Cataloguing energy efficient gears and motors Lifting speed, efficiency and productivity Time to move to high speed at Ludhiana at Mumbai Visit us at... ORBIT+ and ORBIT FIT series by
Trang 1Cataloguing energy efficient gears and motors
Lifting speed,
efficiency and
productivity
Time to move to high speed
at Ludhiana
at Mumbai
Visit us at
Trang 2www.MitsubishiElectric.in MITSUBISHI CNC
• Easier programming with interactive cycles
• High accuracy control for lathe with milling functions
• 3D solid program check function
• Synchronous tapping with Analog I/F spindle
E80 E70
E80 E70
[kilo-blocks/min]
Fine segment processing capability
PLC process capability communication CNC-to-drive
capability
E80 E70
2 times higher than E70 9 times higher than E70 3 times higher than E70 Fine segment PLC p CNC-to-drive
Trang 4C ON TENTS
FEATURES
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COVER CREDIT
Ashish Gadhave
to be done for power loss reduction in a gearbox and to optimise gearbox efficiency in industrial applications
Time to move to high speed
Industry leaders throw light on various benefits of HSM
in industrial applications
Refrigerants and other HVAC systems are causing damage to our ozone layer Therefore, we are on the lookout for lower energy bills, reduced carbon footprint, complete climate control and longer lifespan.
Efficiency mantra for HVAC
12
An industrial analysis on how the speed affects the productivity and efficiency of cranes, and the safety measures taken to avoid any untoward incidents in the industries
An interview with Abhishek Dhupar, Program Manager, Motors, International Copper Association India
Trang 5WB-P500L WB-P400 WB-M350L WB-M500 WB-M350
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Trang 6Quick update
India is emerging as one of the fastest growing economy in the new millennium The MSME segment
is expected to play a significant role
in this growth In an endeavour to empower its further growth, Bharat Fritz Werner Ltd (BFW), one of the leading machine tool manufacturers
in India in association with Universal Robots, pioneers and leaders of collaborative robots (cobots), are aiming to penetrate the sector with new and affordable automation solutions
This partnership will leverage the productivity in the MSME segment by integration of collaborative robots
in the manufacturing processes This aims to disrupt the traditional production setup of MSME segment with top-notch automation solutions and will dramatically impact productivity, quality and working conditions
BFW and Universal Robots aims to redefine the production processes by deploying the robotic arms through modular,
flexible and user-friendly integration solution platform – Arjun Advanced user-friendly and light industrial robotic arms will dramatically impact productivity, quality and working conditions in MSME segment as
it will automate and streamline repetitive industrial processes efficiently, thus empowering the shop floor for higher value creative activities
Ravi Raghavan, MD, BFW said, “Universal Robots and BFW strategic partnership will bring collaborative robot technology on a modular flexible platform to MSME shop floors to enhance their manufacturing competitiveness significantly.”
Pradeep David, General Manager, Universal Robots, South Asia said, “We’re pleased to be working closely with BFW as their CNC machines and automation services are well respected throughout the country, along with a solid sales and support network of over 40 offices It will surely help evangelise this
“Top 50 disruptive technology of 2018” called cobots, among the “Job Shops” in India similar to what Universal Robots has succeeded to do in the rest
Sandvik Coromant presented innovative digital machining solutions designed to reduce waste and increase efficiency for customers These innovations included CoroPlus, Process Control which helps avoid premature failure of tools, ensures consistent quality of components and also reduces damage due to collisions CoroPlus ToolGuide, provides fast and precise tool recommendations for the specific operation and
material type, as well as CoroPlus ToolLibrary, which enables users to integrate tool assemblies directly into their digital machining environment Along with software that helps improve design and production planning, the company showcased networked tool and process-control solutions.Machining insights More than a monitoring system, the solution gathers data, calls attention to issues and provides the insights required to take action It is an easily attainable step for manufacturers that are looking to reduce waste in production and make a smooth transition into a digital way
of working
Speaking about IMTEX and Sandvik Coromant’s participation, Michael Eneberg, Sandvik Coromant, President, Sales Area South & East Asia said, “It is indeed pleasure to be part of IMTEX The trade show always offers an excellent opportunity to meet customers and partners personally in order to optimise future co-operation We are very excited about partnering with IMTEX as it gives the industry a unique platform to collaborate and network by shaping the future together with our partners and customers At the trade fair, we are proud to present our high-end solutions all of which are designed to help our customers become more efficient, productive and profitable.”
Trang 8Quick update
Digitisation on B&R’s 5 th edition of Innovation Day
Digitisation has already conquered our daily lives and industry is not far behind, with evidence of on course Industrial IoT implementations happening across India Digitisation is not only about using digital technology to increase revenue but also creating new business opportunities In this journey, it is essential to choose right technology partner for monetising and leveraging these trends, which adds value to customers
In this context, B&R Industrial Automation took great pride in organising 5th edition of Innovation Day It is a flagship event, which acts as a platform for machine builders and end users to understand latest industry trends and technology advancements This year’s conference was themed around ‘Differentiation through digitisation - Adding value to your customers’
During this daylong conference, thought leader from different industries and technology experts from B&R deliberated on various next generation automation
concepts enabling Indian manufacturers to lay the foundation for digitalisation
In the keynote, Jhankar Dutta, Managing Director, B&R India said, “Digitalisation is fundamentally transforming the way machines are built It is a viable option for each and every machine builder to build more effective and reliable machine assisting them right from design phase to installation to effective after sales.” His talk also highlighted various B&R Innovations for
2019 such as integrated machine vision, human trak collaboration, hypervisor, digital twin and IIoT with ABB ability, which helps in creating successful digital enterprises
Everyone knows collaboration plays a vital role for those who are walking on the path of Industry 4.0
or Industrial IoT implementation Speaking on the importance of collaboration, Sunil Kango, General Manager Operations, ACG Engineering highlighted the successful association of B&R and ACG for over 15 years In his insightful and engaging talk,
he further explained the significance of choosing the perfect automation partner for achieving success and making machines smart and thanked B&R for being one
Godrej Process Equipment,
a unit of Godrej & Boyce Mfg Co Ltd., shipped one of the world’s tallest continuous catalytic regeneration (CCR) reactor to Dangote Oil Refinery, Nigeria With its height measuring a gigantic 95 meters, the CCR Reactor is 22 meters taller than the Qutub Minar and weighs approximately
703 metric tonnes, nine times heavier than a space shuttle
With the completion of this order, Godrej has further strengthened its position as a technology and innovation driven company that has been continually contributing towards making the nation
Speaking about the achievement, Jamshyd Godrej, Chairman and Managing Director, Godrej & Boyce stated,
“We have always been in the forefront of adopting technology to offer the best-in-class solutions to our customers The manufacturing of this complex reactor and the shipping of it in a single piece is a matter of
immense pride for us It is a testimony to our company’s vast technological expertise and also showcases Indian engineering capabilities The successful manufacture of this equipment only adds to the achievements of Godrej & Boyce and its global footprint.”
Adding to this, Allen Antao, Executive Vice President and Business Head, Godrej Process Equipment said, “Godrej Process Equipment is a leading global fabricator of high end critical static equipment for the process industry For several decades now, customers around the world have come to rely on Godrej for their operationally demanding equipment needs The CCR Reactor built for Dangote’s Refinery in Nigeria is the latest in the long list of capability challenging equipment built by Godrej.”
World’s tallest CCR Reactor, India’s contribution to Nigeria
Trang 9The Royal League
of fans
The Royal League in ventilation, control and drive technology
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Trang 10Firmware-by Mobiliya, a QuEST Global company, enables two way connectivity between multiple Electronic Control Units (ECUs) and cloud through the device gateway to allow fleet managers schedule maintenance, reduce downtimes, and in turn, increase efficiency.
The solution is highly flexible and can be quickly and effortlessly integrated with the existing ECU infrastructure of various OEMsand Tier-1s By analysing large volumes of data generated by the ECUs of vehicles, it can enhance operational efficiencies and user experience manifold
Other salient features of thissolution are:
• Fault-tolerant architecture
• Generation of smallest possible delta
• In-place update for faster performance
• Adaptability to various ECU characteristics
• Analytics and reporting for the real-time vehiclestatus
• Improved performance of softwareupgradesregardless of ECU specification
KrishKupathil, Head – Digital and Hi-Tech, QuEST Global, said, “With the recent developments in the connected vehicle ecosystem, automobiles have become increasingly complex These vehicles require regular updates with new features and versions throughout their lifespan This disruptive and innovative FOTA blueprint solution not only ensures faster time-to-market for OEMs through the quick and efficient deployment of value-added services, but also reduces software upgrade cost significantly.”
Mastercam India releases quarterly customer newsletter at IMTEX 2019
Mastercam India released their quarterly newsletter at IMTEX in Bengaluru Titled “Mastercam Notes – India Customer Newsletter”, the private circulation quarterly will be featuring a host of information and news related
to Mastercam, Mastercam’s customers, industry partners and resellers in the region The newsletter was launched amidst the presence of eminent industry leaders from the machine tools, cutting tools and industry association fraternity
Speaking on the occasion, Vineet Seth, MD – South Asia & Middle East (Mastercam APAC), said “This is a momentous occasion for us to be launching our India customer newsletter at the 50th Anniversary of IMTEX We are all about what our customers do and we’d be featuring our champions through this newsletter going forward.”Apart from the customer feature story, the Newsletter also includes content on tips and tricks, what’s new in the latest version of Mastercam and technical articles published by Mastercam in other media
“I’m very pleased about our decision with Mastercam India The teams they have assembled are experts in the field, and the passion that they have for manufacturing allows us to deliver the value our customers and partners expect I am excited to be a part of the team that is shaping the future
of manufacturing in India for our customers, resellers, and partners”, mentioned Gene Welti, Director for APAC at Mastercam/CNC Software Inc
“When we planned to make an investment into India, we were certain that this would take us to the next level in the region, and we were not wrong about it This newsletter is a step we’re taking in the positive direction and would like to tell stories of our Mastercam champions in India.” added Dave Moskey, Territory Manager for India at Mastercam/CNC Software Inc
Trang 11Steam Atomizing
CAREL: integrated control solutions for
Air-Conditioning, Refrigeration & Humidification
In every corner of the world, we are partners to the leading players in the HVACR & humidification businesses, with efficient and high performance solutions, with focus on energy saving.
t x N , g r a M i t k h B , a i c r e m m o s a i V , 3 4
&
2 4 s o N e
Mulund (West) 400 080, India, phone (+91) 22 4119 2929 - fax (+91) 22 4119 2930
Delhi : 312, Prakashdeep, Tolstoy Marg, Connaught Place, New Delhi 110001
Tel : 011 43629500
Chennai : Office no 728 , ‘AMARA SRI”, situated at Old No.313, New No.455, Block No.75, 7th Floor,Anna Salai,
Teynampet, Chennai 600018 Tel (+91) 44 4904 8300
CAREL: integrated control solutions for
Air-Conditioning, Refrigeration & Humidification
In every corner of the world, we are partners to the leading players in the HVACR & humidification businesses, with efficient and high performance solutions, with focus on energy saving.
t x e N , g r a M i t k a B , l a i c r e m m o C s a k i V , 3 4
&
2 4 s o N e
Mulund (West) 400 080, India, phone (+91) 22 4119 2929 - fax (+91) 22 4119 2930
Delhi : 312, Prakashdeep, Tolstoy Marg, Connaught Place, New Delhi 110001
Tel : 011 43629500
Chennai : Office no 728 , ‘AMARA SRI”, situated at Old No.313, New No.455, Block No.75, 7th Floor,Anna Salai,
Teynampet, Chennai 600018 Tel (+91) 44 4904 8300
Trang 12Cover Story
Efficiency mantra
for HVAC Refrigerants and other HVAC systems are causing damage to our ozone layer Therefore,
we are on the lookout for lower energy bills, reduced carbon footprint, complete climate control and longer lifespan.
New refrigerants, the use of intelligent electronics in system components, increasing energy efficiency requirements for air-conditioning and refrigeration systems, stricter regulations, new system concepts and client-specific solutions are the challenges faced by the HVAC industry It is crucial to have the right refrigerant for each application and environment
Harvinder Bhatia, Managing Director BITZER India says,
“As a driver of innovation in the air-conditioning and refrigeration industry, BITZER has been offering climate-friendly, energy-efficient solutions for a whole host of applications for centuries.” These are ideal for a populous country like India, where the transition to sustainable and intelligent technologies is a high priority due to the significant environmental impact It’s going to take brand-new system concepts and further development of existing ones to phase out high-GWP refrigerants, which have always been the ones most commonly used
ORBIT+ and ORBIT FIT series by BITZER India
Flexible solutions for the HVAC industry, ORBIT+ and ORBIT FIT series, takes compressor performance to a new level, enabling users to meet the strictest energy efficiency standards ORBIT+ with line start permanent magnet motor boosts scroll chiller and heat pump system efficiency The economiser operation of ORBIT FIT (flexible injection technology) enlarges the application envelope and increases capacity as well as efficiency
Bhatia says, “All ORBIT series can be used with BITZER Advanced Header Technology (BAHT) in more than
700 tandem and trio combinations, which can also be
uneven, meaning they combine different compressor types The technology guarantees proper compressor lubrication and reduces costs, increasing overall system economy.” All series are suitable for A1 refrigerants like R410A as well as for the low-GWP A2L refrigerants R454B, R452B and R32 Furthermore, ORBIT compressors are easy to install, compact in size and have very low noise emissions
Selecting suitable HVAC systems for a manufacturing plantAccording to Sunil Khatwani, Business Head & Vice President, System Air Conditioning Division, LG Electronics India Pvt Ltd, the selection criteria for air conditioning systems in manufacturing plants depends upon the following factors:
• Temperature and humidity desired
• Capacity, performance and spatial requirements
• Initial and running costs
• Availability of water for the HVAC system
• Required system reliability and flexibility
• Maintainability
• Architectural constraints
• Noise
• Air filtration requirements
• Guidance on meeting workplace legislation
• Air exhaust from the factory area
Trang 13Cover Story
13February 2019nOEM Update
impacts the productivity of employees Khatwani says,
“Refrigerants used should not harm the ozone layer, for
e.g Freon-22 (R 22) should not be used ”Highly energy
efficient systems are easily available now Some examples
are:
• Using inverter ducted units instead of conventional
fixed speed ducted units
• Using inverter scroll chillers instead of conventional
fixed speed scroll chillers
• Using oil free magnetic centrifugal chillers instead of
conventional screw or centrifugal chillers
• Using AHU’s connected to VRF outdoor units instead
of conventional fixed speed ducted or packaged units
According to Bhatia BITZER offers an extensive portfolio
of energy-efficient and environmental friendly
HVAC solutions Apart from products using low-GWP
refrigerants, another great possibility to reduce energy
costs are frequency inverter driven solutions Like this,
users can smoothly adjust a compressor’s capacity
to meet the actual requirements and save energy
If the motor is controlled by a frequency inverter,
the frequency of the starting current, and thus the
speed of the motor can be adapted to the required
refrigerating capacity If less energy is required at
certain points in the process, the frequency inverter
can adjust the electrical frequency and slow the motor
down This ensures that the engine consumes only the
energy the process needs right now Such an
energy-efficient solution is the intelligent, speed-controlled
CSV series
Bhatia says, “The CSW105 is a unique innovation in the
field of compact screw compressors This series can be
used with R134a, R513A, R450A, R1234yf and R1234ze(E)
for improved energy efficiency.” CSW105 boasts high
cooling capacities of up to 1,500 kW in water-cooled
chillers while relying on mechanical capacity regulation
The series offers displacements of up to 2,000 m³/h at
50 Hz Its integrated electronic IQ module operates the
compressor functions and simplifies the integration into
the chiller control
Tech advances to look out for in 2019
In 2018, LG embarked on the journey of GREENOVATION
i.e green, innovative products in the commercial air
conditioning space Khatwani says, “We now have the
widest range of green gas based innovative products with
high energy efficiencies for 2019
The latest product introductions are:
• High energy efficiency VRF systems: One of the most
energy efficient VRF systems in the industry
• Inverter ducted units (high static): The most energy
efficient ducted split system in India with low noise
levels and green gas
• Inverter ducted units (low static):Lowest height of
only 190 mm- up to 2.0 TR with low noise levels and
a green gas
• Inverter cassette units, inverter floor standing units
and inverter rooftop units with a green gas
• Magnetic bearing centrifugal chillers (oil free) - 260
TR to 2200 TR with a green gas: World class energy efficiency (COP up to 7.0) with lower footprint, lower noise levels and consistent performance over time
• Air bearing centrifugal chillers (oil free) - 100 TR to
300 TR with a green gas: A technological innovation
by LG - World class energy efficiency (COP up to 6.4) with lower footprint, lower noise levels and consistent performance over time
• Inverter scroll chillers (air cooled) - 20 TR to 180 TR with a green gas
The Indian market will be shaped by climate-friendly and energy-efficient solutions in the future: the costs for refrigerants with high global warming potential (GWP) are rising Bhatia says, “BITZER has centuries of experience using low-GWP refrigerants - an expertise which is also essential in India BITZER ORBIT scroll compressors and BITZER CSV screw compressors are particularly efficient solutions for air-conditioning applications.” The latter offer a unique benefit: they are extremely efficient and are optimised for use in air-conditioning systems, reversible chillers and heat pump applications as well as
in industrial process cooling According to Bhatia, due to
an integrated frequency inverter, they simplify to a high degree the installation and safe use of speed controlled compressors in relevant applications These particularly powerful compressors have a displacement of up to 1,156 m3/h (50 Hz) The series operates with a wide range of control, is ideal for systems with high part-load and meets the most stringent requirements in terms of seasonal efficiency
HVAC industry to be ‘Industry 4.0 ready’?
It is beyond doubt that digitalisation changes our industry, being first and foremost an issue of improving availability, expanding application limits and increasing system efficiency BITZER offers digitalised solutions such as the BITZER selection software, the customisable platform myBITZER or intelligent products, all of which enable users to select and operate HVAC components in the best possible way
Refrigerants used should not harm the ozone layer for e.g Freon-22 (R 22) should not be used.
Sunil Khatwani, Business Head & Vice President, System Air Conditioning Division,
LG Electronics India Pvt Ltd
ORBIT+ and ORBIT FIT series, takes compressor performance to a new level, enabling users to meet the strictest energy efficiency standards.
Harvinder Bhatia, Managing Director BITZER India
Trang 14As per conventional business practice, motor and gear efficiency form a part of deliverables and specified
in the SOP of delivery catalogues But, fact of the matter
is that total system efficiency (motor and gearbox) is not correctly arrived at as per specifications, as efficiency depends on gearbox loading – heavy v/s normal
Efficiency tolerances or the difference in efficiencies between a heavily-loaded gearbox and one running under normal loads determines the efficiency chart in a given situation As such, usual specs in print line may not match with realistic situation
Optimising gearbox efficiency in industrial applications
Nishit Behera, Executive Director – Business Development
& Strategy, RSB Transmissions (I) Ltd, states “Power loss in a gearbox is attributed mainly to friction, resulting in heat generation While heat generation
is not an issue with smaller gearboxes as it is minimal within the tolerance limit, in case of larger ones, it is more This is compensated by use of oil coolers and pumps
to keep the efficiency at a stipulated level Efficiency also depends on the quality of gearing, the number
of tooth engagements and the torque load to reduce frictional heat.”
Overall system efficiencies depend on the efficiency of the motor and gearbox together At low ratios, motors are more heavily loaded than the gearboxes At higher gearbox ratios, motor and gearbox efficiencies follow similar pattern as the gearbox sees more of the load than does the motor This leads to peak efficiencies in both gearbox and motor To use the least amount of power and obtain gearbox efficiency at its peak, it’s critical to match the motor, gearbox, and load closely to get the best system efficiencies
According to Abhishek Dhupar, Program Manager, Motors, International Copper Association India (ICA India), “Gearbox is actually more of a mechanical device There are two types of gearboxes: Worm and helical gearbox Helical gearbox is more efficient than a worm gearbox So, to improve the loss reduction, we should
go for helical gearbox Let’s say there’s a gearbox with
a standard efficiency motor You can replace it with
an IE3 efficiency motor so that your gearbox becomes more efficient By using a latest technology motor such
as Permanent Magnet Synchronous Motor (PMSM) or a copper rotor motor, you can reduce the size or length and weight of geared motor.”
Energy efficient motors remains low in India
Motors traditionally converts electrical energy into mechanical energy by the interaction between magnetic fields set up in the stator and rotor windings Industrial motors available in India are broadly classified as:
Ambient conditions prevailing
at different locations have a detrimental impact on motor performance.
Nishit Behera, Executive Director – Business Development & Strategy, RSB Transmissions (I) Ltd
Cataloguing energy efficient gears and motors
In this story, experts share their views on what needs
to be done for power loss reduction in a gearbox and to optimise gearbox efficiency in industrial applications.
Continued to 16 g
Trang 15The fresh air cooling load contributes around 30% of the total cooling load on centrally air-conditioned systems
Reduce the cooling load with HMX Indirect Evaporative Cooling – the best solution amongst all fresh-air handling
technologies like energy recovery wheels (ERW), treated fresh air (TFA) units, and heat pipes.
Trang 16induction motors and direct current motors All motor types have the same four operating components, stator (stationary windings) and rotor (rotating windings), bearings and frame
According to Behera, energy losses in Indian motors are characterised byfixed losses and variable losses, under the umbrella of intrinsic losses Fixed losses consist of magnetic core losses and friction or windage losses
Variable losses consist of resistance losses in the stator, rotor and miscellaneous stray losses such as resistance
to current flow in the stator and rotor result in heat generation that is proportional to the resistance
of the material These losses are more due to varied economic factors, but to keep the losses to minimal, the technological up-gradation will be warranted after field study
Performance of motors in India are, by and large, affected by the quality of input power from public utilities, that is the actual volts and frequency available
at motor terminals vis-à-vis rated values as well as voltage/ frequency variations and voltage imbalance
Motors in India need to comply with higher in-built tolerance limits to take care of larger fluctuations
of in-put power in of public utilities in India as such wide fluctuations have shown detrimental impacts on motor performance and consequently on the industrial output
Penetration of energy efficient motors are also low in India due to poor maintenance (inadequate lubrication of bearings, insufficient cleaning of air cooling passages, etc.) leading to deterioration in motor efficiency over time Behera explains, “Ambient conditions prevailing at different locations also have
a detrimental impact on motor performance For example, excessively high temperatures, high dust loading, corrosive atmosphere, and humidity can impair insulation properties; mechanical stresses due to load cycling leading to misalignment.”
Making any product in India takes 30-60 per cent more energy than in countries where manufacturing has achieved high levels of energy efficiency Now spot light is turning on to need for energy efficient motors In India, motors typically consume around
40 per cent of energy produced “Going in for technology up-gradation for energy-efficient motor will have low carbon foot prints With regulatory requirements coming into force to take care of climate mitigation, industry will have to take up the challenge of replacing old motors with higher efficiency motors through adoption of appropriate technology- a move that would bring energy savings and international acceptance of our operations,” adds Behera
Till last year, the penetration of energy efficient motors was low because there was no minimum efficiency standard in place If we look at the
US, Europe, Japan, Korea, they had already made IE3 mandatory India has last year made IE2 mandatory after a long time
ICA India had started a movement with BIS and DIPP
to implement minimum standard in motors Later,
in 2017, the Quality Control Order was rolled out by the Department of Industrial Policy and Promotion, Ministry of Commerce They have made IE2 the minimum energy performance standard in India So, anybody manufacturing motors in India will have IS mark (IS 12615) from BIS If anyone manufactures IE1 they could be penalised or imprisoned
Dhupar states, “Till last to last year, the penetration of energy efficient motors — IE2 and above — was only 11 per cent But, due to the quality control order coming into effect in the last financial year it was around 22 per cent This year, the penetration has been close to 50-55 per cent (IE2, IE3 and IE4 combined) So we can say that the market has now shifted towards IE2 and IE3.”
IE4 penetration in India is not even one per cent, says Dhupar As of now, the motor technology prevalent in the market is induction motor only And few electric vehicle manufacturers and IE4 motor manufacturers have started with PMSM Few are still making IE4 with induction motor, but still their sales volumes are very less
The penetration of energy efficient motors was low because there was
no minimum efficiency standard in place.
Abhishek Dhupar, Program Manager, Motors, ICA India
Cataloguing energy efficient gears and motors
14 f
Trang 18We know how many motors have been sold in India, but
it is difficult to estimate the losses in figures
However, when we move from IE1 to IE2 or IE2 to IE3 or IE3 to IE4, the average reduction in losses for smaller range
or up to 10 HP is close to twelve per cent In the medium range it is around five per cent and in the higher range or motors of over 100 HP is two per cent It is safe to say that there is an improvement of around 8-10 per cent between two consecutive classes — IE1 to IE2 or IE3 to IE4
Why copper and why IE3?
Copper is present in two areas of the motor One is the stator and another is rotor Stator has windings made of copper The purer the copper, the better is the efficiency, because of its conductivity There’s a huge cost difference between aluminium and copper — almost two to three times Normally, 99 per cent of the people use aluminium rotors So, when you use copper windings and copper rotors, your motor becomes much more efficient Currently, copper rotors are only used for special applications where efficiency and reliability is of utmost importance
Last year, Energy Efficiency Services Limited (EESL) had rolled out National Motor Replacement Program in association with ICA India, where IE0-IE1 motors will be replaced with the IE3 motors for better output and cost efficiency to benefit manufacturers for productive returns.What EESL did was that they did a bulk tendering of one lakh motors so they got a very good price, which was lower than the market of around 30 per cent and they also gave extended warranty of three years So, this was also one of the steps taken by ICA India and EESL so that people can move directly to IE3 and the cost will also not be a burden India in a matter of five years can look at saving `5,000 crores per year just by making it compulsory for all industries: small, medium and large to choose the IE3 motors
The claim is “It is often better to buy a more expensive, more efficient motor if it will consume less electricity than a cheaper one.” Do you think it is really practical when it comes to the Indian market where low price prevails over better quality?
The question is very valid Generally, people in India
Motors and motor-driven systems are huge consumers
of electricity They are estimated to account for 65 per cent of the total energy consumed in industries Today, energy efficiency is of dominant importance due to the ever increasing electrical energy demand, increasing awareness around global warming, and the increase in prices of fossil fuels Electrical motors are driving the most important type of mechanical load in every industry In
an interview with Aultrin Vijay of OEM Update, Abhishek Dhupar, Program Manager, Motors at International Copper Association India (ICA India), shares his views on adoption Higher Efficiency Motors (HEMs) in India
What is the current state of motor technology in India?
There are different types of motors available in the market today However, low tension (LT) induction motors (low tension or low voltage three-phase induction motors), are the most widely used motors in the industries LT motors work on 415 volts whereas high tension (HT) motors work from 1.1 KV or 1,100 volts onwards The reason why ICA India is focusing on LT motors is because the energy efficiency standards focus on LT motors, which is 75 per cent of AC motors used in industries and the other 25 per cent would be HT motors
LT motors are classified into different efficiency classes as per international efficiency norms, IE1, IE2, IE3 and IE4
IE1 is the standard efficiency motor, IE2 is high efficiency, IE3 is premium efficiency and IE4 is super premium efficiency So, moving from IE0 or IE1 to IE3, IE4 or IE5 results in reduction of losses, close to 10-15 per cent, and the efficiency improves accordingly
There are two to three technologies available for the IE4 motors So, IE4 motors have the option of using technologies such as permanent magnet synchronous motor (PMSM) and synchronous reluctance motor, other than squirrel-cage induction rotor, used till IE3
While squirrel-cage induction motor is available with different rotors (rotating part in a motor), which is made
up of aluminium or copper So, people can achieve the
Abhishek Dhupar, Program Manager, Motors, International Copper Association India (ICA India)
India, in five years, can look at saving `5,000 crores per year just by choosing the IE3 motors
Leaving IE1 behind and inching towards IE3
Continued to 20 g
Trang 20Speak Out
are price conscious and they prefer low-priced model and equipment The life cycle cost of the motor rather than just the purchase and installation cost, is another critical, but often over looked, factor to consider Life cycle costing can favour the selection of energy efficient motors that usually have higher capital cost and lower operating, and sometimes maintenance costs The motor purchase cost is only 2 per cent while energy cost over its entire lifetime is close to 95 per cent The initial purchase cost increases when a person moves from IE1 to IE2 or above But at the same time when you see the jump in efficiency and good payback period, then opting for IE3 would be a better option
Apart from the energy efficiency aspect, how do you reckon the economic role of copper in motors?
Cost will obviously be more because copper is a precious metal
Whenever you move towards Higher Efficiency motors, the carbon footprints are also reduced The rewinding of the motor should also be done from a reliable service centre to maintain its efficiency orelse the motor may perform inefficiently, and its life is also reduced
What about people using and manufacturing IE1 motors?
Moving from a standard efficiency motor to IE2 or IE3 the overall efficiency gets improved So there is a price which you need to pay And that price is marginal – approximately 10 per cent Maybe initially you may face issues with the budget, but you will reap more benefits in the long run when compared to the 10 per cent incremental costs Also, it should be noted that globally many of the countries have made IE3 mandatory It is
a very good step that IE2 has been made mandatory in India
So, speaking of small motor manufacturers, who also manufactures energy efficient motors, they have faced challenge in manufacturing IE2 and IE3 motors Not everybody was ready! and everybody had to take licence, too, which also took some time because of limited manpower in testing labs in India
ICA India has initiated a project for design of IE3 motors for small motor manufacturers in collaboration with testing labs and motor manufacturers association to build prototypes Once the prototype is ready, tested and validated, then the designs would be an open source and ICA India will share these designs to SME motor manufacturers, so that they can start manufacturing IE3 motors
When will IE4 become a standard in India?
IE4 is already in the market But the penetration is very low IE4 is not a tried and tested technology Bureau of Indian Standards (BIS) last year, published a standard which includes IE4 efficiency IE4 motors costs almost 50 per cent more than an IE1 motor Also, as you go up from IE1 to IE2, IE3 or IE4, the motor’s rpm increases As the rpm increases
to match the speed requirement of the driven equipment, use of VFDs etc will be required Further with significant increase in starting current the existing switchgear and other changes in the system will be required This means the whole system should be changed or replaced, which would
be very difficult and costly So, moving to IE4 motors will take time keeping in mind these factors It may take at least 2-3 years for it to get established
Exicom wins Manufacturing Excellence (EV Infrastructure)
Exicom wins “Manufacturing Excellence (EV Infrastructure)” at ‘3RD ASSOCHAM Auto Forum
& Awards’ with the theme “Moving towards a Greener Transportation” held on Monday, 28th January, 2019 at New Delhi These ASSOCHAM awards are supported by Department of Industrial Policy and Promotion (DIPP), Ministry of Heavy Industries & Public Enterprises, Ministry
of Road Transport & Highways, Ministry of Environment, Forest and Climate Change, Government of India and the NITI Aayog
Dr Arbinda Mitra, Scientific Secretary, Office of the Principal Scientific Advisor to Government of India in inaugural address at ASSOCHAM Auto Forum said, “We are now very soon going to launch the second phase
of (Faster Adoption and Manufacturing of (Hybrid &) Electric Vehicles), this is a consortia approach that
we are putting along with the Department of Heavy Industries and Department of Science and Technology,”
He also informed that in the FAME II mission, the government as of now is going to allocate Rs 350
crores to have a concerted investment in research and innovation addressing three components that are very important for India i.e 1 Development of battery and its component 2 Development of motors using rare-earth magnate materials and 3 Development
of electronic control systems, technologies and know-how which together could be put as power electronics
Anant Nahata, Managing Director, Exicom said, “I would like to thank ASSOCHAM for honoring our efforts in developing EV infrastructure for all types of charging needs We continuously work towards introducing new technologies in the area of energy storage applications to address the ever growing energy demands.” He further emphasized the need for R&D and indigenization to support ‘Make in India’ initiative of government
The event opened new doors to accelerate EV transformation through promoting futuristic technologies which the country needs to gear up in the future
Leaving IE1 behind and inching towards IE3
18 f
Trang 21Industry update
21February 2019nOEM Update
Japanese welding technology for upgrading
Indian industries
AOTS, Japan (Association for Overseas Technical
Cooperation and Sustainable Partnerships) and
Confederation of Indian Industry, India (CII) organised a
technical seminar and workshop on High Precision Arc
Welding Technology at Jamshedpur on 13-14 December
The seminar was organised at Hotel Alcor, Jamshedpur and
the practical demonstration of Japanese latest welding
technology was conducted at Indo Danish Tool Room
(IDTR), MSME Tool Room, Jamshedpur on both the days This
training program at Jamshedpur was funded by Ministry of
Economy Trade and Industry, Japan (METI) This was 3rd and
last METI supported training program scheduled in 2018
First program in this series was held at Chennai (22-23 Aug
2018) and 2nd at Ahmedabad (23-24 Oct 2018) Panasonic
Welding Systems was the industry partner; providing lecture
and practical demonstration on latest welding equipment
and robot technology to improve productivity of Indian
metal fabrication industry Other industry partners were
Kobelco Welding, Japan (welding consumables) and Iwatani
Corporation, Japan (shielding gas)
Masayuki Taga, Consulate General of Japan in Kolkata
said he was happy to welcome the Japanese delegates
to the Eastern part of India He added that more than
1400 Japanese companies are operating in India out of which 700 plus companies are from manufacturing sector
The Government of Japan is committed to support the “Make
in India” initiative and “Made in India” mission by continuing these kind of workshops “Japan has already started taking significant measures to improve the human resource in India and we shall continue to support such kind of initiatives in India,” he added
Tapas Kumar Sahu informed that Japanese technology is
an ideal example of best manufacturing practice giving world “zero defect” principle He also said that “welding”
is one of the most important process in metal working technology He also said that India is, currently, going through infrastructure mode and there is going to be drastic increase in steel consumption from current 100 Million tonne per annum to 300 Million tonne by 2030 as per National Steel Policy (NSP) 2017
HIDA Jam 5 Dignitaries
on the dias
Trang 22Industry report
High-speed machining (HSM) is one of the modern technologies, which in comparison with conventional cutting enables to increase efficiency, accuracy and quality
of the product and at the same time to decrease costs and machining time
HSM: An effective way of metal cutting
High-speed machining (HSM) is one of the most popular topics in CNC machining methodology Simply defined, HSM is a methodology to improve machining throughput
by using higher-than-normal spindle speeds coupled with extraordinarily high feed rates without compromising the quality of the finished part
However, in practice, HSM is not a straightforward methodology to implement In addition to the higher spindle speeds, numerous other factors such as feed, chip loading, width and depth of cut, cutter path, tooling, machine construction, CNC-machine controls and CAM software all impact the HSM process
Most conventional CNC machines are equipped with a spindle with lower rpm limits (under 12,000 rpm), so the term “high performance machining” is adopted (HPM)
Applying HPM methodology requires the manufacturing engineer to possess in-depth knowledge of the limits of the CNC machine and how to work around them An initial investment into discovering the limits of any CNC machine
is critical to applying HSM techniques to non-specialised CNC machines to obtain high performance machining
Gautam K Ahuja, Managing Director, Dormer Tools India Pvt Ltd says, “High-end machines can run at higher parameters with more consistency Our tools are already equipped to run with more consistency, better accuracy, and give maximum tool life possible.”
Role of CNC in the application of HSM methodologies
The use of HSM allows us to shorten the production time and to increase the accuracy of machined parts HSM is
being mainly used in three industry sectors due to their specific requirements
HSM is used in industries, which deal with machining aluminium to produce automotive components, small computer parts or medical devices, because it needs fast metal removal, as the technological process involves many machining operations
Another sector is the aircraft industry, which involves machining of long aluminium parts, often with thin walls The third industry sector is the die and mould industry, which requires dealing with finishing of hard materials In this sector it is important to machine with high speed and
to keep high accuracy
According to Dr Masahiko Mori, President CEO, DMG Mori
Co Ltd, “We can achieve speed machining using end CNC machines Today, machines with over 50,000 rpm are considered as high-speed.”
high-He underscores that in this advanced age, high-speed is must But, many industries are sticking to very low speed
Time to move to high speed
Industry leaders throw light on various benefits of HSM in industrial applications
High-end machines can run at higher parameters with more consistency
Gautam K Ahuja, Managing Director, Dormer Tools India Pvt Ltd
Trang 23Industry report
23February 2019nOEM Update
machining, which results in low productivity Mori warns that
those using machines below 20,000 rpm would eventually run out
of business in the coming years and suggests they must change
Even though high speed spindle options for conventional
machining centres have been available for some time, it is only
recently that machine tool designers and engineers have been
developing the machines for HSM
“Some people think machine shops are an old fashioned business
But, it’s not This is one of the most advanced businesses existing
in the world,” Mori concludes
We can achieve high-speed machining using high-end CNC machines
Dr Masahiko Mori, President CEO, DMG Mori Co Ltd.
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Yamaha Motor (IYM) Pvt Ltd has introduced dual channel
ABS enabled YZF-R15 Version 3.0 in India Yamaha YZF-R15
Version 3.0 was launched at the Auto Expo 2018 and has
gained enormous admiration from Yamaha loyalists as its first
year sales doubled up the targeted production
With the launch of the new dual channel anti-lock braking
system (ABS) enabled YZF-R15 Version 3.0, Yamaha has
pioneered the industry by introducing the first 150 CC class
model that has dual channel ABS The motorcycle will hit
the Indian roads with an all new Darknight colour along
with Thunder Grey and Racing Blue while retaining all of its
original features like VVA technology and A&S Clutch along
with a dual channel ABS The dual channel ‘Anti-lock Braking
System’ (ABS) technology comes with adjustable fluid pressure
which will further be reliable to ensure immediate braking on
slippery roads It is armed with a powerful 155 cc engine with
high compression ratio resulting in maximum 19.3 PS power
at 10,000 RPM delivering a torque of 14.7 N.M at 8500 RPM
With its weight (wet) of 142 kg and a massive 170 mm ground
clearance, the new YZF-R15 (Version 3.0) with dual channel
ABS gets a stylish look from its fully digital instrument console,
LED head and tail light and an added ABS logo
Dual channel ABS for
YZF-R15 V3.0
Trang 24To re-lube or not!
Lubricating oils are made with base oils, which forms the majority composition There are performance enhancing additives that are also used to go with the base oil in a physical and chemical equilibrium So, all lubricating oils are engineered to target a certain specific engineering application That’s why you need not only the primary properties of the oil through the base oil, but also performance enhancing additives, which are basically chemicals, mixed for making sure the lubricant delivers on specific requirement of the application So, once the oil is put into the equipment and it starts getting used, the oil goes through a chemical change and sometimes physical change as well These changes are sometimes irreversible as it’s a chemical reaction that happens due to load, temperature and speed — factors which are operating on the lubricant as the lubricant delivers on friction and wear reduction So, the disposed oil normally changes its original complexion in terms of physical and chemical composition
Is re-lubrication the right choice?
Re-lubrication is important especially when people are tending to cut corners There are re-refiners who take the used oil and refine to bring it back as base oils This is not the right practice as these base oils would have already gone through some change and now may be harmful for the operators and sometimes even the machines too
What’s important here is to consider whether you need
to reuse the oil from an industry standpoint or usage standpoint However, it’s better or it is advisable for the industry to use better technology products which can run for a longer period of time Better oil life, improved equipment life, and overall contributing to the total cost
of ownership, which through technology such as Mobil XHC and Mobil Grease range of products, can be delivered
to the industry So, our advice primarily is to go for better
technology usage and higher performance products, which can deliver on the productivity requirements of the industry rather than try and go for re-lubrication
How to select a lubricant?
One of the aspects that needs to be considered while selection of lubricants is to not only look at the product data sheet as the performance goes much beyond those characteristics, our recommendation is to look at the different performance aspects and choose a product, balanced in terms of its formulation and delivery required for the specific applications in the industry
In terms of the design and metallurgy, there are certain calculations such as the EHL calculation, which our technical services deliver to the customer and equipment builders on the field So, they look at the operating conditions, load speed, and temperature parameters, specific to an application and then make the right choice
by calculating and recommending the right product
We also make sure that we document our activities in alignment with our customers At the end of the year, we come out with a report for the customers to present to their management, what the benefits have been delivered and the decision to shift over to Mobil Lubricants was right or not And most often it is right!
Re-lubrication intervals of the bearings
Selection of lubricants based on EHL calculation and parameters such as load speed and temperature are key
in terms of understanding the operational needs of the equipment or bearing and selecting the right product which can suit those application parameters Consider selection as a primary step for getting best output of the bearing as well as the product lubricant that is used in the bearing So, re-lubrication is a factor of right selection
If the selection of the product is not optimal, then you need to frequently change the lubricant in the bearing However, that would also mean downtime because you will have to stop the equipment from pumping more grease into the bearing casing So, you need to select the right product and the right technology for the specific
Trang 2525February 2019nOEM Update
application needs of the bearing that would give you better
re-lubrication intervals as well It also saves on maintenance time or
re-lubrication activity
Mobilgrease XHP 200, 300 and 400 series
In term of the greases of the bearing applications, we have
a wide variety of products which specifically cater to the load,
speed and temperature requirements We have the Mobil
Grease XHP 200, 300 and 400 series of products which address
most of the application around the industry whether it is
manufacturing industry or energy, mining, construction, paper,
petrochemical or cement industry For highly loaded applications,
we normally recommend higher viscosity grade greases, the
Mobil Grease XHP 462 where 460 stands for the viscosity of
the base oil and 2 stands for the energy upgrade of the grease
These products are typically recommended for highly loaded
applications
Mobilgrease XHP 222
Mobil Grease XHP 222 is known as the glue and sticky grease, a
globally popular product And likewise in the industry, we’ve been
seeing significant growth in our volumes for Mobilgrease XHP 222,
which caters to pretty much all the sectors around the industry
One of the most popular applications in the construction industry
is the wheelhub grease Mobilgrease XHP 222 delivers very long
re-greasing intervals in wheelhub greases in particular There
are instances of this product going much above 150,000 kms in
wheelhub application, sometimes even touching 200,000 in terms
of usage
Environmental friendly lubricants
India is now becoming a major export hub Awareness to only
use environmental friendly products is definitely on the rise
Now with more and more awareness, clearly there is more and
more need for lubricants which addresses the environmental
protection aspects in their formulation, usage and disposal
Beyond that we have the export market In India, there are more
and more manufacturers who are reaching out to the world, by
coming into the global scenario and becoming more and more
competitive, thereby delivering products to various markets
around the world
The awareness of products to meet certain global demands on
environmental aspects is becoming more relevant The acceptance
for products which are formulated right, specifically keeping
environmental protection in view and also in terms of the usage
is going up From a regulation standpoint as well, and also with
Government of India taking up the Swachh Bharat initiative,
there is more awareness that has been created and there are lot of
regulatory steps that are put in place as well It’s a very important
for the industry to adopt and embrace and make sure they use the
right products, specifically lubricants
Authored article by:
Shankar KarnikGeneral ManagerIndustrial LubricantsExxonMobil Pvt Ltd
Trang 26Influence of speed in crane’s efficiency and productivity
Some consider that an increase in crane’s speed results
in more efficiency and productivity But some have a different viewpoint altogether Sanjay Vijan, Director
of Astavinayak Cranes and Equipments LLP, says,
“Yes! More the speed, more the efficiency! We should take into account the load bearing of the winches
If the cranes are too slow when compared to its load bearing capacities, then the production would be stalled.”
The speed depends on the winch and the motor drive The winch motors have to be of the best quality So, if the capacity of the winches is higher, the loads and speed of the cranes would also increase
However, Dinesh Sindhwani, Senior Sales Manager, Pioneer Cranes & Elevators Pvt Ltd has a different opinion: “No! Speed depends on the application.” He adds, “For example, cranes in steel plants require more speed Since the equipment needs to work for the whole day, more speed would result in better productivity and work can be done faster.” But in case of moulding and die machines, Dinesh says, slow speed EOT cranes are required, because precision is important If the speed of the crane is fast, work will not happen properly.“So it all depends upon application.”
Modernising old cranes
Vijan says that old cranes can be modernised because
the steel structures are very efficient “You only need
to replace the tracks with modern ones along with the electrical components and winches, which is the heart
of EOT cranes
However, he suggests that there is no need to replace the entire system “It is better to replace the parts and components instead of the entire crane If the structure of the crane is in a perfect condition, then you can utilise it,” he adds Basically, all EOT cranes have the same structure “If we take Industry 4.0 into consideration, it is nothing but latest components and electronics So, you can replace the control panel, electronics and the winches on the existing cranes and
it should work just fine,” he adds further
Meanwhile, Dinesh says that there is a feature called Variable Frequency Drives (VFD), which can control the speed of EOT cranes “It is being used in the modern cranes and was not used in the older ones.”
“If the physical condition of the crane is good, you can modernise it by implementing VFD But, if the crane needs to be upgraded, then replacing the entire system would be better,” he adds
Safety considerations
“First and foremost concept of the safety is the overload,” says Vijan “Secondly, the electronic components and winches are tested at regular intervals.If the overhead cranes having big capacities are stalled, the entire production line suffers And also, it increases the risk of accidents if it is not tested properly.”
An industrial analysis on how the speed affects the productivity and efficiency of cranes, and the safety measures taken to avoid any untoward incidents in the industries.
Continued to 28 g
Trang 28However, Dinesh explains that there are different aspects that need to be considered “First thing is limit switches, which are critical components of overhead
crane safety Apart from that, there are different features available in VFD, which are automated and doesn’t require any additional settings Also, there’s
a function for overload as well It stops the operation when the load is more than the capacity of the crane Also, if the current is more, it will stop the crane automatically.”
If there are two cranes working on the same rail, collision device can be implemented to avoid collision
anti-In a working environment, the labours may not be aware about how to use the crane So, in such situations, parameters (in meters) can be set for cranes so that the cranes do not come in contact with each other Meanwhile, Dinesh is of the opinion that safety is top priority right now “Everyone is concerned about safety because crane is a critical item Consider
a crane weighing 20 tonnes or 50 tonnes or even
1 tonne If that load falls on a person, it would result in
a fatal accident So, the safety aspect is given utmost importance nowadays.”
However, he suggests that some people look at the economic aspect and sacrifice on safety “So, according
to me, this should not happen and safety must be given utmost importance or priority while selecting a crane,”
he concludes
You can replace the control panel, electronics and the winches on the existing cranes and it should work just fine
Sanjay Vijan, Director of Astavinayak Cranes and Equipments LLP,
If the crane needs to be upgraded, replacing the entire system would be better instead of modernising it
Dinesh Sindhwani, Senior Sales Manager, Pioneer Cranes & Elevators Pvt Ltd.
Solid carbide deep-hole drill for engineering sectors
BILTZ Cutting Tools Company has introduced a new Solid-Carbide Drill for deep-hole production The new deep-hole drills are available with length ratios in 15xD, 20xD, 25xD, and 30xD Available diameters range are from 3.0 to 14.0 mm
These tools are specially developed for the production
of parts for the automotive, oil-and-gas, and-die, medical, and general engineering sectors
mould-These drills have a faceted point geometry with a point angle of 135°
This cone-point geometry gives it a low thrust and excellent centering ability, for increased hole quality The drill design includes a high-strength core and wider opened flute design of 30-degree helix that allows easy evacuation of chips Its four-margin design improves stability during drilling Highly polished surfaces increase wear resistance and reduce friction on margins and cutting edges The tools are coated keeping in mind the area of application
of the user Internal coolant holes accommodate all types
of cutting fluids and operating conditions, including minimum quantity lubrication
They have special machining capabilities and specially engineered support systems for regrinding and recoating
of these extra-long tools
For more details, contact : Biltz Cutting Tools Company
J-351 M I D C Bhosari Pune 411026 Mob : 9823022042
Ph : 02046761014 Email : biltz@vsnl.net Web : www.biltzindia.com
Trang 29cutting and welding india
Trang 30Cyber security and AI
Artificial intelligence is the core of automation Modicon connects the connected components to the apps and applications, which are connected to the cloud This cloud is where cyber security aspect comes in Modicon
is the only PLC in the world, which has cyber security built-in We have an industry-level cyber security layer built into our systems
Adoption of technology and automation
Modicon is the basic flagship where automation started
in the manufacturing space The adoption of IoT and Industry 4.0 in manufacturing have started happening since last few years Right now, SMEs are largely adopting automation, which is helping them to improve their efficiencies However, adoption of automation is very low with small players compared to the mid-sized (`500- `1,000 crore) industries
With automation we could potentially reduce the cost of production, optimise the processes, and improve efficiency
by up to 20 per cent As manufacturing sectors have started understanding it, they have started showing interest in it
Most of the multinational companies in India require their products to be globally compliant in terms of all regulators’
requirement So, Modicon gives them this flexibility The adaptation has been much faster in last few years and the rate at which it is going on will be multiple times than what it is today
Maintaining the quality of products
The message that I want to share to manufacturers is
start from where you are in adopting Industry 4.0 This means manufacturers need not replace their entire system Instead, they can implement Modicon with their existing systems This can improve efficiency of the plant, improve the reliability and quality of the product, and reduce defects with sustainable and scalable architecture It is interoperable So, it can work with any of the products which is not Schneider oriented
We are expecting the industrial automation manufacturing market will be around $3.5 billion in India by 2020 This is also going to generate good amount of jobs According to the data we’ve collected from our studies, we are expecting around 90 million jobs to be generated in manufacturing industry alone because of this revolution and investment
We primarily see maximum growth, in terms of adopting automation, in industries which are into utilities, manufacturing space, transportation, automotive, and the supply chain These are the areas where we see lot of investment and attraction of IoT and Industry 4.0 coming in
Govt initiatives to boost digitisation
We have automated one of our 24 factories in India — our flagship factory in Hyderabad — which is equipped with all levels of connected products, edge controls, apps and applications We are also contributing to
‘Make in India’ campaign We are getting the awareness done regarding Industry 4.0 to all our customers through various domestic and government players The government is also doing a lot about adaptation
of digital technology, digital transformation, smart technology, smart cities, smart water, etc These are the initiatives that the government has taken now They are themselves driving the need for automation
Need for more investments
There is a need for investment in R&Ds and innovations
I firmly believe that we should continuously invest in R&Ds in ensuring that our efficiencies improve further, number of moving devices reduce further, the speed of processing become faster, and the physical start getting converted into digital
AI, AR and AM
Artificial Intelligence (AI) is the core of Big Data and Analytics We are looking at AI, fuelling the growth of processes automation in industries very effectively and efficiently
Additive Manufacturing (AM) is something which is built up So we do see a future of that coming in We
Modicon: For a cyber-secured manufacturing phase
Continued to 32 g
Trang 32Operational efficiency and profitability
When we look at IoT and automation combined, the speed
to market has improved The processes have become five times faster than the old processors and they can actually reduce the time to market by 25 per cent For a large company, it means they can save around $1.2-1.3 million
in annual return
Due to the cyber security layers built into the processors, the amount of money saved by the end customers is also around $1.2-1.3 million per annum
Also, with increase in efficiency and reduction in cost
of energy consumed for the process, around 20 per cent optimisation has been possible in today’s industry with the advent of IoT It is possible by optimising the existing resources we are using, making them more productive by not adding more resources
This 20 per cent yields roughly $20 million in savings for a large organisation If you combine these things together, it’s a huge amount of saving what these industries get Earlier, to localise a fault, it used to take over two hours to two days Today, it takes only seconds
to identify a fault So, these benefits are tangible and intangible, but give a lot of benefits to the end customers
One of the perceptions of people is that connecting products and connecting systems take lot of money The fact is they can do it with very little capital, which they want to Even if it’s an older plant it doesn’t take a lot
to connect the few basic parameters, which can yield them the efficiency improvement which are beyond what they can expect
Secondly, one of the biggest myths that people have is that if it’s a Schneider PLC it will only be compatible with Schneider products This is not the fact These are interoperable and can communicate even with products, which are not a part of that
Securing IoT from ‘Internet of Threats’
Modicon is the only PLC in the world, which has industry standard cyber security layer built-in within the processor So with this protection, we protect our customers from cyber threats
Modicon: For a cyber-secured manufacturing phase
The Power milling chuck delivers 5-micron runout accuracy
at 3XD Through direct clamping technology, one Seco chuck can hold cylindrical plain 20 mm, 32 mm, 0.75” and 1.25” and Weldon shank tools of 20 mm and 0.75” With the use of reduction sleeves, a single chuck also can handle shank diameters in cylindrical plain, Weldon and Whistle
Notch tools from 6 mm up to 25 mm, 0.25” up to 1.00” The chucks accommodate milling tools – for roughing and finishing operations – as well as drilling and tapping tools.Seco Tools power milling chucks offer shop innovative advantages over standard collet chucks A nut and needle-bearing design produces superior clamping power with minimum tightening force/torque requirements, compared with the steel-to-steel contact on collet chucks
Optional coolant-stop screws enable power milling chucks
to engage through-tool coolant These Seco chucks require
no additional expense for ancillary equipment such as heating or hydraulic units
Seco power milling chucks are available for HSK-A, Capto, DIN, BT and BT taper-face, and ANSI and ANSI taper face spindle interfaces Each chuck includes a sleeve extractor, stop screw (with DIN, BT and ANSI interfaces) and operating instructions
Seco-For more details, contact:
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Power Milling Chuck
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