

Predictive maintenance helps companies to plan their maintenance work and foresee the putative development of the machine’s condition. It is able to reduce the number of

maintenance routines involved, and increase machine availability levels. Photo: IPK

Eckhard Hohwieler, how does predictive maintenance (PM) differ from condition monitoring?

EH: Condition monitoring detects and monitors the wear-and-tear status, whereas predictive maintenance forecasts the putative development of the machine’s future status, and plans the appropriate maintenance work required.

Claudio Geisert, how does PM specifically benefit the owner of machine tools?

CG: Care and maintenance are governed by the condition of the machine. This means the staff concerned carry out precisely the care and maintenance work that is actually required. Effective PM reduces the number of maintenance routines needed and increases machine availability levels. It also enables line use to be more efficiently planned, because care and maintenance work will now be carried out on pre-specified dates.

One of your specialisms is process monitoring and condition diagnostics: can you give us a highlight from your research work?

EH: For one machinery manufacturer, we have created a tool monitoring feature without any additional sensors or other electronics. A software package integrated into the control system monitors tool wear-and tear and fracturing. On this basis, we developed further algorithms enabling the machine’s condition and behaviour to be checked. This allows an employee to determine weak points with astonishing accuracy using the characteristic values of the drive shafts:


even textile flaws in belt drives have been discovered in this way.

Where are the data actually located – at the IPK or the company concerned? Who owns the data, and who is entitled to use them?

CG: The data created during the utilization phase belong (unless something to the contrary has been contractually agreed) to the operating company. As a rule, the companies concerned will not reveal these data to outsiders, since they fear that sensitive information will be among them, or can be derived from them. One solution commonly adopted is to install an appropriate server inside the company’s own network. This, however, will in its turn deprive the manufacturer of an option for gaining additional insights into the behaviour of his machines in the field. In order to master this problem, a relationship of mutual trust between the manufacturer and the operator is always imperative, though contractual safeguarding for utilization of the data is indubitably helpful.

How has this new form of monitoring evolved into PM at your institute?

EH: While working on a project on e-maintenance, we took a long, close look at how information from condition monitoring can be utilized for planning maintenance work. As an aid here, we used an electronic service checkbook that specifies the next worksteps required. It also explains how users are supposed to prepare and carry

To quote Claudio Geisert, the manager responsible at the IPK for condition

monitoring and maintenance, “thanks to complete-coverage data acquisition and storage, service personnel can see when and under what circumstances problems occurred for the first time, and thus find it

easier to identify how they can be remedied.” Photo: IPK

Cont. on page 26

out the maintenance routines; and where they can order the requisite tools.

Is there a practical example of a PM solution that you’ve developed together with a machine tool manufacturer?

CG: The automotive industry demands guarantees on availability from the machinery manufacturers, plus particulars of the anticipated lifecycle costs. This, however, necessitates complete-coverage monitoring of the machine involved. Our solution developed in conjunction with the grinding machine manufacturer Schaudt-Mikrosa – electronic monitoring of the drive elements using the machine’s own control system – acquires and evaluates all messages and signals from the machine, which the system then uses to determine the dynamic behaviour of the drive shafts and spindles over a lengthy time period. This solution is meanwhile being utilized in all machines.

How does the PM tool benefit the manufacturer?

EH: Schaudt-Mikrosa is already using it as an important tool for purposes of quality assurance – in machinery acceptance-testing, for example, or in the warranty phase to clarify the causes of damage, such as collisions between drive elements, tools and components.

CG: The service personnel use the tool for looking backwards into the past: thanks to complete-coverage data acquisition and storage, they see when and under what circumstances problems occurred for the first time, and can thus more easily identify how they can be remedied.

Monitoring and condition diagnostics involve huge quantities of data. When acquiring 20 values (64 bits) per milli second, the electronics will already be storing more than four gigabytes during an 8-hour shift, according to the Machine Tool Laboratory in Aachen. How do you proceed for evaluating this kind of big data?

EH: It’s not a problem for us, because we don’t acquire the raw data, but true to our motto of smart data, not big data, we determine and store only the typical characteristic values. My impression is, you know, that quite often, big data accumulate merely because it’s possible to store huge quantities and generate redundant data copies. It’s more sensible to make an intelligent pre-selection near the machine concerned before storage, so that a reduced data record is then transferred to the cloud.

How can users ensure that a reduced data record does not overlook effects that can then no longer be reconstructed? What options are already available for making a selection?

CG: Compression of raw data to selected characteristic values always entails concomitant losses. So the possibility cannot

be ruled out that some effects will be overlooked. However, this also applies to data acquisition: what physical variables are to be actually acquired using what sensors with what accuracy? Without a certain amount of domain-specific expert knowledge, a monitoring concept cannot be translated into viable reality.

In order to make the correct selection, users can utilise machine learning processes in the development phase. This helps the expert to choose meaningful characteristic values. It must always be remembered that for developing a sustainable monitoring concept you need both knowledge of the fundamental theory involved and experiential knowledge as well.

What are the long-term benefits of predictive maintenance for the manufacturer?

EH: You get a fleet effect: over the course of the production lines’ lifecycle at the customer’s facility, you see, huge amounts of information are created, which enables the manufacturer’s service capabilities to be improved.

Please tell us about your personal vision: what – in conjunction with Industry 4.0 – might an optimum PM solution look like?

EH: It would be conceivable that the machine itself utilises the information created in order to optimise its process or to call the maintenance service.

What are you expecting (not least in regard to your research work and predictive maintenance) from your visit to EMO Hannover 2017, the world’s premier trade fair for the metalworking sector?

EH: I’m keenly looking forward to seeing how the machinery manufacturers are responding to the issue, and what apps they will be presenting. Perhaps, too, someone will even be premiering the Machine Tool 4.0, one that tweets on Twitter and allows visitors to the EMO to contact it on their smartphones.

The interview was conducted by Nikolaus Fecht, specialist journalist from Gelsenkirchen


NEWSInternational

A look at actual practice: predictive maintenance in the machine tool industry

Machine tool customers’ interest in and requirements for predictive maintenance are increasing. Industry 4.0 is perceived here as an accelerating factor. “Predictive maintenance is also a part of Industry 4.0, even though our customers definitely view them in a highly differentiated context,” says Dr. Holger Rudzio, Managing Director of DMG Mori Software Solutions from Kempten. “Thus predictive maintenance can be implemented even without an Industry 4.0 approach.”

Predictive maintenance, and thus the requirements of DMG Mori’s customers, aim to detect possible defects of a machine or problems in a process before they actually occur. The company possesses the requisite predictive maintenance components, including the relevant programs for acquisition, evaluation and visualisation (see “Joint development of Machine Tool 4.0 with INA Schaeffler”) sensors in the machine record even the tiniest of changes, which are compared with the relevant limit values so as to predict future events from them.

Artificial intelligence in the data cloud

The acceptance and the success of predictive maintenance stand and fall with the quality of the information obtained and the benefits to the customer of the predictions concerned. This is why DMG Mori is prioritizing the development of high-performance evaluation logics, so as to join forces with its customers to effectively filter out the necessary information from the mass data and to use it to calculate dependable predictions for its machines and its customers’ processes. To quote Dr. Rudzio, “in future, cloud-based

Cont. from page 25

To quote Sandra Schuster, Industrial Data Services, Schwäbische Werkzeugmaschinen

GmbH from Waldmössingen, “the trend towards Industry 4.0 has created

significantly greater acceptance of the cloud concept.” Photo: Schwäbische Werkzeugmaschinen

To quote Dr. Holger Rudzio, Managing Director of DMG Mori Software Solutions

GmbH from xsKempten, “predictive maintenance can be implemented even

without an Industry 4.0 approach.”

solutions featuring artificial intelligence will gain steadily in perceived importance. We shall be presenting the relevant results to the trade public at EMO Hannover 2017 in Hall 2.”

For more than ten years now, Schwäbische Werkzeugmaschinen from Waldmössingen has been working on comprehensive data acquisition, under the term life data, designed to support predictive maintenance. There’s increasing interest in this, as Sandra Schuster, Industrial Data Services, has observed, “in the past one or two years, it’s been increasingly evident that due to the trend towards Industry 4.0, we are seeing significantly greater acceptance of the cloud concept, or at least the will and the desire to engage with it.”

Changing awareness among customers

The company used to have to take the initiative in approaching customers in order to talk to them about data acquisition, and in some cases this needed a lot of persuasion. But meanwhile, many customers are keen to use the products from Waldmössingen, and in most cases are grateful for advice as well. To quote Sandra Schuster, “the requirements involved, however – meaning cost reduction, transparency in the production and maintenance processes, plus better resource planning – have basically remained the same.” It’s only that awareness has altered in terms of how companies are approaching the issue, she adds.

Digital transparency is also a major priority with the manufacturers of systems for sheet-metal forming. For example, the Machine Monitoring System (MaMS) from Schuler in Göppingen provides entirely new insights into presses: thanks to comprehensive line monitoring, the user can upgrade availability levels, improve production and part quality, and downsize the energy consumption involved. The MaMS is part of Schuler’s Smart Press Shop, in which the company collects solutions for networking in the field of forming technology. It brings together data for intelligent diagnostics, condition, process and energy monitoring, and production data. This means a company can use the MaMS to collect and analyse characteristic values and data of all kinds. Line owners can thus obtain an overview of the production status and the requisite basis for calculating the overall equipment efficiency (OEE). The system also acquires and archives for every part produced all the data of importance for quality (e.g. typical process parameters like cycle time or mechanical strength of the formed materials). This enables the user to provide the requisite documentary evidence regarding safety-related components in the automotive or aircraft industries, for example

– experts speak of parts subject to mandatory documentation.


UPBEAT MINDSET IN THE INDIAN ECONOMY

India Day at EMO Hannover 2017 will be showcasing potentials for production technology and capital investment

are Modinomics fuelling an industrial renaissance in india? This question will be addressed during the India Day hosted by the VDW (german Machine Tool Builders’ association) at EMO Hannover 2017 on 20 September. investors and rating agencies on the indian stock exchange, at least, are anticipating good business opportunities in the medium term. Jeremy Leonard, Director of global industry Services at the British research institute Oxford Economics notes that “more scope for proactive economic stimuli when it comes to the refinancing costs of the commercial banks, plus the planned tax reform for goods and services, could unleash some accelerated dynamics.”

A view that’s confirmed by V. Anbu, Director General & CEO of the Indian Machine Tool Manufacturers’ Association. “Game-changing initiatives such as Make in India, opening up of strategic sectors to foreign direct investments and the implementation of One nation, one tax for goods and services have spurred manufacturing growth”, is his firm conviction.

India’s economy is growing

India’s economy is indeed expanding, as is its industrial production output. In the machine tool industry, the nation ranks 8th among the world’s largest markets, with a volume of most recently 1.7 bn euros in 2016. This corresponds to growth of eleven per cent in euros. For 2017/2018, too, a continuingly moderate increase in consumption is predicted. India imports around 70 percent of the machine tools it needs. In 2016, these were worth approximately 1.2 bn euros.

EMO’s India Day aims in particular to elucidate the perspectives for the mechanical engineering, automaking and aviation user sectors. Dr. Andreas Wolf from Bosch Ltd., for example,

sees potential in the automotive industry. “Triggered by the new legislation in regard to vehicle safety and emissions, we’re going to be seeing rapid implementation of modern-day technologies,” he says. Milind Madhav Shahane, Member of the Board of Directors at Tata Advanced Materials Ltd., sees major opportunities in the growing importance of privately owned companies: “since the turn of the century, India’s aviation industry has been experiencing dynamic growth at privately managed companies, supported by large conglomerates and their engineering expertise.” This is one of the main reasons why United Grinding has opened a subsidiary in Bangalore and set up a technology centre. “This enables us to perform meaningful tests on customers’ components and to offer realistic training for machine operators,” says C.R. Sudheendra, President India Operations of United Grinding.

India’s government keen to attract investors

EMO’s India Day will also be supported by the Indian government. We shall be honoured to host Shri N. Sivanand, Joint Secretary of the Department of Heavy Industry in the Ministry of Heavy Industry & Public Enterprises. He will be spotlighting the government’s initiative for boosting the manufacturing sector. We shall also be welcoming six delegations of high-ranking Indian entrepreneurs, which will be organized and accompanied by various Indian customer associations and the staff of the VDMA’s liaison office in Kolkata.

“We are particularly gratified to note that it will be almost exclusively Indian speakers or pundits who are thoroughly familiar with the country from their own career experience there who will be presenting their expertise on the India Day,” says Gerhard Hein, who is the co-organiser of the India Day at the VDW, who are hosting EMO. “So we’re expecting an exciting event, offering exceptional added value to everyone involved.”

High-ranking experts from India inform about the growing market at EMO Hannover 2017 on 20 September. India sends the second biggest visitor group from outside

Europe to EMO Hannover. Picture source: Deutsche Messe AG

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NEWSInternational

INDUSTRY 4.0 REQUIRES MORE OPENNESS

Dialogue on digital challenges at EMO Hannover

Despite fantastic digital opportunities, Prof. Dr.-ing. Frank Barthelmä, Executive Director and institute Manager of the german Society for Production Technology and Development (gFE – gesellschaft für Fertigungstechnik und Entwicklung Schmalkalden e.V.) is certain of one thing: without more openness in the machine tool industry and in the user sectors involved, the digital industry 4.0 concept is not going to pay off for small and mid-tier enterprises (SMEs) in particular. Reason enough for the tool expert to use EMO Hannover 2017 not only for acquiring information, but also for recruiting co-campaigners for digital networking.

Professor Barthelmä, how is the trend towards Industry 4.0 influencing metal-cutting applications?

FB: Industry 4.0 is influencing the process chain in two ways: firstly in terms of technology and engineering and secondly in terms of the data flowing along it. When both of these interact to optimum effect, we obtain a textbook example for Industry 4.0. This applies in regard to quality and disturbance variables, but also and increasingly to predictable parameters such as tool paths and tool lifetimes, achievable surface qualities and for maintenance intervals for machines and lines. Ideally, users receive all important information on the entire spectrum of process-related factors. What’s more, all data available can now be recorded and evaluated in real-time and control loops created, so as to upgrade the efficiency of the processes and the quality of the products involved thanks to more transparent metal-cutting.

Important role for sensors and actuators

How far are intelligent tools already the state of the art?

FB: If you remember: a bit more than ten years ago, there was an on-going debate on whether or when a tool can be classed as intelligent. Nowadays, within the context of Industry 4.0 we are talking about intelligent holistic solutions, in which, of course, tool sensors and actuators play an important role. So when you say state of the art, you’re absolutely correct. Not only in terms of using increasingly miniaturized and more energy-efficient sensors or actuators in the tool itself, but also with a view to their utilization in the overall system comprising the tool, the machine and its control system and

Frank Barthelmä, Executive Director and Institute Manager of the German Society for Production Technology and Development (GFE – Gesellschaft für Fertigungstechnik

und Entwicklung). Photo: GFE

the application concerned.

But how can the multiplicity of data now being acquired be evaluated to optimum effect?

FB: The answer to this is still in its infancy at many of our typical customers, the small and mid-tier companies. Many potential users of intelligent solutions of this kind, especially in these SMEs, are sometimes unable to assess what data they actually need in order to render their technology/IT fit for purpose and to generate from these new production lines when needed. This extends to new business models that may prove necessary. Universities and large corporations are already well advanced in this respect, whereas many of the small and mid-tier companies are still in the exploratory phase. For meaningful analysis, moreover, a comprehensive data history is required, in order to correlate it with new key statistics: but what do we actually know about the technical wisdoms of our predecessors? So what we need here is even more collaboration between the academic and business communities when it comes to generating new ideas, models and above all new solutions. What I would like to see here, for instance, is more joint projects involving partners from the academic community and the industrial sector representing a highly disparate range of scientific disciplines, which elucidate these questions not least with the aid of live demonstrators, for example.

Doesn’t that also mean that new network alliances have to be formed across the boundaries of sectoral and scientific specialisms – meaning collaboration between software analysts who understand nothing about metal-cutting, and metal-cutting experts who usually aren’t all that familiar with big-data analytics?

FB: Yes, but this is only going to work if the SMEs get involved at an early stage. The networks supported by the Federal Ministry of Economic Affairs, for instance, have proved well worthwhile in this context. For example, the GFE is currently a partner in the SME 4.0 Competence Centre of the Ilmenau University of Applied Science and in a model factory is addressing problems encountered with data generation and data transfer in connection with metal-cutting – for transfer especially in SMEs. The question involved here is this: how can I utilise a control loop in the machine so as to ensure that quality, efficiency and productivity can serve as controlling target variables?







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How does analyzing the metal-cutting parameters make metal-cutting easier – in terms of new materials, for instance?

FB: In the case of new materials, especially, it’s becoming progressively more important to close the loop in the control circuits with the aid of analytics. There is still quite a bit of work to be done on the path to purposeful evaluation. There is room for improvement, too, in the transparency of the results. Here I would propose a pre-competition platform, accessible to manufacturers and users alike. I would like to see a data pool, so that everyone doesn’t have to keep on re-inventing the wheel. As a role model, I would cite a front-ranking tool manufacturer who at the Schmalkalden Tool Conference in November of last year promised to be more proactive than previously in terms of data disclosure. It should be noted that it’s worthwhile for a manufacturer if users learn which of his tools are best suited for efficiently machining new materials. Here, too, the GFE is making its own contribution with the SME 4.0 Competence Centre.

Is there a current highlight from your work?

FB: Yes. The EU’s Dyna-Tool – Enhanced Efficiency in Metal-Cutting Applications project, supported by the German Engineering Federation’s Precision Tool Association and

the research institute Forschungskuratorium Maschinenbau e.V., is tasked with investigating how vibration-stable metal-cutting processes can be designed using sensor technology in the tools and the tool holders. For this purpose, the GFE has within the framework of the project developed a sensor-integrated tool for hard machining, which thanks to direct integration in the machine’s control enables the process to be controlled well-nigh in real-time. The Dyna-Tool consortium has succeeded in putting more transparency into the metal-cutting process, so that it can be kept within defined limits for low vibrations, but at the same time is able to exploit its performative potentials to the full. What’s more, we are currently examining the integration of high-resolution metrological devices in the tool, including an interface with the control system, so as to use this to create a real-time control loop. Anyone interested can learn more about this and other projects at EMO Hannover and its forum entitled Innovative Solutions for Industry 4.0 hosted by the German Engineering Federation’s Precision Tool Association.

And what does EMO Hannover 2017 mean for you in general; where is your informational focus?

FB: I’m primarily interested in examples of best practice, not least in order to see where we still need to take action. In addition, I want to talk to other advocates of these ideas on more transparency, so as to already encourage them to practise mutual feedback or to give a presentation at a separate forum. I shall thus be attempting at EMO Hannover, within the context of my networking activities, to gain additional co-campaigners for more openness and transparency in the sector.

The interview was conducted by Nikolaus Fecht, specialist journalist from Gelsenkirchen







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NEWSInternational

$40 BILLION OF NEW COMMERCIAL AIRCRAFT ORDERSProviding strong evidence that the commercial aircraft market remains healthy, airbus announced $39.7 billion worth of new business during the 2017 Paris air Show. The company won commitments for a total of 326 aircraft, including firm orders for 144 aircraft worth $18.5 billion and MoUs for 182 aircraft worth $21.2 billion.

A320 Family aircraft sales and commitments were robust, with business accounting for a total of 306 aircraft worth $33.8 billion. This total comprises 132 firm orders worth $14.7 billion and MoUs for 174 aircraft worth 19.1 billion. In the Widebody segment, Airbus won business for 20 aircraft worth $5.9 billion, comprising 12 firm orders worth $3.6 billion and MoUs for eight aircraft worth 2.3 billion.

John Leahy, Chief Operating Officer Customers, Airbus Commercial Aircraft said,

NEARLY 35,000 AIRCRAFT VALUED AT US$5.3 TRILLION REQUIRED IN THE NEXT 20 YEARSThe world’s passenger aircraft fleet above 100 seats is set to more than double in the next 20 years to over 40,000 planes as traffic is set to grow at 4.4 percent per year, according to airbus’ latest global Market Forecast 2017-2036.

Over this period, increasing numbers of first time flyers, rising disposable income spent on air travel, expanding tourism, industry liberalization, new routes and evolving airline business models are driving a need for 34,170 passenger and 730 freighter aircraft worth a combined total of US$5.3 trillion. Over 70 percent of new units are single aisle with 60 percent for growth and 40 percent for replacement of less fuel efficient aircraft.

A doubling in the commercial fleet over the next 20 years sees a need for 530,000 new pilots and 550,000 new maintenance engineers and provides Airbus’ global services business a catalyst to grow. Airbus has expanded its global network of training locations from five to 16 in the space of three years.

Air traffic growth is highest in emerging markets such as China, India, the rest of Asia and Latin America and almost double the 3.2 percent per year growth forecast in mature markets such as North America and Western Europe. Emerging markets currently

home to 6.4 billion of the world’s 7.4 billion population will account for nearly 50 percent of the world’s private consumption by 2036.

“Air travel is remarkably resilient to external shocks and doubles every 15 years,” said John Leahy, Chief Operating Officer – Customers, Airbus Commercial Aircraft.

“Asia Pacific continues to be an engine for growth, with domestic China to become the world’s largest market. Disposable incomes are growing and in emerging economies the number of people taking a flight will nearly triple between now and 2036.”

Over the next 20 years Asia Pacific is set to take 41 percent of new deliveries, followed by Europe with 20 percent and North America at 16 percent. Middle class numbers will almost double to nearly five billion as wealth

creation makes aviation even more accessible particularly in emerging economies where spending on air travel services is set to double.

In the twin aisle segment, such as the A330 Family, A350 XWB Family and the A380, Airbus forecasts a requirement for some 10,100 aircraft valued at US$2.9 trillion.

In the single aisle segment, such at the A320neo Family, Airbus forecasts a requirement for some 24,810 aircraft valued at US$2.4 trillion. Airlines adding capacity by upsizing to the largest single aisle, the A321, will find even more business opportunities with the A321neo thanks to its range up to 4,000nm and unbeatable fuel efficiency. In 2016, the A321 represented over 40 percent of single aisle deliveries and over 60 percent of single aisle orders.

“our commercial success this week at Paris extends our already diversified order backlog to a new industry record of over 6,800 aircraft, with 326 orders worth $40 billion.”

Further to the new orders, the show also saw a repeat order from DHL Express for four more A330-300 Passenger-To-Freighter conversions, in partnership with EFW and ST Aerospace.

At this year’s show, Airbus not only marked a solid sales tally but also extended its value offering at both ends of its commercial product portfolio. In the Single-Aisle family Airbus decided to offer the Airspace Cabin brand

– which, on the A320, includes the biggest overhead bin in its class. For the A380, Airbus has increased revenue-earning potential with even better fuel efficiency, thanks to enhanced large winglets, greater cabin capacity and a new higher take-off weight capability to increase its payload-range.

In addition, Airbus this week launched a new open aviation data platform called Skywise to support the digital transformation of the industry and add value for our customers’ operations. Skywise combines Airbus’ aerospace expertise with advanced data analytics solution provided by Palantir Technologies.

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NEWSInternational

CECIMO ANNOUNCES POSITIVE FORECASTS FOR 2017 The European machine tool builders cope well within the feeble international environment. According to preliminary forecasts, the machine tool production in Europe is projected to grow at an annual rate close to 4% and record more than 25 billion euro in 2017, after exceeding 24.3 billion euro last year.

although exports from the European machine tool industry were 3% lower in 2016, CECiMO members were outperforming internationally as the global MT trade decreased around 7%. The global machine tool consumption contracted 6-8% in 2016. CECiMO countries exported machine tools worth around 18.3 billion euro in 2016, accounting for the clear majority (96%) of the European exports in the sector and for almost one of every two machine tools sold in the foreign markets. it is difficult to make a forecast for 2017, as plans for international trade barriers seem to emerge. Though, if the business climate remains unchanged, CECiM0 exports are likely to grow to a level of 19 billion euro. amongst the reasons of this positive trend, Dr Frank Brinken, Chairman of the CECiMO Economic Committee and Vice-Chairman of Starrag Holding ag, points out that “digitization and future proven high quality standards increase the attractiveness of the European MT portfolio in foreign markets”.

On the domestic European side, modernization of production equipment and previously postponed investments for capital goods will likely contribute to a rise in machine tool sales. The European consumption is expected to pass 18 billion euro in 2017 and to retain a solid market share in global MT consumption above 26%. Such increment relates to an annual market expansion of nearly 3.5 percent.

Finally, the levels of investment, necessary to modernize manufacturing with digital ready equipment, are still insufficient. However, the growing acceptance and speed of the digitization of our industry support the economic recovery in Europe, while political stimuli and the positive sentiment among European businesses should drive investment in the MT sector upwards.

Frank Brinken, Chairman of the CECIMO Economic Committee and Vice-Chairman

of Starrag Holding AG.

Filip Geerts, CECIMO Director General.

framework on machine-generated data. Yet, we remind policy-makers that industrial data mirrors processes, products and systems, so it’s context-sensitive and often contains trade secrets. The goal is not to implement new premature rules, but rather, to increase our companies’ technical and organizational capacity. Together with policy-makers we should generate a common understanding fit for the digital era” says Mr Filip Geerts, CECIMO Director General.

So, MT industry does not favour strict regulations on access rights to data with a top-down approach, which might hamper legal certainty and trust in data economy. Access to data generated by machines is defined by bilateral contracts between businesses, which seems to work sufficiently well for now. “To build a thriving data economy in Europe, the complex manufacturing sector needs the European institutions to be cautious in designing policies on data rights. Any strict regulation might be perceived as an intervention in the market and block investment in data-driven solutions. Businesses should negotiate and decide freely the extent of the industrial data to be shared” adds Mr Luigi Galdabini, CECIMO President. Policy-makers should rather provide long-term certainty, raise awareness on new business models, and support high-speed internet across Europe, with a focus on SMEs.

Lastly, the machine tool sector is becoming increasingly global, trading within and beyond Europe. As data economy cannot be built at national level, the EU should increase its efforts on free flow of data across the EU and on data exchange with third countries.

Luigi Galdabini, CECIMO President.

European machine tool builders favour data-driven business models.

Data is one of the most important production factors and European machine tool builders favour data-driven solutions that improve machine performance, maintenance and environmental efficiency. Nevertheless, the industry is still at the early phases of understanding the full scope of data-driven solutions, and we need a future-proof public policy to underpin the growth of European machine tool builders.

“We are glad to see that European policy-makers put connectivity in industrial context at the forefront, and that they foresee a dialogue with trade associations for a EU


NEWSInternational

WORLD’S LARGEST FLOATING PHOTOVOLTAIC POWER PLANT TEST-BED

ABB drives the energy revolution with newly emerging use of solar power in Singapore

Land scarcity has severely limited Singapore’s adoption of solar power. Floating solar panels may be a viable alternative for the city-state surrounded by water. Floating panels could be eleven percent more efficient than solar panels placed on precious land. Pioneering technology leader aBB is providing critical components on a landmark one megawatt floating solar photovoltaic test-bed. it measures 1 hectare or 1.5 football fields. The energy generated will be fed into the national energy grid, providing electricity for up to 250 households.

“We are proud to support this important project in Singapore with our technological expertise and domain knowledge,” said Tarak Mehta, president of ABB’s Electrification Products division. “This project is perfectly aligned with our Next Level strategy around the energy revolution and is an important step in collaborating with partners to bring more renewables into the future energy mix.”

Located in the Tengeh Reservoir in west Singapore, the installation features multiple solar solutions from providers to study the performance and cost-effectiveness of floating solar platforms. ABB supplied 100 kW of market-leading TRIO-50 solar inverters to Phoenix Solar, one of several system

integrators for the project. These essential components convert the direct current produced in solar panels into alternating current for use in electrical grids. Additionally, ABB low-voltage molded case and miniature circuit breakers protect the electrical circuits on the water.

In Singapore – a country with an area of only 719 square km and a population of 5.6 million

– high average annual solar irradiation of about 1,500 kWh/m2 makes solar an attractive source of renewable energy. Floating solar platforms will be naturally cooled by the surrounding water, which increases the efficiency of the energy yields significantly. A study has found that the natural cooling effect of the water beneath the solar cells makes them up to 11 percent more efficient than solar panels placed on land. In a synergistic effect, the floating platform helps reduce evaporation of the valuable water.

JOINT DECLARATION ON THE NEXT RESEARCH

AND INNOVATION FRAMEWORK PROGRAMME

(FP9)23 associations, representing industry and research institutes at the European level, signed a Joint Declaration. it outlines improvements for the next EU Research & innovation Framework Programme (FP9) whose formal launch should take place in the first semester of 2018.

We call the European Institution to build on Horizon 2020’s achievements and make the FP9 an ambitious framework programme. We strongly believe that this means increasing significantly the overall EU budget for research and innovation in FP9 within the current discussion on the Multiannual Financial Framework, focusing on a well-balanced three-pillar structure, while allocating an equivalent share of the budget to each pillar, strengthening the EU industrial leadership to guarantee sustainable application and implementation of European research and continuing financial incentives in form of grants for all actors of the value chain, including small & large companies.

Massive European R&I investment, both private and public, notably in applied research is one of the key answers to keep up with global competition. Despite many efforts, the EU (2.0%) is still lagging behind countries like Japan (3.6%) or the US (2.7%) in terms of R&D expenditures as a percentage of GDP and China is catching up rapidly. With the highest share of R&D spending coming from the business sector, which accounts for 65% of all R&D spending in the EU, it is extremely important to significantly increase public spending both at EU and national levels and support the global competitiveness of European industries. In this context, European R&I Framework Programmes play a crucial role.

We are ready to strengthen our cooperation with the European Commission, the European Parliament and the Council of the European Union to define and implement an ambitious FP9 with a strong focus on EU industrial leadership aiming at positioning Europe as a global industrial leader and safeguarding our growth and jobs.

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NEWSInternational

THE FUTURE OF TRANSPORT IS MAGNETICIn advance of a recent CWIEME Berlin seminar, project leaders from two prestigious universities revealed their exciting experiences in developing magnetically-propelled transit pods for the SpaceX Hyperloop.

The idea of creating new high-speed mass transit systems is a hot topic for many scientists around the world. Spurred on by technology engineering entrepreneur, Elon Musk, the race is on to create pods that can transport passengers and cargo at high speeds. Musk – the founder and co-founder of several innovative companies including Tesla (premium electric cars), SolarCity (solar energy supply), and PayPal (online payment portal) – has inaugurated the Hyperloop project with one of his companies, SpaceX. although SpaceX was originally set up to explore aerospace manufacture and transport, with the ultimate goal of enabling colonization of other planets, Musk recognized that harnessing the expertise of aeronautical engineers could revolutionise ground transport and so set up Hyperloop.

The Hyperloop concept is being developed so that pods will travel at very high speeds along a tube, to provide an alternative to flying, rail transportation and driving, while also being safe, convenient and kinder to the environment in not using power that is dependent on fossil fuels. There are several Hyperloop sites being established around the world and in 2015

built. The levitation was definitely the most challenging part of the project, because there were so many options.”

As part of the competition, the rules stipulated that participants from different study areas such as engineering, technology, manufacturing and business management should work together. Musk realized that in order for innovative ideas to become a realistic proposition for high-speed, low-carbon and scalable mass transit, a practical all-round approach would be needed.

Edouard Schneiders, an applied physics student was on the team for TU Delft’s competition entry. “It was very exciting to take part in this competition – the atmosphere was ecstatic,” he says. “Hyperloop is extremely fast and extremely efficient. It will have enormous social and economic consequences whilst vastly reducing emissions.

“Transportation has not significantly pro-gressed since the release of the Boeing 747 and the invention of MagLev trains in 1970. The transportation industry needs to evolve and look for completely new solutions like Hyperloop in order to make a real impact.”

Experts from SpaceX and Tesla, along with university professors, judged the competititon entries. The TU Delft Hyperloop team won first prize overall, while MIT Hyperloop won an award for safety and reliability.

At the forefront of technology

Max and Edouard conducted a workshop at CWIEME Berlin to talk about their ground-breaking designs for the SpaceX Hyperloop competition and the future of transport. Both are excited to see what else is on offer at the show and hear from experts about how technology has a beneficial impact on different industries.

CWIEME Berlin is the world’s leading exhibition for coil winding, electric motor and transformer manufacturing. With seminar and workshop speakers from disciplines such as design engineering, manufacturing, R&D, procurement and management, visitors were informed about the latest trends in electronics, electric motor, transformer, generator, automotive and energy sectors.

MIT’s pod carries out its test run at the SpaceX Hyperloop tunnel in California.

TU Delft’s Hyperloop pod.

A member of the TU Delft team makes final adjustments of the pod before its test run.

Musk launched a competition to encourage the best international student groups to push the boundaries of science and create their ideas of how pods could operate.

Two such top universities – Massachusetts Institute of Technology (MIT, in the US) and Delft University of Technology (TU Delft, in the Netherlands) – took part in the first phase of a competition in January this year to unveil their prototype pods at a Hyperloop test track in California. Challenged with a tunnel of one mile in length and six-feet diameter, the teams had to demonstrate that their pods could safely accelerate to speeds of up to 250 mph and break to a standstill without crashing. Both teams used magnetic levitation as their method of propulsion.

The future of transport innovation

Max Opgenoord, a PhD student who is researching transonic aeroelasticity (the interaction between the aerodynamics and the structural dynamics of aircraft) was the project leader for the MIT Hyperloop team.

“It has been an exciting ride,” he says. “When we started with the competition, no one knew what a Hyperloop pod should look like, so we had incredible design freedom. And now, almost two years later, we have demonstrated that a Hyperloop pod can be

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NEWSLocal

SAEFA CONFIDENT THAT COMMITMENT TO INTERESTS OF ALL PARTIES CAN STILL AVOID ENGINEERING SECTOR STRIKESWhile trade unions have applied for a certificate to launch strike action within the South African engineering sector, this does not necessarily mean that strikes are now inevitable, nor that such action is the only option still available to workers in the sector.

That’s the view of gordon angus, Executive Director of the South african Engineers and Founders association (SaEFa). SaEFa have appointed an independent lead negotiator to represent employers in the current wage negotiations with engineering and steel sector workers and their unions.

“The reality is that strike action will be extremely detrimental to employees and the sector as a whole,” Angus emphasizes, “not to mention the additional pressure that it will bring to bear on the already tenuous economic situation in the country.”

Angus points to Jonathan Goldberg’s appointment as an independent negotiator by SAEFA, at their own expense, as a clear indication by the Association and the more than 400 businesses it represents of their sincere desire to reach a solution that will prevent strike action while also setting a solid and realistic foundation on which the sector can build going forward.

However, he points out that reaching such a solution requires the same level of commitment

by the labour representatives to acting in the best interests of all parties, particularly the financial wellbeing of the employees they represent. “Offers presented by employers have been summarily dismissed by unions, indicating the absence of a sincere desire to reach a sustainable solution that benefits all parties,” Angus explains, “but rather a predisposition by the union towards strike action.”

He points in particular to NUMSA’s outright rejection of a proposal of a reduced entry-level wage for new employees in the sector as indications of the union’s unwillingness to find solution that promotes the long-term sustainability of the sector.

“SAEFA and the other employer representative associations have repeatedly assured employees that the proposed lower hourly wage (initially proposed at R20 per hour, the same level as the national minimum wage) is only for new, unskilled employees in the sector,” he says “and that this will never be passed on to existing employed, trained and

experienced workers.” However, he says that unions appear unwilling to trust that this is the case, nor that the intention behind the lower entry-level wage structure is to make it financially viable for the industry to provide further work opportunities and training to even more South Africans, thereby helping to reduce the sharply rising and wholly unsustainable SA unemployment rates.

“I am confident that, if the parties are willing to come to the table with an open mind, and a willingness to consider all viewpoints and concerns, a solution can be found that avoids the potentially devastating consequences of industrial action, Angus concludes, “but agreeing on that solution will require a sincere commitment by the employers and the union to set aside any other agendas they may have and negotiate with the best interests – both current and future – of the entire industry in mind.”

Gordon Angus, Executive Director of the South African Engineers and Founders

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NEWSLocal

STEEL INDUSTRY NEGOTIATIONS – MISINFORMATION BY NUMSAThe Metal and Engineering Industry Bargaining Council (MEIBC) currently finds itself in watershed negotiations.

it is common cause that the industry is in distress. according to the MEiBC the industry lost 150 000 jobs over the 10 year period from 2006 to 2015. The iDC recently confirmed a further 25 000 job losses and 500 business closures during the last twelve month period. The issue of uncompetitive wages is one of the main causes stifling job creation in the industry.

The wages in the Steel Industry are currently, on average, double that of other Industries covered by bargaining council agreements. The wage gap is even bigger when it is compared to wages determined by wage determinations.

The wage proposal by NEASA and other employer groupings in this round of negotiations are to address this ever worsening trend in terms of job losses and also to create a position in which new jobs

could be created. One of the employer demands is to establish a new entry level wage for newly appointed employees in this Industry.

In press releases by the National Union of Metalworkers of South Africa (NUMSA), they constantly create the impression that this constituted a downward variation of wages.

This is simply not true. It is not the case now, and it has never been the position of employers. In terms of the employers’ position in this regard, the wages of existing employees will not be affected.

The same applies to the misinformation being circulated to the effect that, apart from employers proposing to reduce the wages of current employees, they also want to increase working hours. Again this is not true. The proposal by employers in this regard

The Indaba, to be held at the Industrial Development Corporation (IDC) Conference Centre in Sandton, from 14-15 September, is set to take place against the backdrop of negative sentiment about the South African economy because of, among others, falling Gross Domestic Product (GDP) and contraction in the secondary sector in the first quarter of this year.

According to the South African Reserve Bank’s Quarterly Bulletin June 2017, manufacturing production contracted for the third successive quarter in the first quarter of this year. This was mainly due to weak domestic demand and low business confidence.

Presented by the Steel and Engineering Indus-tries Federation of Southern Africa (SEIFSA) in partnership with the Industrial Development Corporation and the Department of Trade and Industry, the Indaba is an opportunity for business executives, policy makers and trade union representatives to collaborate towards addressing the challenges facing the sector.

Speaking ahead of the Indaba, Steel and Engineering Industries Federation of Southern Africa (SEIFSA) Chief Executive Officer, Kaizer Nyatsumba said, in addition to tackling the challenges in the sector, the conference would also consider the steps necessary to reverse the contraction in the metals and engineering sector.

According to Statistics South Africa, the metals and engineering sector has shrunk in each successive year since 2013.

“We need to urgently turn around that trend because the steel and engineering sector is an important contributor to the GDP and job creation,” Nyatsumba said.

He added, “this requires collaboration between government, labour and business. With unemployment currently at unacceptably high levels, South Africa needs a vibrant and competitive steel and engineering sector. The Indaba is an opportunity for the different stakeholders to exchange ideas.”

Gerhard Papenfus, Chief Executive (NEASA).

SEIFSA Chief Executive Officer, Kaizer Nyatsumba.

HIGH-PROFILE DIALOGUE FOR THE EMBATTLED STEEL AND ENGINEERING SECTOR

is simply to add an additional five hours to the normal working hours before overtime is introduced.

In spreading misinformation about the employers’ proposals, knowing perfectly well that it is not true, NUMSA is playing a very dangerous game – probably aimed at inciting employees to strike – for the wrong reasons. This is dangerous, mischievous and irresponsible.

Stakeholders at the negotiating table, both employers and trade unions, must remember that they are not only negotiating for their own interests. There is indeed much more at stake. Opening the opportunity of employment to the millions of unemployed people has now become one of South Africa’s most strategic objectives. In the Steel Industry, taking the lead in this regard and doing something constructive, is within our power.

By Gerhard Papenfus, Chief Executive of the National Employers’ Association of South Africa (NEASA).

The contraction in the metals and engineering sector will be the focus of the 3rd annual South african Metals and Engineering indaba in September.


NEWSLocal

SEIFSA WELCOMES AUTOMOTIVE SECTOR’S COMMITMENT TO INCREASE SOURCING OF LOCALLY-PRODUCED GOODSThe Steel and Engineering Industries Federation of Southern Africa (SEIFSA) welcomes the automotive industry’s commitment to increase its sourcing of locally-produced goods.

SEiFSa Senior Economist Tafadzwa Chibanguza said the announcement made by representatives of the national association of automobile Manufacturers of South africa in Sandton recently that Original Equipment Manufacturers (OEMs) would increase their sourcing of locally-produced goods as part of their 2035 Transformation Plan boded well for the metals and engineering sector, which was a supplier to auto manufacturers. The announcement was made after a meeting with the anC leadership, which was also part of that press conference.

Chibanguza said that the announcement speaks directly to the metals and engineering sector, which SEIFSA represents. He said the automotive sector makes up 31% of the total demand profile of the metals and engineering sector.

“It is, in fact, the largest domestic demand source for metals and engineering products, followed by construction and then mining. Prospects to increase local sourcing of inputs translates favourably to the metals and engineering sector since it indicates a potential growing share of activity for local companies.

“This is a classic case of a dynamic and pragmatic approach to a difficult economic environment,” Chibanguza said.

He said that current levels of economic activity are very weak and only economic growth would counter that situation, but that would not happen overnight. The announcement by the automotive sector was a welcome, dynamic response to that weak environment.

Chibanguza expressed the hope that the current impasse in the mining sector occasioned by the new Mining Charter would be resolved speedily in order to improve demand levels from that sector to the metals and engineering sector.

SEIFSA Senior Economist Tafadzwa Chibanguza.

RISING UNEMPLOYMENT SHOWS AN ECONOMY IN TROUBLEThe employment figures released by Statistics South africa (StatsSa) indicate a deeply troubled economy which, in the absence of a solution, will see ordinary South africans continuing to suffer badly, the Steel and Engineering industries Federation of Southern africa (SEiFSa) said.

SEIFSA Senior Economist Tafadzwa Chibanguza said that given the 2017 first-quarter Gross Domestic Product (GDP) figures recently published, which revealed that South Africa had fallen into a recession, it almost seemed a forgone conclusion that the employment figures for the same period would confirm a negative picture.

“In fact, the employment figures mirror those of the GDP, with the tertiary services contributing the most to the employment declines,” Chibanguza added.

The quarterly employment statistics released

by StatsSA showed that a total of 48 000 jobs were lost between the fourth quarter of 2016 and the first quarter of 2017, amounting to a 0.5% decrease. Between the first quarter of 2016 and the first quarter of this year, a total of 58 000 jobs – representing 0,6% of jobs – were shed.

The 48 000 jobs lost in Q1 2017 is a net number, which is the result of decreases in most sectors and increases in some. Chibanguza said if all the jobs lost in the tertiary sector were added up, then a total of 64 000 jobs were lost between the end of Q4 2016 and Q1 2017. If the 4000 jobs lost in the manufacturing sector were added, then a total of 68 000 jobs were lost in Q1 2017.

Chibanguza said that, with employment being an outcome variable which increases or decreases on the back of higher or lower levels of economic activity, South Africa “a thorough introspection of its challenges in order for meaningful solutions to be found”.

He said that it was encouraging to note that the mining sector had added 8000 jobs and the construction sector 12 000 jobs in Q1:2017. He said that the increase in mining jobs was to be expected given the relatively better mining production statistics released for the first quarter of 2017, which was assisted by stronger commodity prices.

However, Chibanguza cautioned that the new version of the Mining Charter released by the Minister of Mineral Resources last week had the potential to undo this upside.

He added that construction employment generally tended to be volatile, depending on the number of projects in progress and sounded a caution that the current weak levels of business confidence and the accompanying slow gross fixed capital formation were likely to imperil this trend.

“Rome is burning and the man on the street is the biggest victim”, Chibanguza warned.


NEWSLocal

OXYFUEL SOLUTIONS FOR THE ALUMINIUM INDUSTRYWith the growing need for reducing production costs, increasing productivity and yield, enhancing quality and environmental awareness in the aluminium industry, afrox – through its parent company, the Linde group – is evolving and refining its technologies to increase productivity in the aluminium process chain. From melting and dross handling to refining, extrusion and annealing, afrox has the technical competence and process knowledge to add value throughout the aluminium process chain.

As a member of the global Linde Group, Afrox has access to cutting-edge gas solutions, and is able to assist customers in the aluminium sector in the use of oxygen to enhance the combustion process, increase efficiency and reduce emissions. Afrox’s oxyfuel solutions for the aluminium industry have shown to increase melting rates by as much as 100%, reduce fuel consumption by up to 50% and cut flue gas and emissions by anything up to 90%.

Simphiwe Molefe, Applications Specialist for Bulk Markets at Afrox, explains the different combustion solutions available from southern Africa’s leading gases company and why they have proved popular in the aluminium sector industry.

“Melting is a core step in the processing of primary and secondary aluminium but also extremely energy intensive and can impact both the productivity and total cost of aluminium production.

“Air consists of approximately 20,95% oxygen by volume with approximately 78,09% being nitrogen. With this amount of nitrogen by

volume, during airfuel combustions nitrogen tends to absorb heat, in a way acting as an extinguisher. By increasing the amount of oxygen in the melting process, you reduce the amount of inert nitrogen in the combustion reaction. This has several advantages which include increased thermal efficiency, reduced fuel consumption, improved control over the process and less fuel emissions,” explains Molefe.

He adds that this is applicable to both primary and secondary aluminium processing as well as new or existing furnaces. While this is not new technology, it is often challenging for smelters to determine the exact suitable combustion solution to meet their individual needs. “Together with the Linde Group, we have extensive experience with oxyfuel for aluminium melting which enables us to provide our customers with suitable combustion solutions that meet individual demands.”

Afrox’s oxyfuel solutions include a wide range of oxyfuel burners and technologies designed by the Linde Group to suit different processes and requirements for aluminium melting.

WASTOX® oxygen lance installed.

Low temperature oxyfuel installed.

Low-temperature oxyfuel combustion technology

This technology is designed for the aluminium industry and is based on flameless oxyfuel combustion. The combustion in the process occurs under a diluted oxygen concentration. Basically the flame is diluted by mixing it with hot furnace gases and this slows down oxyfuel combustion reactions and results in lower flame temperatures, comparable to those of an airfuel system. The mixing of flue gases with the flame also disperses the energy throughout the entire furnace for a faster and more uniform heating. The dispersed flame contains the same amount of energy as a normal airfuel burner, but with more effective distribution. The dilution of the flame also slows down the oxyfuel combustion reactions and results in lower flame temperatures, lower emissions, higher melt rates and lower fuel consumption, while avoiding hot spots and dross formation.

AIROX® Combustion Technology

The AIROX® burner solution is an advanced tool for flexible and economic melting. The technology allows furnace operators to easily switch between oxygen or oxygen-enriched gases during the melting process, and air during the holding phase. This results in greater melting capacity and flexibility as well as lower emission rates and energy consumption. AIROX® combustion technology is well suited for furnaces that are used for melting and holding intervals, light metal foundries, extrusion companies and foil producers.

WASTOX® Combustion Technology

This solution is most suitable for the economic melting of low-grade scrap and turns unwanted contaminants into valuable fuel. The secondary aluminium industry is often challenged to find economic, environmentally sound ways of melting scrap contaminated with organic compounds, as emissions can limit productivity and restrict the choice of raw material. WASTOX® provides a powerful answer to these challenges by using oxygen lances to combust emissions within the furnace that are simple to install and operate.

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TDM POWERED SKILLS DEVELOPMENT PROGRAMME CELEBRATES MILESTONE History was made recently when the National Tooling Initiative Programme (NTIP), celebrated the milestone of handing over the first Occupational Certificates: Toolmaker (NQF level 5) South African Qualifications Authority qualifications at an event held at Necsa, Pretoria.

During the past decade, it became clear that the knowledge economy and 4th industrial Revolution require a different, more flexibly-skilled worker who can contribute to greater profitability and productivity. it was evident that the skills development programmes should align with the needs of industry to ensure successful employment of workers.

The TDM (Tool, Die and Mouldmaking) Powered Skills Development Programme was initiated as a solution to counter the skills erosion and job losses hampering the TDM sector by addressing the challenges identified. This Programme forms part of a multi-stakeholder initiative that was established in 2009 under the auspices of the Department of Trade and Industry (the dti) and the Toolmaking Association of South Africa

(TASA) to implement a turnaround strategy for South Africa’s distressed tooling industry.

To this end it was decided to introduce a comprehensive articulated skills delivery system in South Africa to provide the basic and advanced skills required by the TDM sector. The intervention is based on the following guiding principles: Dedicated career guidance, assessment and selection processes, specialized student support services, strengthening of students’ entry into the Programme, the new qualification structures, new qualification design principles, capacity building through partnerships, deployment of newly skilled resources and sustainability.

Dirk van Dyk, CEO of NTIP said that the training of sufficient skilled people for the

tooling industry is of critical importance as manufacturing is one of the cornerstones of a South African economy, facing serious growth challenges. “South Africa has to build its tooling manufacturing capacity to become globally more competitive if the country wants to create more jobs. The TDM Powered Programme plays a pivotal role in providing sufficient skilled people to the aerospace, automotive, chemical, electronics, leisure, marine, medical, mining and packaging industries,” Van Dyk added.

“The programme is a strategic growth stimulator for manufacturing and technical skills development and is a complement to the South African government’s commitment to eradicate poverty and unemployment,” explained Van Dyk. He added that the accomplishment of these candidates receiving their Occupational Certificates: Toolmaker, will contribute towards adding better workmanship, techniques and high standards of knowledge into the somewhat stale and old-fashioned manufacturing industry.

Van Dyk said that handing out these first Occupational Certificates: Toolmaker is a milestone for the TDM Powered Programme, as manufacturing industry has been waiting for qualified Toolmakers with international standards. This group of new-generation Artisans will bring advanced Toolmaking skills to the manufacturing industry. “Our candidates are innovative and can operate independently. During the TDM Programme, they were encouraged to be aware of and adapt to global manufacturing trends. This group of candidates is playing an important part in our company’s mission to alleviate skills shortage in South Africa,” Van Dyk concluded.

From left: Aletta Zikalala (Employment Coordinator NTIP), Allen Sithebe (Toolroom Foreman at WaterTech and one of the speakers at the event), Christie Lennon, Travers Gallent, Keiven Kwinda, Ruan Steenekamp, Marie Oosthuysen (TCOE Coordinator NTIP), Juanay Johnson,

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TOOLING ASSEMBLIES – ADAPTIVE TRENDS IN COMPLEX PROJECTSThe challenging installation schedules and time constraints demanded when delivering turnkey projects, the need to quickly bring installed systems to the required levels of production and the requirement to prove the quality of manufactured parts: all these factors place a range of pressures on the world’s machine tool builders (“MTBs”).

When working with MTBs involved in turnkey projects, each partner is deeply involved in the installation, adjustment and start-up work for technical and tooling equipment that is intended for the end-user.

Efficient functioning of complete and often complicated technical systems to meet customer requirements – integrating the supply, mounting, adjustment and initiation of all interrelated elements while concurrently ensuring that all the elements work as a single cohesive system – is a fundamental need not only for project management but for project completion and success.

Although metal cutting tools are always a vital part of each project, it often happens that minimal time is allowed for the balancing and tuning of the tools. As a result, additional human resources are required to complete these essential tasks, meaning that experienced tooling assembly specialists need to be on hand to perform complicated procedures in a short time space and in unfamiliar environments.

Sometimes essential supporting equipment is not supplied, and may even be missing when needed for adjustment procedures. In addition, the tools and their accessories are often packed in different containers, causing

unwelcome time losses when searching for necessary components.

A world leader in cutting tools and related accessories, ISCAR supplies complete assemblies of rotating tools for complex turnkey projects. ISCAR MTB specialists work in constant cooperation with MTB companies involved in the management of large turnkey projects, in order to study and interpret customer needs and provide appropriate and effective solutions. These comprehensive schemes save time and cut down on the workforce required for start-up procedures, especially for larger projects.

Each proposed turnkey package integrates distinctive features to maximize efficiency and simplify project implementation.

Tool management

Tools are fully assembled, adjusted and all individual tools are supplied with assembly and tooling layout drawings. If needed, each assembly can be equipped with electronic sensors for data management (Pic.1).

Electronic sensor for data management.

Tooling layout.

Assembly marking.

For projects using tools intended for high speed machining (HSM), ISCAR is able to perform tool or assembly balancing by employing appropriate technical equipment and software for theoretical analysis and correction. The instruction guide includes an assembly drawing containing data related to balance characteristics and relevant data from balancing test results.

Different forms of tooling layout representation can be prepared according to the complexity of the technological process or upon customer request (Pic. 2).

Assembly identification and designation

Each tooling assembly is clearly marked according to its designation in the appropriate technological process (Pic. 3) with a code, tool number and other attributes necessary for tool identification within an automatic management system. This information is supplied with a customer report containing data related to the tool’s dimensions for QA inspection.

Cont. on page 50

Pic. 1

Pic. 3

Pic. 2

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Secure, identifiable packaging

An often overlooked aspect of cutting tool supply with turnkey schemes is quality packaging. Ultra-secure packaging, as shown at Pic. 4, ensures the safe delivery of tools and assemblies to customer sites. It

also helps to guarantee that all dimensions that resulted from previous adjustment and balancing procedures are preserved.

Well packed, assembled tools can be supplied into secure wooden box for multi-usage purposes (Pic. 5). A common situation for large MTB projects is that a tooling assembly initially arrives at a machine producer’s facility for test, then, if applicable on to a local MTB dealer, finally to the end-user’s site. If at one of the stages there is no dedicated place for tool storage, secure and re-useable packaging can play the vital role of a temporary ‘warehouse’ during each phase of the project and when it travels between each location.

In addition, ISCAR has developed a unique identification system enabling a quick and easy search system. This allows a requested assembly to be efficiently located even amongst a huge quantity of supplied containers.

For more information, please contact Iscar South Africa – Tel: 011 997-2700.

Cont. from page 48

Tool packaging.

Wooden boxes for transporting and temporary storage.

Successful cooperation between ISCAR and leading machine tool builders of multiple, large and complex projects throughout the world, illustrates the efficiency of the company’s highly evolved methodologies for maximizing productivity and effectiveness in turnkey projects.

WHISPERLINE ANTI-VIBRATION BORING BARS WITH EXCHANGEABLE TURNING HEADS

ISCAR introduces a new line of WHISPERLINE vibration-dampening boring bars intended for large L/D boring ratios.

The maximum overhang for solid steel boring bars is up to 4 x BD. Machining with a longer length of steel shank (more than 4 x BD) can induce unwelcome vibrations due to the elasticity and characteristics of the steel.

Solid carbide boring bars can limit vibrations on a higher overhang of more than 4 x BD and up to 6 x BD and offer an excellent, highly efficient option for boring applications of up to six times the tool’s machining depth. However, even the use of a solid carbide shank can cause vibrations when machining with high overhangs of more than 6 x BD.

WHISPERLINE anti-vibration boring bars have been designed to significantly reduce and even totally eliminate vibrations when working with a high overhang from 7 x BD to 14 x BD, thanks to a unique damping mechanism inside the tool, consisting of a heavy mass supported by a rubber spring

element containing oil to increase the required dampening effect.

In addition, the system contains other elements which help to further reduce vibrations. The reactive damping mechanism comes into action during machining with high overhang work depths and acts as an effective counter to vibrations.

The highly effective, anti-vibration damper

effect is applicable for large D.O.C and high feed rates and ensures continuous, efficient machining. ISCAR’s inspired WHISPERLINE anti-vibration tools considerably improve machining stability and enhance insert life. These factors enable meaningful increases in productivity to be achieved, improvements in surface quality on high overhangs to be attained, scrap levels to be reduced and users’ profitability to be enhanced.

WHISPERLINE anti-vibration tools enable the delivery of internal coolant to be supplied directly to where it is required – the insert’s cutting edge. Efficient distribution of coolant increases the insert’s tool life by reducing temperature and also improves chip control and chip evacuation.

The WHISPERLINE boring bars represent a cost-effective, modular system with a wide range of standard shanks and eight different interchangeable boring heads.

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EVERY DRILL BIT COUNTS

Machining is a core element of the manufacturing process, whether it’s drilling, milling, turning or planing. Not only the workpiece sheds material, however: these processes also lead to gradual wear on the tool. The decision on when to have a tool replaced or reground depends on its service life. This is far from easy to determine, however, on account of the differing circumstances to which each individual tool is exposed. A tool’s properties are easy enough to calculate, but the impact of machine settings, which are usually left to the employee, has been unquantifiable to date. As a result, a tool’s service life can vary by around 25 percent. In a bid to avoid downtime and damage to workpieces, tools often end up being exchanged too early – and this can push costs up by as much as 50 percent.

RFID tags enable uninterrupted operations

The key to success – and more tool productivity – is to be able to determine each individual tool’s maximum possible service life. This means factoring in a range of parameters, including the nature of the cutting operation, employee settings and the workpiece material. The solution is to create an individual tool service record that details every event in the time a tool has been in service. This data is then fed into a special management tool to

create a digital twin of the tool, which lets users determine exactly when a tool must be serviced or replaced. But how to get the data from the tool to the management tool? Manual reading is not an option. Not only would it disrupt operations, but tools are often located in hard-to-access areas. On top of this, the surroundings tend to be highly metallic and therefore disruptive of conventional communication techniques, ruling these out.

In response, researchers at Fraunhofer IMS have developed a new RFID technology. The new transponders operate at a frequency of 5.8 GHz and can be read from up to a meter away even in the tricky metallic environment of a production plant. This allows for effective communication between tools and the management database. Since the RFID transponders take up an area of less than 5mm2, they can be easily installed on tools’ surfaces.

New applications for Industrie 4.0

For companies embracing the era of Industrie 4.0, the technology goes beyond making maximum use of their tools. “A big part of Industrie 4.0 is how it collects data to facilitate a production process as transparent as possible. That’s exactly what we’re doing with this new solution,” says Dr. Gerd vom

A drilling spindle used in industrial manufacturing: Using smart tools for Industrie 4.0, processes can be optimized autonomously. © Fraunhofer IMS

Bögel, head of the Wireless & Transponder Systems business unit at Fraunhofer IMS. “Of course, the first step is to identify the tool, but as the project continues the sensors could also be used to provide information about a tool’s environment as well as about the tool itself. That’s what makes it possible to monitor processes in real time, make them more transparent and, ultimately, more effective.”

What is more, the technology could also be employed in other areas of Industrie 4.0. One option would be to equip all physical assets, including tools, workpieces, machines or vehicles, with RFID tags – thereby providing even more information. This could then be used to identify further potential for optimization.

In addition to Fraunhofer IMS, the project consortium comprises the technology companies CIMSOURCE and PROMETEC Gesellschaft für Produktions-, Mess- und Automatisierungstechnik, ID4us, the Heinz Nixdorf Institute of the University of Paderborn and the application partner Sandvik Coromant. The Cute Machining project is supported by the German state government of North Rhine- Westphalia and the EU as part of the EFRE-NRW program.

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Currently, factories work on a principle of one size fits all when it comes to replacing or regrinding tools such as drill bits, milling machines or planes after a specified period of time – whether they need it or not. not only does this unnecessarily increase the time spent on maintenance, it is expensive, too. in the Cute Machining project, researchers from the Fraunhofer institute for Microelectronic Circuits and Systems iMS in Duisburg are working on the issue by creating individual tool service records and employing a new communication technology that uses RFiD tags. The aim is to optimize productivity, quality, throughput time and inventory in the manufacturing operations of the industrie 4.0 era.


NEW SAFETY TECHNOLOGY ENABLES TEAMWORK

Heavy-duty robots in manufacturing, which can easily lift components weighing 200 kilos, swivel around quickly or move with a speed of up to two meters per second, pose a danger to human lives. To rule out any potential risk to employees, these steel colleagues have so far operated in a separate environment. However, cooperation would be much more efficient if humans and robots worked side by side, without protective barriers. But how does one ensure safety? The Fraunhofer institute for Machine Tools and Forming Technology iWU has now come up with a solution to this problem.

The experts at Fraunhofer IWU have developed a differentiated safety concept that begins by defining different levels of collaboration. The more intensive the interaction between human and machine, the higher the level and more stringent the safety regulations. For example, if the robot needs to hand over a component to an employee, it moves as slowly and carefully as determined for this level. When working on separate tasks at a safe distance from each other, robots can work at full speed. Fraunhofer researchers have defined a total of four levels of collaboration.

These levels are supplemented by dividing collaborative work areas into spatial zones.

Each zone specifies how close humans and machines are to each other. At the lowest level, there are only two zones – a green and a red zone. If the employee is at a safe distance from the robot, it indicates a green zone and the robot can work at full speed. As soon as an employee approaches, a red zone is activated and the robot immediately

Until now, heavy-duty robots have always been housed in separate work areas to safeguard factory employee safety. Researchers at Fraunhofer want to change that with an ingenious security concept and intelligent robot control. This technology will enable people and robots to collaborate as a team.

Safety zones – the display shows the different zones. In the yellow zone, robots

and humans collaborate, with the robot moving significantly slower in this zone.

© Fraunhofer IWU

Good teamwork – the robot hands a component to its human colleague. © Fraunhofer IWU

stops working. In instances where teamwork is required – for instance to swap components or tools – then a yellow zone of cooperation is added. The heavy-duty robot now moves carefully and at low speed.

Cameras, sensors and intelligent algorithms

In order for the robot to respond properly, it must know the employee’s position and route at all times. It can do this with the help of several cameras that enable it to see. Two cameras are placed above the work area and provide a view of the entire work space. They also show the employee’s current location. An additional camera sits on the head of the robot and captures the close-up area. It helps the robot recognize the face, hand or component in the employee’s hand.

A row of sensors supplement the cameras. To prevent a collision, they register parameters such as the robot’s position, acceleration and power as well as the employee’s position and movement. The intelligent algorithms developed by Fraunhofer IWU help evaluate all this data. They ensure that the robot’s behavior is constantly aligned with all the safety regulations based on the task and situation at hand.

“Our system is already fully functional and has been tested in the lab. This year, the goal is get the trade association to test an application and enable its implementation in the industry,” says Prof. Matthias Putz, Director of Fraunhofer IWU.

Teamwork in virtual reality

This technology has already been tested in virtual reality. Using VR goggles, users can virtually experience teamwork with the machine. The system runs at full speed in virtual reality mode. “VR technology is thus an excellent way to realistically test the interaction with a robot,” says Prof. Putz. Fraunhofer experts want to refine the system in the near future. “Soon it should be able to adjust to the employee’s behavior by analyzing the person’s movements,” explains Putz. “In addition, we are working on gesture recognition, which will enable an employee to control the steel colleague with hand movements. For example, using a hand gesture to ask the robot for a tool.”


12 – 14 October 2017

METALEX VIETNAM 2017Asean’s largest International Machine Tools and Metalworking Technologies Trade Exhibition & Conference.Saigon Exhibition and Convention Centre (SECC), Vietnamwww.metalexvietnam.com

9 – 13 April 2018

MACH 2018MACH is the UK’s premier event for engineering-based manufacturing technologies. Taking place from 9-13 April 2018, MACH is poised to be the destination of choice for engineers and manufacturers, bringing together the best of UK manufacturing under one roof. With over 25 000 visitors across a 5 day period, a vibrant seminar programme and unrivalled networking opportunities MACH showcases the heart of UK advanced engineering.NEC Birmingham, United Kingdomwww.machexhibition.com

28 - 31 July 2017

IMTOS India Machine Tool ShowIs a biennial event showcasing path breaking ideas and innovations in machine tools.Pragati Maidan, New Delhi Indiawww.superexpo.com

26 – 28 July 2017

KZN INDUSTRIAL TECHNOLOGY EXHIBITION (KITE) An industrial trade show that showcases products, services and solutions appropriate to the KwaZulu Natal region. It provides an excellent platform for trade discussions between exhibitors and visitors and a forum for business networking.Durban Exhibition Centre, South Africawww.kznindustrial.co.za

10 – 12 October 2017

FINNTEC, TOOLTEC and JOINTEC Trade Fair for the Metal and Engineering Industries.Helsinki Exhibition and Convention Centre, Finlandwww.expobase.com

13 – 16 November 2017

CCIMT (China Chongqing International Machine Tool Show)CCIMT will showcase the latest in manufacturing technology and bring buyers and sellers together from all over the world to the dynamic market of Chongqing and southwest China.Chongqing International Expo Center, Chinawww.jmtba.or.jp

23 – 26 February 2018

NORTECWhere decision-makers in manufacturing technology and mechanical engineering meet.Hamburg Fair Grounds, Germanywww.nortec-hamburg.de

20 – 24 February 2018

METAV 2018The 20th International Exhibition for MetalworkIng Technologies.Düsseldorf Exhibition Centre, Germanywww.metav.com

14 – 17 March 2018

GRINDTECInternational Trade FaIr for Grinding Technology.Messe Augsburg, Germanywww.grindtec.de

18 – 23 September 2017

EMO HANNOVEREMO Hannover – the world’s premier trade fair for the metalworking sector.Hannover Fairground, Germanywww.emo-hanover.de

7 – 10 November 2017

BLECH & SCHWEISSTEC13th Blechexpo – International Trade Fair for sheet metal working. The practical trade fair duo of Blechexpo and Schweisstec takes place on a two-year cycle in the state trade fair centre in Stuttgart and is the only event in the world that deals with the complementary technologies of sheet metal processing and joining technology.Stuttgart New Exhibition Centre, Germanywww.blechexpo-messe.de

2017

2018

TRADE FAIRS & EVENTS


25 - 30 January 2018

IMTEX 2018 & TOOLTECH 2018Imtex is a specialised b2b fair featuring contemporary technological trends in metalworking machine tools and manufacturing solutions.Tooltech showcases machine tool accessories, metrology and CAD/CAM cutting tools, tooling systems and current trends in the tooling industry.Bangalore International Exhibition Centrewww.imtex.in

3 - 7 April 2018

SIMTOSCapture the future:4th Industrial RevolutionSimtos (Seoul International Machine Tool Show) is held bi-annually attracting decision makers of the automobile, shipbuilding, semiconductor, metal molding industry and other sectors in which machine tools are used. Represented products include all kinds of industrial machines as well as industrial robots, machine components, measuring intruments, machine controls etc.Kintex 1-2, Goyang, South Koreawww.simtos.org

9 - 13 October 2017

MSVInternational Engineering Fair.Brno Exhibition Centrewww.bvv.cz

21 - 22 August 2017

INFRASTRUCTURE AFRICA BUSINESS FORUMPresents stakeholders with an opportunity to unpack the enormous growth potential in addressing Africa’s infrastructure needs.Sandton, Convention Centre, Sandton South Africawww.infrastructure-africa.com


12 – 14 October 2017

METALEX VIETNAM 2017Asean’s largest International Machine Tools and Metalworking Technologies Trade Exhibition & Conference.Saigon Exhibition and Convention Centre (SECC), Vietnamwww.metalexvietnam.com

9 – 13 April 2018

MACH 2018MACH is the UK’s premier event for engineering-based manufacturing technologies. Taking place from 9-13 April 2018, MACH is poised to be the destination of choice for engineers and manufacturers, bringing together the best of UK manufacturing under one roof. With over 25 000 visitors across a 5 day period, a vibrant seminar programme and unrivalled networking opportunities MACH showcases the heart of UK advanced engineering.NEC Birmingham, United Kingdomwww.machexhibition.com

28 - 31 July 2017

IMTOS India Machine Tool ShowIs a biennial event showcasing path breaking ideas and innovations in machine tools.Pragati Maidan, New Delhi Indiawww.superexpo.com

26 – 28 July 2017

KZN INDUSTRIAL TECHNOLOGY EXHIBITION (KITE) An industrial trade show that showcases products, services and solutions appropriate to the KwaZulu Natal region. It provides an excellent platform for trade discussions between exhibitors and visitors and a forum for business networking.Durban Exhibition Centre, South Africawww.kznindustrial.co.za

10 – 12 October 2017

FINNTEC, TOOLTEC and JOINTEC Trade Fair for the Metal and Engineering Industries.Helsinki Exhibition and Convention Centre, Finlandwww.expobase.com

13 – 16 November 2017

CCIMT (China Chongqing International Machine Tool Show)CCIMT will showcase the latest in manufacturing technology and bring buyers and sellers together from all over the world to the dynamic market of Chongqing and southwest China.Chongqing International Expo Center, Chinawww.jmtba.or.jp

23 – 26 February 2018

NORTECWhere decision-makers in manufacturing technology and mechanical engineering meet.Hamburg Fair Grounds, Germanywww.nortec-hamburg.de

20 – 24 February 2018

METAV 2018The 20th International Exhibition for MetalworkIng Technologies.Düsseldorf Exhibition Centre, Germanywww.metav.com

14 – 17 March 2018

GRINDTECInternational Trade FaIr for Grinding Technology.Messe Augsburg, Germanywww.grindtec.de

18 – 23 September 2017

EMO HANNOVEREMO Hannover – the world’s premier trade fair for the metalworking sector.Hannover Fairground, Germanywww.emo-hanover.de

7 – 10 November 2017

BLECH & SCHWEISSTEC13th Blechexpo – International Trade Fair for sheet metal working. The practical trade fair duo of Blechexpo and Schweisstec takes place on a two-year cycle in the state trade fair centre in Stuttgart and is the only event in the world that deals with the complementary technologies of sheet metal processing and joining technology.Stuttgart New Exhibition Centre, Germanywww.blechexpo-messe.de

2017

2018



25 - 30 January 2018

IMTEX 2018 & TOOLTECH 2018Imtex is a specialised b2b fair featuring contemporary technological trends in metalworking machine tools and manufacturing solutions.Tooltech showcases machine tool accessories, metrology and CAD/CAM cutting tools, tooling systems and current trends in the tooling industry.Bangalore International Exhibition Centrewww.imtex.in

3 - 7 April 2018

SIMTOSCapture the future:4th Industrial RevolutionSimtos (Seoul International Machine Tool Show) is held bi-annually attracting decision makers of the automobile, shipbuilding, semiconductor, metal molding industry and other sectors in which machine tools are used. Represented products include all kinds of industrial machines as well as industrial robots, machine components, measuring intruments, machine controls etc.Kintex 1-2, Goyang, South Koreawww.simtos.org

9 - 13 October 2017

MSVInternational Engineering Fair.Brno Exhibition Centrewww.bvv.cz

21 - 22 August 2017

INFRASTRUCTURE AFRICA BUSINESS FORUMPresents stakeholders with an opportunity to unpack the enormous growth potential in addressing Africa’s infrastructure needs.Sandton, Convention Centre, Sandton South Africawww.infrastructure-africa.com

10 – 15 September 2018IMTS 2018International Manufacturing Technology Show. Industrial decision-makers attend the International Manufacturing Technology Show (IMTS) to get ideas and find answers to their manufacturing problems.McCormick Place Convention Center, Chicago, USAwww.imts.com

20 - 23 November 2018PRODEXInternational Exhibition for machine tools, tools and production measurement.Messe Basel, Switzerlandwww.prodex.ch

18 – 22 September 2018AMBAMB, the international exhibition for metalworking, is the leading industry trade fair and is one of the top five trade fairs worldwide for metal-cutting technology.New Stuttgart Trade Fair Centre, Germanywww.messe-stuttgart.de

15 – 18 May 2018INTERTOOLIntertool is Austria’s only trade fair for manufacturing technology in the metal processing sector. It focuses on machine tools and precision tools for separating and forming work piece processing, as well as fixtures and fittings, techniques, technologies and systems along the entire process chain.Messe Wien, Austria www.intertool.at

25 – 28 September 2018MICRONORABiennial microtechnology and precision trade fair for cutting edge technology.Besançon, Francewww.micronora.com

16 – 20 April 2018

wire DÜSSELDORFThe most important exhibition for wire manufacturers and processors.Düsseldorf Exhibition Centre, Germanywww.wire.de

16 – 20 April 2018

TUBE DÜSSELDORFInternational Tube and Pipe Fair.Düsseldorf Exhibition Centre, Germanywww.mdna.com

5 – 7 June 2018LASYSInternational Trade Fair for laser material processing.Messe Stuttgart, Germanywww.messe-stuttgart.de

Machine Tool Market – July/Auguste 2017 3


10 - 14 September 2018ELECTRA MININGAFRICA 2018Ranked as the second largest mining show in the world and with global recognition for its broad reach across mining, construction, industrial and power generation industry sectors, Electra Mining Africa once again proves its status as a worldclass event attracting high numbers of quality exhibitors and visitorsExpo Centre, Nasrecwww.electramining.co.za

23 - 26 May, 2018

METALTECHMalaysia’s main trade event for metalworking and machine tool industries.Putra World Trade Centre, Kuala Lumpur, Malaysiawww.metaltech.com.my

23 - 26 October, 2018

EURO BLECHThe 25th International Sheet Metal Working Technology Exhibition will open its doors again in Hanover, Germany. As the world’s leading exhibition for the sheet metal working industry Euro Blech offers a global platform for the presentation of the latest technology to a specialized audience of the industry’s key purchasers and decision makers.Exhibition Grounds, Hanover, Germanywww.euroblech.com

7 - 11 November 2018TMTS 2018Featuring metal cutting machines, metal forming machines, machine tool accessories, components, parts, fluid power, CNC control systems and auxiliary equipment, cutting tools, toolholding and workholding devices, measurement instruments and smart manufacturing systems.Greater Taichung International Expo Center (GTIEC)www.tmts.tw

9 - 11 October 2018ALUMINIUM 2018Aluminium is the world’s leading B2B tradeshow for the aluminium industry and its key application areas. The show unites manufacturers, technology suppliers and end users through the entire production chain from raw material to finished products.Messe Düsseldorf, Germanywww.aluminium-messe.com

9 - 13 October 2018

31. BI-MUInternational exhibition dedicated to the Italian machine tools, robot, automation systems and ancillary products industry.Exhibition Grounds, Fieramilano, Italywww.bimu.it

1 - 6 November 2018

JIMTOF 2018The 29th Japanese International Machine Tool Fair.Tokyo Big Sight (Tokyo International Exhibition Center)www.jimtof.org

28 May - 1 June, 201830 BIEMHThe participation of the world’s leading machine tool manufacturers makes this event practically unique in its field. The BIEMH is a market driver event that shows off the latest trends and needs of industires and brings visitors up to date in the field of manufacturing.Bilbao Exhibition Centrebiemh.bilbaoexhibitioncentre.com

16 - 19 May 2018MTA 2018The International Precision Engineering, Machine Tool and Metalworking Exhibition and Conference.Bangkok International Trade & Exhibition Center (BITEC)www.mta-asia.com

2018

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