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5-axis competence and precision. Process dependability included.

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Current discussions about 5-axis machining centres are ongoing. Whilst some sceptics claim that more challenging programming or higher demands on the machine and the control speak against the technology, insiders emphasise the benefits of faster machining resulting in savings potentials plus higher precision and reduced tool wear due to shorter milling paths. That is also why HELLER placed the focus on this particular technology during WerkTage 2014, being already the 7th edition of this event. With seven machining centres live in action, guided plant tours and moderated panel discussions, the event was again fully geared towards the tasks of the users.

Already ahead of the event, organisers were aware of the expected number of visitors and an international response to WerkTage 2014. However, none of them had anticipated that they would be welcoming more than 800 guests from 20 different countries. With a share of more than 60%, the majority of visitors still came from Germany, followed by guests from Switzerland, Portugal, Spain and the US. Just as diverse as the nationalities of visitors to Nürtingen were the branches of industries interested in economically viable manufacturing solutions, including representatives from the automotive industry and its suppliers, machine builders, mould and die manufactures through to aerospace companies.

The 7th edition of HELLER WerkTage provided visitors with an opportunity to gain an understanding of tomorrow’s trends. Aspects presented included solutions offering precision and 5-axis competence and a comprehensive approach to the process chain. HELLER demonstrated its full spectrum of productivity with seven machining centres on display, machining a diverse range of components and meeting a wide variety of requirements. An out-facing head solution and trochoidal milling, universal application using oversized tools and boring in all its facets were presented on three 4-axis machining centres from the H series. Three 5-axis machining centres from the F series were the focal points in terms of 5-axis machining. Model FP 4000 demonstrated high precision with in-process gauging and 5-axis machining from 6 sides, whilst model FT 4000 showcased strategic 5-axis simultaneous machining. Additionally, HELLER cycles and combined mill/turning operations were demonstrated on 5-axis machining centre model CP 8000. Live machining demonstrations were complemented by a total of three new developments and numerous product enhancements, including the expansion of the process chain in crankcase manufacturing with HELLER CBC (CylinderBoreCoating).

This year for the first time, practical machine demonstrations were accompanied by moderated panel discussions. They also provided an opportunity to focus on a number of decisive questions: implementation in practical application or the questions of why, when or which solutions are chosen and how these strategies are transferable to other fields. Volker Schmitt, Head of Industrial Engineering Manufacturing at Linde Hydraulics GmbH in Aschaffenburg, for instance, illustrated cost-effective manufacturing of special cylinder blocks for axial piston pumps through use of a 5-axis machining centre. Up to now, these components have been manufactured using 4-axis machines with an additional attachment axis on the pallet. One specific type of cylinder block required machining in two setups, resulting in a very laborious process accompanied by a loss in quality and repeatability. To enable machining of the inclined bores in a single setup, a 5-axis solution was needed. For Linde Hydraulics, the decisive advantage was that the FP series of machines and the fork-head unit allowed machining at negative angles below the centre axis. The Aschaffenburg-based company required machining at a negative angle of 21°.

Formula for success for reliable operation

For Walter Kreidler, Managing Director of Kreidler GmbH & Co. KG in Horb, chip removal rate, dynamics, precision and reliability of the HELLER machines are the measure of all things. The requirements in terms of precision and availability in the machining of its workpiece spectrum, including parts for leading German transmission manufacturers, are usually extremely high and complex. Walter Kreidler comments: “Being confronted with challenging operations almost every day, these requirements are nothing new to us. Although the term ‘challenging’ is relative. It depends on what you are referring to. The die casting industry is subject to high standards and demands. Knowing this, you adapt to these requirements and adopt a conscientious approach. Walter Kreidler has his own recipe for achieving “precision and reliability for safe production processes” which has proven successful over many years: “I have known the machines supplied by HELLER from the very first day and we know what we are doing with them. HELLER may come at a higher price tag than other manufacturers, however, the longevity of the machines compensates for that. For reliable operation the machines simply have to keep running – around the clock. In my opinion, switching the machines on and off, powering them up and down, resulting in temperature fluctuations that have a negative effect on the lifetime of a machine. When operating the machines at constant temperatures, there are virtually no problems at all.” The company based in Horb achieves the required precision with complete machining in a single setup, without making a difference between roughing and finishing operations. According to Walter Kreidler this has no negative effects on the machines whatsoever: “We have been operating machines for 15 years still using the same guideways. We even purchased an 11-year-old machine model MC 16 from HELLER. Right from its installation the machine has been providing the same high precision as a new one. We never had to replace a spindle or guide rails. Workpieces are machined at high precision. We are using the machine for machining of current crankcase types.”

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Availability at 95 percent even without automation

The above approach may sound a little strange to Karl Semmelmann, Head of Engineering and Development at MDS Abele GmbH & Co. KG. The company based in Mühlacker is required to achieve a process capability of Cm/Cmk 1.67. As a whole, the component in question required extremely high manufacturing precision in alternate machining. Due to the required Cm/Cmk 1.67 capability, tolerances were reduced from 0.05mm to 0.035mm. With daily batch sizes of 50, 220 and 500 pieces, precision and process capability have to be provided over a long period at high process dependability. That is why the company from Mühlacker opted for two 4-axis machining centres model H 4000 from HELLER. The machines commissionined in 2013 were immediately used for production. Although the company had expected them to require a certain start-up phase, they already reached 95 to 96 percent availability without the use of automation.

According to Karl Semmelmann, the stability of the machines contributes significantly to the high availability by safeguarding a high level of repeatability, whilst eliminating fluctuations in terms of stiffness and thermal growth. Following a short warm-up phase the machines are ready for machining from the thermal and mechanical point of view. The focus at MDS Abele is not on chip removal rate but on high speeds, high feed rates and precision. These attributes are not necessarily associated with horizontal machining centres. For Karl Semmelmann these things are relative: “In case of manufacturers providing other concepts the question is whether rapid traverse rat
es can be achieved across the overall traverse path at all. Model H 4000 has a traverse path of 800mm. However, if you accelerate across this distance, you also need to be able to decelerate. Operating costs are an important factor to be considered in this context. Today’s power consumption of linear drives almost requires a separate power generator for every machine.”

That exactly was the decisive factor for the company from Mühlacker. According to its calculations, the cost of power has increased by 60 percent in the last 5 years. Independent of political decisions, the company assumes that the increase is likely to continue in the coming years.

Insights, transparency, perspectives

This year, HELLER also welcomed renowned process chain suppliers to the event. In particular automation manufacturers KUKA, SCHULER, GÜDEL, LIEBHERR, RILE and FASTEMS provided information about solutions for stand-alone machines and linked machining centres. Additionally, the perfect symbiosis of a virtual and transparent machine provided in-depth insights. HELLER showcased a transparent machine model FP 4000, illustrating the quality of the machine structure, whilst virtual machining revealed the possibilities for optimising the process chain from the idea to the finished part. The programme was rounded off with a presentation of the complete portfolio of HELLER Services and our partner WENZLER, attractive financing solutions and a comprehensive exhibition of workpieces and finished products of numerous HELLER customers.

As during previous editions, HELLER WerkTage 2014 also provided an opportunity to visit Plants 1 and 2. In addition to insights into manufacturing, sub-assembly installation, final assembly and vocational training, visitors had a chance to learn more about the assembly of crankshaft machines, large-part manufacturing and retrofitting “Made by HELLER”.

Already in 2013, organisers at HELLER were confident that the 2014 event would again be a meeting place for experts in step with actual practice. The exchange of experiences and the technologies in focus contributed to fulfilling these expectations. Another important factor in the event’s success was the participation of partner companies and market leaders from the automation industry, suppliers of measurement and inspection equipment and clamping fixture providers, providing the relevant technology competence. They were able to present a wide range of possibilities for realising manufacturing solutions for a broad spectrum of components and workpieces. [www.heller.biz]

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RFID와 무선시스템을 통한 식품 자재창고 식별 솔루션 구축

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터크 RFID및 무선통신 시스템으로 실시간 생산 모니터링 및 물류, 유통기한 관리까지 구현하다!

터크 RFID 및 무선통신 시스템;
실시간 생산 모니터링 및 물류, 유통기한 관리까지

최근 RFID기술은 전세계적으로 물류 및 창고관리 뿐만 아니라 생산라인에도 널리 적용되고 있다. 특히, 중국 기업들은 원자재 처리, 생산, 저장 및 운송에 RFID 기술을 사용해 보다 효율적인 프로세스를 구축하는데 많은 노력과 투자를 하고 있다. 이를 통해 식품업계에서 중국기업의 입지가 높아지고 있다.

터크 RFID및 무선통신 시스템으로 실시간 생산 모니터링 및 물류, 유통기한 관리까지 구현하다!

터크 RFID및 무선통신 시스템으로 실시간 생산 모니터링 및 물류, 유통기한 관리까지 구현하다! (사진. 터크)

업계에서 유명한 중국의 한 회사는 창고 관리에 신뢰성있는 비용 절감 기술을 필요로 했다. 이에, 터크의 RFID 기술로 원자재 운송의 추적 및 관리를 수행하는 실시간 자재 관리 시스템을 구현했다. 이 시스템은 자재창고 데이터 목록을 확인하고 각 팔레트를 재고로 지정한 뒤, RFID 읽기/쓰기 헤드 (안테나)를 통해 팔레트에 부착된 데이터 캐리어로 데이터를 기록하는 방식으로 구성된다. PLC는 창고 내에 팔레트의 위치를 자동으로 지정하고 해당 위치에 자재가 보관되도록 지게차를 안내한다. 이 때 사용되는 지게차에는 읽기/쓰기 헤드 (안테나)가 설치되어 자재 및 제품의 위치 및 정보를 중앙 관제 시스템에 저장한다.

터크의 IP67 등급 RFID 모듈 BL ident와 BL67 필드버스 게이트웨이를 선택해,<br />지게차에 이 제품들을 설치하여 건조하거나 습한 환경 모두에서 작동이 가능하도록 구현했다.

터크의 IP67 등급 RFID 모듈 BL ident와 BL67 필드버스 게이트웨이를 선택해,<br />지게차에 이 제품들을 설치하여 건조하거나 습한 환경 모두에서 작동이 가능하도록 구현했다. (사진. 터크)

높은 가용성을 위해 시스템은 전체 데이터가 중앙 관제 시스템과 분산데이터로 이중화되었고, 출고시에는 선입선출법을 적용했다. 시스템은 생산 작업에 따라 자재가 정확한 생산 라인으로 이동되도록 지게차를 안내한다. 운송 도중 지게차의 읽기/쓰기 헤드는 팔레트의 데이터 캐리어를 확인해 자재 필요 여부를 확인한다. 오류 발생 시, 시스템은 알람을 내보내고 자재를 채우기 위해 취해야 할 조치를 자동으로 표시한다.

팔레트 적재제품을 한번에 리딩하는 RFID 기술

팔레트에 이미 RFID 태그가 설치되어 있으므로 다량의 제품에 대한 정밀한 디지털 관리가 매우 간단하다. 이제 작업자가 수많은 바코드 라벨을 미리 인쇄하여 팔레트에 붙이고 바코드 스캐너로 스캔 할 필요 없이 태그형 팔레트를 통해 이 모든 작업을 한 번의 읽기/쓰기 과정에서 완료할 수 있다. RFID 태그는 표면의 스크래치나 얼룩이 영향을 주지 않기 때문에 까다로운 물류 환경에도 적용이 가능하고, 재활용 역시 가능하다. 태그는 바코드 라벨과 달리 우천 시에도 사용할 수 있고, 특정 태그의 UID 정보는 자재 트래킹 정밀도를 향상시킬 수 있다.

습도가 높은 환경에서 생산되는 글루탐산 나트륨은 분말 원료를 별도로 보관해야 하기 때문에 이 시스템은 습한 환경뿐만 아니라 건조하고 먼지가 많은 환경에서도 완벽하게 작동할 수 있어야 했다. 고객은 이러한 이유로 터크의 IP67 등급 RFID 모듈 BL ident와 BL67 필드버스 게이트웨이를 선택하였고, 지게차에 이 제품들을 설치하여 건조하거나 습한 환경 모두에서 작동이 가능하도록 구현했다. BL ident 읽기/쓰기 헤드는 운송 중에도 데이터의 읽기 및 쓰기가 가능하므로 지게차에 장착하여 사용할 수 있었다.

팔레트에 이미 RFID 태그가 설치되어 있으므로 다량의 제품에 대한 정밀한 디지털 관리가 매우 간단하다.

팔레트에 이미 RFID 태그가 설치되어 있으므로 다량의 제품에 대한 정밀한 디지털 관리가 매우 간단하다. (사진. 터크)

무선통신 시스템으로, 움직이는 지게차 게이트웨이의 데이터를 취합하다!

이 시스템 구현의 가장 큰 과제는 지게차의 게이트웨이를 중앙 관제 시스템으로 연결하는 것이었다. 지게차가 계속해서 움직이기 때문에 케이블로 연결하는 것은 불가능했고, 여러 번의 논의와 테스트를 거쳐, 터크는 프로그래밍 가능한 게이트웨이와 제어 레벨의 통신이 가능한 무선 이더넷 네트워크 솔루션을 제안했다. 이 솔루션으로 고객은 생산 시스템의 전체 물류관리 및 제품 유통기한 관리를 실시간으로 구현했다.

프로젝트 담당자는 “터크의 읽기/쓰기 헤드의 외형이 근접센서와 동일해서 사용이 용이하고, 설치가 쉬었습니다. 0~ 200mm의 작동거리는 어플리케이션 요구사항을 만족시켰고, 터크는 견고한 하우징의 RFID 시스템과 함께 50미터 길이의 조립 가능한 연결 케이블을 함께 제공하여 열악한 환경 조건에서도 안정적인 데이터 전송을 보장하였습니다. 또한 무선 네트워크는 게이트웨이와 네트워크 노드만으로 간단히 구현하였습니다.”라고 전하며 터크의 BL Ident 시스템의 장점을 요약했다. [제공. 터크코리아]

박은주 기자 news2@icnweb.co.kr

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IEEE Announces IT Healthcare Standard in Advance of the IEEE Annual International Conference of EMBS

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The 39th Annual International Conference of the IEEE Engineering in Medicine and Biology Society (EMBS) to highlight latest advancements in biomedical engineering, healthcare technology R&D, translational clinical research, technology transfer and entrepreneurship, and biomedical engineering education.

IEEE, the world’s largest technical professional organization dedicated to advancing technology for humanity, and the IEEE Standards Association (IEEE-SA), today announced the availability of IEEE 11073-20702™—Health informatics: Point-of-Care Medical Device Communication—Standard for Medical Devices Communication Profile for Web Services in advance of the upcoming EMBC ’17 to be held 11-15 July at the International Convention Center on JeJu Island, South Korea. IEEE also announced the approval of two new healthcare-related standards projects: IEEE P1708™—Standard for Wearable Cuffless Blood Pressure Measuring Devices, and IEEE P1752™—Standard for Mobile Health Data.

Sponsored by the IEEE 11073™ Standards Committee (EMB/11073), IEEE 11073 family of standards are utilized to structure data and enable data transmission across multiple healthcare devices, ensuring effective interoperability and communication between medical, health care and wellness devices, as well as with external computer systems. IEEE 11073-20702 defines a communication protocol specification for a distributed system of point-of-care (PoC) medical devices and medical IT systems that need to exchange data, or safely control networked PoC medical devices, by profiling Web Service specifications.

“IEEE 11073-20702 is the first standard that streamlines the integration of medical devices with the IP stack common to IT specialists around the world,” said Bill Ash, strategic technology program director, IEEE-SA. “Ensuring the safe and secure transmission of healthcare data is essential to advance value-based healthcare, giving patients easy access to their medical information and simplifying IT processes for point-of-care facilities.”

The IEEE EMB Standards Committee (EMB/ Stds Com) is the technical sponsor for all the other standardization development projects.

IEEE P1708 is working to establish guidelines in a standardized way for manufacturers to qualify and validate their products, potential purchasers or users to evaluate and select prospective products, and health care professionals to understand the manufacturing practices on wearable, cuffless blood pressure (BP) devices. The intent is to establish objective performance evaluation of wearable, cuffless BP measuring devices and may be applied for all types of wearable BP measurement devices, regardless of their modes of operation (e.g., to measure short-term, long-term, snapshot, continuous, beat(s)-to-beat(s) BP, or BP variability). The standard is independent of the form of the device or the vehicle to which the device is attached or in which it is embedded.

IEEE P1752 is intended to provide meaningful description, exchange, sharing, and use of mobile health data to support analysis for a set of consumer health, biomedical research, and clinical care needs. The standard will leverage data and nomenclature standards such as the IEEE 11073 family of standards for personal health devices as references, defining specifications for a mobile health data applications programming interface (API) and standardized representations for mobile health data and metadata. Furthermore, IEEE-SA is active on many eHealth related projects, including four standards in development addressing medical 3D printing undertaken by the IEEE 3333.2™ working group.

“The IEEE EMBS members are highly committed, informed, and innovative biomedical engineers from around the world dedicated to finding new discoveries that can advance biomedical technologies through collaboration and translational engineering into product realization in the market place,” said Carole Carey, chair, IEEE Engineering in Medicine and Biology Society Standards Committee. “With the significant growth in the development and innovation of new technologies being applied to health and healthcare systems, the need for developing consensus standards in an open and global environment is essential. EMBS is pleased to host its 39th Annual International Conference, where IEEE EMBS has assembled an extensive agenda and a prestigious list of keynote speakers for sharing best practices and discovery to meet the technological challenges today and for the future.”

hordon kim / hordon@icnweb.co.kr

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