INTERVIEW HOFFMANN GROUP
September 2019
SPECIAL REPORT
OKUMA – COMPLETION OF THE NEXTGENERATION SMART FACTORY Mikron Tool – Drilling in one stroke Mitsubishi Electric CNC Total Care package service
#MACHINING #INDUSTRY #AUTOMATION #MACHINES #CUTTINGTOOLS #MANUFACTURING
IN THIS ISSUE INDUSTRY NEWS
Worcon | September 2019
MANUFACTURING
4 SCHUNK Is Investing 85 Million Euros In Its Production Sites
12 Laser Technology - 12,000 Holes Per Second With 1 µm Diameter
6 Okuma - Completion Of The Next-Generation Smart Factory - The New Kani DS3 Plant
13 Mitsubishi Electric CNC Total Care package Service
8 Italian Machine Tool, Robot And Automation Manufacturing Industry With Record Numbers
14 Lincoln Electric Is Adding Layers To Its Business
10 ABB Announces Björn Rosengren As Chief Executive Officer
17 Mastercam 2020 - Getting The Best Out Of 5-Axis Technology For Barrel Tools 18 Renishaw Collaborates To Produce Unique Surgical Implants 20 YASKAWA Cockpit Industry 4.0 Software Platform Now Available In EUR 1.0
30 EMO FAIR - SPECIAL REPORT AUTOMATION 22 BMW Introduce ‘Measurement Cell’ For Quality Control Of The Future 24 Kaspersky: Over Half Of Security Incidents Caused By Employee Errors 25 Haas Automation Is Now Available On MachiningCloud 26 Using AI o Predict CNC Machine Spindle Issues Before They Are Issues 28 Robotics Trends Taking Over Manufacturing
EMO FAIR 30 Belotti S.P.A. 32 Chiron 34 Hainbuch GmbH 36 Heller 39 Liebherr 40 Tezmaksan Makina 41 WFL 42 Erdwich Zerkleinerungs-Systeme GmbH
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IN THIS ISSUE
Worcon | September 2019
INTERVIEW 44 100 Years Of Existence Is The Quality Assurance Of The Hoffmann Group
22
BMW Introduce ‘Measurement Cell’ For Quality Control Of The Future
MACHINES 48 A CNC Made Of Wood 49 FPS - Universal Milling Machines For Flexible Use 50 EU Machine Tool Orders Dropped In The First 3 Months
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Robotics Trends Taking Over Manufacturing
TOOLS 52 Garant Xtric Centering Vise 53 New Cutting Tools By Walter AG 54 Mikron Tool - Drilling In One Stroke
MARVEL OF ENGINEERING 56 The Golden Gate Bridge
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Okuma - Completion Of The Next-Generation Smart Factory 3
INDUSTRY NEWS
Worcon | September 2019
SCHUNK Is Investing 85 Million Euros In Its Production Sites With an investment Schunk is looking to grow internationally. Aside from new production space, a new administration building has also been built recently. With a broad-based investment program, Schunk is preparing for the next step of its global growth: around 85 million euros will be invested in the locations Brackenheim-Hausen, Mengen, St. Georgen and Morrisville / USA by mid-2020, creating around 42,000 square meters of additional production and administration space. It all starts with the US plant in the state of North Carolina, where the new buildings were officially handed over a few days ago.
with an official ceremony followed by a Family Day. Alongside Managing Partner Heinz-Dieter Schunk and Chief Executive Officer Henrik A. Schunk, the President of Schunk Intec USA, Milton Guerry was enthusiastic about the opportunities that the investment offers for the future. Anthony Copeland, Minister of Economic Affairs of North Carolina, praised Schunk as a great example of a company that creates jobs and highlights the assets of North Carolina as a business location.
In addition to the expansion of the production area, Schunk Intec USA created a new administrative building that, through its open architecture, encourages and inspires creativity and lateral thinking, so the company. The largest subsidiary of Schunk was founded in 1992 to ensure proximity to In the newly-created Customer Center, American customers and to the subsidusers can experience Schunk’s com- iaries of German corporations. On-site ponents live and receive additional production ensures short delivery times know-how in technology forums and and high flexibility, especially when it workshops. comes to specific components that are produced specifically for the American Under the motto “One Team - One market. Family One Future”, the approximately 4,000 square meter new building expansion was inaugurated in early May 4
Worcon | September 2019
Henrik Schunk expects high growth rates, especially for mechatronic and increasingly intelligent clampingdevices and gripping systems.
INDUSTRY NEWS
Boom in automation and digitalisation
Image courtesy of: schunk.com
In addition, 40 million euros are being put into the Competence Center for Gripping Systems in Brackenheim-Hausen, just five kilometers from the headquarters in Lauffen. The expansion covers an area of 22,000 square meters and represents a doubling of the existing production area. Schunk is investing another 30 million euros in the Competence Center for Lathe Chuck Technology and Stationary Workholding in Mengen, in the district of Sigmaringen. Here, 12,000 square meters are to be added for production, research, and development.
Image courtesy of: schunk.com
Schunk also recently announced its cooperation with Anotherbrain, one of the world’s leading specialists in artificial intelligence, according to the company.
5 million euros were invested at the St. Georgen site in the Black Forest, where the production area was doubled with an increase of 4,200 square meters. The Chief Executive Officer Henrik A. Schunk, sees the total volume of 85 million euros as a consistent investment in the future of the company: “In the coming years, we will experience a boom in automation and digitisation worldwide, and we’ll only be able to handle this by having the right capacities,” says the CEO. 5
INDUSTRY NEWS
Worcon | September 2019
Okuma - Completion Of The Next-Generation Smart Factory - The New Kani DS3 Plant Okuma has completed the construction and started operation of the new Kani Dream Site 3 (DS3) plant, that continues the concept behind the headquarters’ factories, Dream Site 1 (DS1) and Dream Site 2 (DS2).
Evolving Factories Okuma builds factories that are constantly evolving with the goal to spur improvement and innovation. Together with the trends of IoT, big data, AI, and intelligent technology in the Fourth Industrial Revolution, the construction of smart factories that can achieve high-mix low-volume production while maintaining productivity equivalent to that of mass production has been moving forward. Okuma was one of the first companies to start operation of a self-contained startto-finish production system (DS1) in 2013.
In 2017, the DS2 parts factory was opened and has been using IoT to achieve super high-mix-low-volume production that is highly efficient and has high value-added. The DS1 and DS2 parts factories integrate automation and expert techniques. Due to the advanced measures described below, these smart factories are 50 percent more productive then older production plants and have reduced production lead time by 50%.
Image courtesy of: Okuma Europe 6
INDUSTRY NEWS
Worcon | September 2019
Image courtesy of: Okuma Europe
The latest automation, unmanned operation technology, advanced IoT, and know-how from the shop floor The new Kani DS3 factory uses cutting-edge smart machines, robots, and FMS together with advanced IoT to accurately understand production progress and operation conditions. The machine parts production at DS3 is synchronized with the assembly processes, so that the necessary parts are
produced at the necessary time in the necessary quantities. The new Kani Plant is constructed to become a startto-finish production plant for vertical and horizontal machining centres and double-column machining centres. Okuma is expanding their production capacity by categorizing the plants by the models they produce, by building self-contained start-to-finish production systems throughout the company and by increasing production efficiency.
Smart CNC machine tools, robots, and FMSs, such as super multitasking machines that have built-in AI and lasers, are used in advanced ways to achieve automation that allows 72-hour unmanned operation. In addtion to that, accurate and fast work instructions that utilise IoT, as well as progress and operation monitoring systems boost the overall optimization of the producition plants. Image courtesy of: Okuma Europe 7
INDUSTRY NEWS
Worcon | September 2019
Italian Machine Tool, Robot And Automation Manufacturing Industry With record Numbers Ucimu’s President Massimo Carboniero recently said: “The 2018 results of the Italian industry of the sector are, by far, the best ever achieved, with double-digit increases for almost all main economic indicators.” At the annual members’ meeting of the Ucimu-Sistemi per Produrre late June, Carboniero noted that for 2018 the best record numbers have been achieved since 2014 and added that the forecasts for 2019 indicate stability and should be levelling. The President of Ucimu said that the Italian Government was asked to abandon the “logic of intermittency” and to provide a structural Package of Provisions on 4.0 immediately to enable SMEs to plan their medium/long-term investments.
rose 15.2% to €3,112m, and exports that amounted to €3,663m, thereby registering a growth of eight percentage points compared to the previous year. In 2018, the main markets for Italian products of the sector were Germany (€394m, +15.1%), the USA (€354m, +11.5%), China (€341m, -0.4%), Poland (€229m, +41.7%), France (€227m , +6.7%), Spain (€144m, +7.9%), Russia (€100m, +11.9%) and Turkey (€90m, +2.6%).
Consumption was positive. For the In 2018, the country’s machine tool, fourth consecutive year, it recordrobot and automation manufactur- ed a double-digit growth, totalling ing industry indicators registered the €5,164m that is 15.7% more than 2017. best double-digit increases for almost all main economic indicators since Ranking fourth among manufacturing the positive trend started in 2014. countries, the Italian industry in these sectors took third place among exportAccording to the final data from the Eco- ing countries. Italy strengthened to be nomic Studies Department and Business fifth in consumption ranking, which Culture at Ucimu, output of machine is a testimony of dynamism of its dotools, robots and automation systems mestic demand that took advantage achieved €6,775m in 2018, correspond- of the incentive provisions for competing to an 11.3% upturn compared to itiveness (Industry 4.0/Enterprise 4.0). 2017. This outcome is the result of both the positive trend of manufacturers’ deliveries in the domestic market, which 8
INDUSTRY NEWS
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Forecast for industry in 2019
pared to 2018. The export/output ratio is also expected to grow to 55.6%.
The forecasts for 2019, however, show a setback, for the first time in five years, mainly because of uncertain and unstable situation, both domestically as well as with foreign markets. The trend of the Italian industry of the sector will very likely remain the same in 2019, Ucimu disclosed. In particular, the growth in production should slow down, forcast to increase 3.6% at €7,020m while exports are expected to achieve €3,900m, which is a 6.5% increase com-
Even consumption is predicted to be slower, attaining €5,220m (+1.1%), which would mean the same as 2018. Ucimu also noted that manufacturers are expected to reflect the same trend. The Ucimu meeting was also attended by the President of Confindustria (Italian Industrial Federation), Vincenzo Boccia and economist and Vice-President of Fondazione Edison -Marco Fortis.
Image courtesy of: Pixabay 9
INDUSTRY NEWS
Worcon | September 2019
ABB Announces Björn Rosengren As Chief Executive Officer ABB appointed industrial veteran Bjorn Rosengren to take over as chief executive officer next year and lead a sweeping overhaul of the Swiss engineer after he rejuvenated Swedish mining-equipment giant Sandvik AB. The 60-year-old executive will take the helm in March after more than four years with Sandvik. Shares of Zurich-based ABB jumped as much as 4.4%, the most since April 17 - when ex-CEO Ulrich Spiesshofer announced his sudden exit. ABB locked Rosengren into a minimum five-year contract to drive expansion in robotics and a revamp that dragged out under his predecessor. ABB is looking to increase focus at its individual businesses and is selling the bulk of
its power-grid division to Hitachi Ltd. for about $6.4 billion, a move pushed by activist shareholder Cevian Capital. Having stepped in as interim CEO, Voser added he plans to stick around for “a few more years” as chairman. Cevian co-founder Lars Forberg said Rosengren has the “right experience and leadership style” to take ABB forward. Investor AB, the company’s largest shareholder, also applauded the appointment.
Björn Rosengren, Image courtesy of: ABB 10
INDUSTRY NEWS
Worcon | September 2019
Investor Backing “We fully support ABB’s new strategic direction with a simplified and decentralized organization,” said Johan Forssell, CEO of Investor AB. “He is the right person to lead ABB in the next phase of the company’s journey.” Forssell highlighted Rosengren’s history of transforming the corporate culture, improving results and delivering value. For his part, Rosengren said in the statement today that ABB needs to have unique technology and a digital solutions portfolio to enhance its productivity. ABB traded 3.7% higher at 18.18 francs in Zurich as of 12:03 p.m., for a market value of almost 40 billion francs ($41 billion). Sandvik shares fell as much as 2.2%, and traded 1.1% lower at 137 kronor.
Long Enough
DNB analyst Olof Larshammar said in a note. Although helped by better markets, the company improved under his watch as Rosengren unpicked an overly centralized corporate structure, implemented extensive performance reviews and benchmarked units against one another, Larshammar added. Björn Rosengren (60), a Swedish citizen, is an international executive and leader of industrial businesses. He has been the CEO of Sandvik, a hightech global engineering group, since 2015. During this time, he has overseen the implementation of a decentralized structure of Sandvik. Prior to that, he was CEO of Wärtsilä Corporation, which manufactures and services power sources and other equipment for the marine and energy markets (2011-2015) and spent some thirteen years (1998-2011) in a variety of management roles at Atlas Copco, a provider of sustainable productivity solutions.
During Rosengren’s tenure, Sandvik shares gained more than 70%. The CEO Sandvik said its board of directors has been “instrumental” for the com- will meet soon to start working on Rosengren’s replacement. pany’s improvement in recent years, finding
“I’m happy to say he committed to a minimum of five years,” Chairman Peter Voser.
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MANUFACTURING
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Laser Technolgy - 12,000 Holes Per Second With 1 µm Diameter The current challenge is to develop new beam guidance and process concepts to distribute the average outputs over the workpiece surface. It is process technology that currently poses the main limitation: Laser systems with high repetition rates require scanners with speeds of up to 1,000 m/s, while laser systems with high pulse energy require new beam-splitting and shaping concepts to distribute the energy. “It’s all about how we apply the power,” said Dr. Arnold Gillner.
using a wet chemical technique. As a result, the DOE’s static beam distribution is much more precise and resistant than dynamic beam-shaping approach based on liquid crystal modulators. For efficient material processing, the laser beam is transformed by a DOE into a beam matrix with many parallel beamlets. Using a scanner system and f-theta optics, the parallel beamlets are then focused on the workpiece and can be moved simultaneously over the workpiece along all possible paths.
Using DOE’s
In micro-drilling, the team from Fraunhofer ILT has achieved extraordinarily high precision. With their new multibeam system, the experts in Aachen are able to create precision holes with diameters of less than one micrometre. The spacing between holes can be reduced to a few micrometres. To increase throughput, they work with a DOE that generates over 200 beamlets.
One option for making better use of pulse energy is the multibeam concept, which involves splitting a laser beam into many beamlets. At the Fraunhofer Institute for Laser Technology ILT, a team has been working on this technology since 2012. Since then, the experts have learned how to use diffractive optical elements (DOEs) for the targeted application of over 200 This way, they have already managed to beamlets in micro and nano-structur- produce over 12,000 holes per second ing. This allows them to obtain precise with an outlet diameter of under 1 µm. results in the sub-micrometre range. For the DOE, the team uses a structured glass surface on which light waves are bent. The surface structure is etched into the glass with extreme precision 12
Image courtesy of: Fraunhofer Institute for Laser Technology ILT
MANUFACTURING
Worcon | September 2019
Mitsubishi Electric CNC Total Care Package Service Mitsubishi Electric Automation announces the CNC Total Care Package service for its CNC systems. The service package is tailored for Mitsubishi Electric’s M8, M7, and M6 Control Series. Your CNC Machine is a critical part of your manufacturing process. Ensure your machine tool is running at optimal levels and maximizing your business potential by implementing Mitsubishi Electric’s CNC Total Care Package. The Total Care Package provides maintenance by combining three existing services: CloudCNC backup, machine tuning, and preventive maintenance. The resulting outcome is increased efficiency and accuracy, and the overall reduction of machine downtime.
Image courtesy of: mitsubishielectric.com
While Mitsubishi Electric CNC Total Care Package service is customized to meet each customer’s machine needs, some of the services will include: Replacing control, servo, and spindle drive fans (if applicable) • Replacing control and home position backup batteries (if applicable) • A machine inspection, including incoming power, power supplies, control contamination, cables, interlocks, ground, and emergency stop operations • Axis and spindle operations inspection, to look for excessive current, abnormal noise, or vibration • Verifying program and parameter uploading/downloading communications • A full comprehensive CloudCNC backup of your machine’s parameters, ladders, and data 13
MANUFACTURING
Worcon | September 2019
Lincoln Electric Is Adding Layers To Its Business Welding products expert Lincoln Electric Co. is moving into additive manufacturing. But the way Lincoln Electric does additive manufacturing makes use of its expertise. Essentially, the company is “welding layer upon layer upon layer upon layer” of metal onto itself, creating predetermined shapes, explained Mike Whitehead, president of Lincoln Electric’s global automation, cutting and additive businesses.
It may sound like a simple concept, but it’s difficult to perfectly layer those welds and make sure the layers are bonding correctly. And Lincoln Electric already makes the products needed for the process: the wire consumable, the controlling software and the automated welding equipment.
Image courtesy of: lincolnelectric.com
“There’s a lot of challenges that go in with that, and there’s really no better company in the world to do it than a company that has expertise in welding,” Whitehead said.
ing for about five years, but it was in more of a research-and-development function, Whitehead noted. Its newly established metal additive manufacturing service business will formalize LinLincoln Electric has been working in coln Electric’s role in the space. The forlarge-scale metal additive manufactur- mal launch will take place in mid-2019. 14
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Previously, Lincoln Electric had been doing work in its automation building and at Oak Ridge National Laboratory. But now, the company is in the process of building out a new additive manufacturing center at 26250 Bluestone Blvd. in Euclid, by the company’s headquarters. Lincoln has a long-term lease for the approximately 75,000-squarefoot building, Whitehead said.
MANUFACTURING tools it needed to transport in order to fix its equipment. Large-scale metal additive manufacturing would let them take one robot that could make what they needed on site, he said. Customers can get their parts in less time - sometimes within days as opposed to months, Whitehead said - and the parts can be made with less waste. Large parts can be expensive to fabricate because they need to start with far more raw material than ends up in the part. With additive manufacturing, the products can be printed close to the final dimensions.
The buildout started at the end of 2018. About a third of the building is already completed with office space and some existing robotic weld cells. Whitehead said more robotic weld cells, where the additive manufacturing is actually done, The products still need some machining will be added in the next three years. after they’re printed, said Whitehead. That’s where the company’s recent Lincoln Electric has a group of about acquisition of Michigan-based Baker 10 engineers working in the addi- Industries Inc. comes into play, allowtive manufacturing space, but White- ing Lincoln to serve as a single-source head said he expects that to ramp supplier for customers. Baker does up quickly as the business expands. both large- and small-scale machining, Whitehead said, often serving the The metal additive manufacturing parts automotive and aerospace industries. being made by Lincoln are large: excavator arms, propeller blades. For ex- “From beginning to end now, we can realample, an excavator arm may be seven ly handle that,” he said. feet tall and 600 or 700 pounds, Whitehead noted. In comparison, products Baker also uses plastic 3D printing in made through metal powder 3D print- its work and can bring that expertise ing tend to be much smaller, he said. to Lincoln Electric. While a lot of what Lincoln Electric has been doing so far There are different benefits to mak- has been creating experimental or proing those large parts in this way. For totype parts, Whitehead sees a lot of example, Whitehead said Lincoln Elec- opportunity in additive manufacturtric had been approached by the mili- ing. And he thinks the large-scale mettary in the past. The Navy was looking al parts market has been neglected. for a way to minimize the number of Lincoln Electric isn’t the only local en15
MANUFACTURING
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tity that sees opportunity in this announcement. Lincoln Electric’s expansion into this space supports Northeast Ohio’s becoming a “center of excellence” for additive manufacturing, said Jay Foran, senior vice president of industry and innovation at Team NEO. Additive manufacturing is one of the technologies Team NEO has focused on supporting in recent years. Being able to provide different types of additive manufacturing with different kinds of materials, from metal to polymer to ceramic, is a benefit to the region.
utive director of America Makes, the National Additive Manufacturing Innovation Institute in Youngstown. This kind of expertise is going to make what he called the “Tech Belt” of Northeast Ohio and western Pennsylvania more competitive. Lincoln Electric is a member of America Makes and has worked on some of the institute’s projects.
Gorham said he hopes to see “Lincoln Electric times 100,” building a deep competency in the state rather than “oneoff capabilities.” He said that’s what will help the state be successful as manAdditive manufacturing, and the com- ufacturing becomes more digitized. panies that are spinning out, starting up or maturing into the space, rep- “So Lincoln Electric’s just on the forefront resents a “huge opportunity for Northof that,” Gorham said. east Ohio,” said Rob Gorham, exec-
Image courtesy of: crainscleveland 16
Worcon | September 2019
MANUFACTURING
Mastercam 2020 - Getting The Best Out Of 5-Axis Technology For Barrel Tools US-based CNC Software, developer of Mastercam CAD/CAM software, has integrated the new Moduleworks 5-axis barrel mill components into its latest Mastercam version, expanding the software’s accelerated finishing technology support. CNC Software says its latest version of the Mastercam CAD/CAM software is now integrated with Moduleworks new 5-axis barrel mill components, which expands its accelerated finishing technology tool support. Mastercam 2020, said to have best-in-class tool management and intuitive user interface, utilises the full productivity benefits of the barrel mill strategies, which now support taper, oval and lens-style tools. The software already uses the full range of Moduleworks multi-axis toolpath generation and simulation technology and the two companies worked closely to ensure a fast, seamless and high-quality integration of the latest barrel mill features. Barrel mill tools are especially useful for cutting parts with steep features like those required in the aerospace, automotive and die/mould industries. According to the company, the barrel shape of the tool generates smaller cusps to deliver a high-quality surface finish, using large step overs that significantly accelerate the machining process. The Mastercam user interface simplifies and optimises the toolpath genera-
tion workflow and adds further productivity and quality enhancing features controlling step-over and step-down parameters that utilise the full potential of the Moduleworks components. As part of the integration project, CNC Software conducted in-house machine trials to rigorously test and optimise the 5-axis barrel mill strategies. Moduleworks is the leading software component provider for the CAD/CAM industry.
Image courtesy of: mastercam.com 17
MANUFACTURING
Worcon | September 2019
Renishaw Collaborates To Produce Unique Surgical Implants Renishaw has announced a collabora- er range of implants, UDH is bringing tion with the teaching University Dental these benefits to its patients and staff. Hospital of Wales. The two are collaborating on the production of implants. AM for production of implants Global engineering technologies company Renishaw is collaborating with University Dental Hospital of Wales (UDH), Cardiff, to help overcome some of the challenges associated with surgical implants. UDH has previously used Renishaw’s additive manufacturing (AM) services to manufacture a series of dental products, including cobalt chrome frameworks. However, the hospital has also been using AM to produce custom maxillofacial implants and surgical guides.
“AM allows hospitals to achieve high precision when producing implants,” explained Ed Littlewood, Marketing Manager of Renishaw’s Medical and Dental Products Division. “By collaborating with Renishaw, UDH can develop their maxillofacial implants further, seeing improvements with each case and helping a wider range of patients and surgeons across different departments.”
“Several hospitals are reaping the benefits of additive manufacturing in implant production,” explained Roger Maggs, SeBy using custom-made devices, hos- nior Chief Dental Technologist and Head pitals can reduce surgery time con- of Dental Technology Services at UDH. siderably as, unlike standard ‘off the shelf’ implants, each device is de- “We have the advantage of havsigned to fit the patient. Standard im- ing worked with Renishaw for three plants may need modifications or the years in the dental field. This has put patient’s surrounding bone may need us ahead of the game and in a posiextra trimming for the device to fit. tion where we can now start thinking about producing more unique deNot only is this highly likely to improve signs that will benefit our surgeons. patient experience and reduce the risks related to extended time under “The staff at UDH are also benefitanaesthesia, but it can also save sig- ting from the partnership,” continued nificant time in surgery and therefore Maggs. “The team are involved in evcost. By using AM to produce a wid- ery stage of the development of new 18
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MANUFACTURING
technologies for medical applications, including inputting CT data and making and manipulating digital models ahead of surgery. It is admirable that our staff are at the forefront of the latest medical technology. This fact has enabled the evolution of some very talented technologists, such as Luke Maxwell and Paul Clark, who must be considered leaders in this technology.� UDH treats 100,000 patients per year and acts as a teaching hospital for Cardiff University’s School of Dentistry. It is the only teaching dental hospital in Wales and provides unique and important leadership in dental research, teaching and patient care. Renishaw is fast becoming a major supplier of dental and medical AM solutions. The company is the only UK manufacturer of metal AM machines and works with hospitals across Europe to develop innovative manufacturing that ultimately benefits surgeons and patients. Furthermore, the uses of AM technology are a testiment to the versatility of AM processes and their adaptability. Image courtesy of: Matt Revell
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MANUFACTURING
Worcon | September 2019
YASKAWA Cockpit Industry 4.0 Software Platform Now Available In EUR 1.0 Introduction to the advantages of kit (SDK) also enables experienced users to further customize the software. Industry 4.0 At the Hannover Messe trade fair, YASKAWA responded to the vast range of concepts and visions for the future of Industry 4.0 with a fully functional software solution: The new EUR 1.0 version of YASKAWA Cockpit, the central software platform for networked production environments, is now available for customers. Image courtesy of: Yaskawa
Pilot customers’ requirements and user feedback were systematically incorporated into development of EUR 1.0, the market-ready, more advanced version of YASKAWA Cockpit. The results include a redesigned graphical user interface to make the software even more user-friendly, and a new, integrated calendar function for scheduled preventive maintenance measures.
Industry 4.0 in Real Time
Presented for the first time at the last Hannover Messe trade fair, YASKAWA Cockpit allows users to collect and analyze relevant process and system data from networked production facilities in a scalable database in real time, or provide it for external further processing. The data is visualized directly and clearFirst and foremost, however, the plat- ly in the software platform. For this platform offers industrial manufactur- form, the company draws on technology ing companies of all sizes a toolkit for such as the OPC UA standard interface. application-specific mapping of their individual production environments. For example, users can define their own key performance indicators (KPIs) based on preset tables, diagrams or trend graphs, and link them to data sources. The software development Image courtesy of: Yaskawa 20
MANUFACTURING
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YASKAWA Cockpit can visualize live data from production. The live data collected over a certain period of time represents the performance of a system, which can be used to draw valuable conclusions about possible weak points. YASKAWA Cockpit predicts the system’s future performance based on the performance data. At the same time, the software generates schedules for preventive maintenance and required measures to keep production running as smoothly as possible. In the event of a malfunction, the system offers valuable targeted information to allow a
fast return to functioning production. The data can also easily be transferred to existing ERP, MES, big data or AI environments in compliance with the highest security standards to allow sound decisions to be made on this basis. YASKAWA Cockpit works with data from YASKAWA robot production facilities and drive components, as well as many other installed components such as PLCs, safety technology and sensors from other manufacturers, as long as these components meet the communication standards (ideally OPC UA).
Image courtesy of: Yaskawa
The “i³ Mechatronics” solution concept YASKAWA Cockpit is a key element of the “i³ Mechatronics” solution concept for Industrie 4.0. In this concept, YASKAWA combines conventional mechatronics, information and communication technology with digital solutions such as artificial intelligence, big data
and the Internet of things. “i3” stands for integrated – intelligent – innovative. This integrative approach comprises both existing and newly developed Motoman robots, products and solutions for drive and control technology, and in-house software solutions. 21
AUTOMATION
Worcon | September 2019
BMW Introduce ‘Measurement Cell’ For Quality Control Of The Future As Industry 4.0 introduces a new era of digitization, BMW has developed a new and innovative, fully automated inline measurement cell for quality control. Featuring Laser Radar, the multiple measurement cell combines a whole range of industry leading measuring solutions for full geometric inspection of vehicle body parts. In the past, body-in-white measurements had been performed in two phases. Firstly directly on the production line with low accuracy sensors to monitor the process, and secondly in a dedicated metrology room with offline CMMs and other measurement systems. This is typically very time consuming and requires extra manual work for fixturing and alignment leading to a disjointed process. The inline measurement cell features four robots and a range of innovative measurement methods, including the Laser Radar. The Laser Radar is used to measure the geometry of the car body to ensure all 300 bolts are present and correctly positioned in the floor of the car body in only 20 minutes. The process of the inline measurement cell greatly improves productivity and enables a higher quality output. Until recently sampling control vehicles had to be outsourced from ongoing production and controlled in a separate measuring room using various measur22
ing methods, the multi-cell is fully integrated into the production flow of the bodies - and works around the clock, seven days a week if required. It offers tremendous advantages in terms of flexibility, time and cost, but also an even more efficient quality control. Today, within 30 minutes, a fully automated complete measurement of the entire vehicle body is possible. In addition, the measuring system, in which the plant has invested over two million euros, has been designed to be extremely flexible: all vehicle models manufactured in BMW Dingolfing can be inspected in this way. The cell thus plays an important role in ensuring the quality of new vehicle model introductions.
Image courtesy of: BMW
AUTOMATION
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Virtual Image Vehicle Body In 30 Minutes The space-saving measuring cell with its four measuring robots combines various innovative measuring methods: Bolt and geometry measurements are carried out using laser radar technology. Body floor groups can be checked in just 20 minutes for the completeness and positioning of the approximately 300 bolts. Finished bodies are fully digitized within 30 minutes by using 3D surface scanning technology. This virtual model delivers in seconds a complete picture of the geometric state of the body. Each robot checks 210,000 measuring points per second, ten gigabytes of evaluation data is collected per body. The respective manufacturing expert receives the measurement results online, in real time. If required, the employee can initiate targeted measures in order to further optimize the body
Image courtesy of: BMW
and ensure premium customer quality. A unique highlight of the system is eight additionally integrated small robots that fully automatically check gap and offset measurement. During the measurement, they align the doors and flaps of the body in accordance with the position of the attachments previously determined by laser radar.
Cross-Technology Measurement Strategy The aim of the quality specialists in the BMW Group Dingolfing plant is always to realize optimum vehicle quality throughout the entire production process. The multi-purpose cell in the Dingolfinger body shop makes an important contribution to this. Integrated into a cross-technology measurement strategy at the site, the measuring cell is connected to corresponding gap and offset measurements in the paint shop and assembly.
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AUTOMATION
Worcon | September 2019
Kaspersky: Over Half Of Security Incidents Caused By Employee Errors According to a new report from Kaspersky, 52% of incidents affecting operational technology and industrial control system (OT/ICS) networks last year were caused by employee errors or unintentional actions. The report, “State of Industrial Cybersecurity 2019�, found this issue to be the result of the growing complexity of industrial infrastructures and a shortage of professionals who understand how to detect new threats as well as low awareness among existing employees.
Kaspersky State of Industrial Cybersecurity 2019 Report, Image courtesy of: Pixabay
According to the survey, digitalization of industrial networks and adoption of Industry 4.0 standards are a priority for many industrial companies. Four out of five organizations (81%) consider operational network digitalization to be an important or very important task for this year. A majority (87%) of respondents confirmed that OT/ICS cybersecurity is becoming a top priority for industrial companies. Despite stating it as a priority, only just 24
over half of companies (57%) have allo cated budget for industrial cybersecurity. In addition to budget constraints, there is also a question over skilled staff. Organizations are not only experiencing a lack of cybersecurity experts with the right skills to manage protection for industrial networks, but also are worried that their OT/ICS network operators are not fully aware of the behavior that can cause cybersecurity breaches. In almost half of the companies (45%) surveyed, the employees responsible for IT infrastructure security also oversee the security of OT/ ICS networks. Although operational and corporate networks are becoming increasingly connected, OT and ICS specialists can often have different approaches (37%) and goals (18%) when it comes to cybersecurity. Almost half of companies (41%) are ready to connect their OT/ICS network to the cloud using preventive maintenance or digital twins.
AUTOMATION
Worcon | September 2019
Haas Automation Is Now Available On MachiningCloud Haas CNC machine tool product data is now available on MachiningCloud. The files are in GDML format and contain simplified 3D models of the machine tool along with the machine’s kinematics making them ready for use in your CAM and simulation software. For this initial release, GDML product data is available for the following machines: VF-2, VF-2SS, VF-3, VF-3SS, VF-4, VF-4SS, VF-5/40, VF-5SS, VF-6/40, VF6SS, VF-7/40, UMC-750, UMC-750SS, Mini Mill, Super Mini Mill, Mini Mill 2, Super Mini Mill 2, Mini Mill-EDU, VM-2, VM-6, EC-400, ST-20Y, DS-30Y. The Haas MachiningCloud partnership utilizes the convenience and reach of MachiningCloud’s technology and enable customers to easily gather the product data they need to drive their CAM, Simulation and other data-hungry shop software. MachiningCloud
simplifies the way customers gather the 3D CAD Models for their Haas CNC machines, workholding and cutting tools by providing them in one place and in the formats needed for today’s shop software. Included with the product data of more than 750,000 cutting tools, beyond the 3D CAD models, MachiningCloud also provides the descriptive information needed for part programming, and the usage information, including speeds and feeds, needed to run the selected cutting tools on the customer’s Haas machines. While Haas Automation designs and manufactures CNC machine tools for the metalworking industry, MachiningCloud is a product data provider for world-leading cutting tool, CNC machine tool, workholding, and metrology manufacturers.
Image courtesy of: Haas 25
AUTOMATION
Worcon | September 2019
Using AI To Predict CNC Machine Spindle Issues Before They Are Issues Artificial intelligence (AI) is poised to make industrial equipment predictive maintenance truly predictive. enabling any maintenance tasks to be more conveniently scheduled. Joe Sanders, process development coordinator for Mazak, says the key difference between the company’s AI-based system and other spindle monitoring technology is that the SHMS is not based on threshold data. That would be the case in which an alert would be sent when a specific spindle vibration frequency is detected that would suggest damage has already or is very soon to occur. Instead, he says the Image courtesy of: Mazak SHMS can detect issues months before they happen, providing time to A machine tool builder is using artifi- schedule spindle repair or replacecial intelligence technology to predict ment at the most convenient time. when a spindle problem might occur, so shops can better prepare for and schedule necessary maintenance. One of examples is Mazak’s AI-based Spindle Health Monitoring System (SHMS) that is currently an option for its HCN horizontal machining centers (HMCs). Mazak’s SHMS was created to enable shops to take spindle maintenance measures long before spindle or spindle bearing damage occurs, minimizing downtime and 26
Image courtesy of: Mazak
AUTOMATION
Worcon | September 2019
Image courtesy of: Worcon
Data crunched from one year of extensive spindle destructive tests led to the creation of the SHMS’s AI spindle neural network self-organizing maps, spindle-specific signatures that can determine the difference between good vibrations and bad ones. Algorithms created from these maps predict how spindles will degrade over time (barring a crash) while displaying remaining lifespan as a percentage. This differs from estimating a timeline of a spindle’s life, because we don’t know if a machine will be used for light-duty work, heaving cutting, 24/7 opera-
tion or any other possible scenarios. The SHMS’s primary components include vibration and current sensors, a data acquisition module, and an industrial computer to process the SHMS algorithm. Upon installation, a onehour modeling test maps that particular spindle’s operating signature. After that, users can perform periodic 60-second tests that compare data to the spindle model. When cycle times are sufficiently long, we suggest performing a test after each part is completed. However, this likely is not necessary for parts with relatively short cycle times.
The SHMS is available as an option on Mazak HCN machines equipped with the company’s Smooth CNC and as a retrofit for those machines with Matrix CNCs. 27
AUTOMATION
Worcon | September 2019
Robotics Trends Taking Over Manufacturing Manufacturers incorporation and adaptation of robotics has developers at work right now, and their innovations likely to influence manufacturing sooner than you expect. The accelerated pace of automation and especially robotics equipment - has impacted manufacturing substantially in the past decade, and these developments show no signs of reversing or slowing down. Here are six trends in robotics technology that are underway right now, and are likely to influence manufacturing operations in the near future.
More reliance on mobile cobots
Image courtesy of: American Machinist
People in manufacturing are accustomed to collaborative robots (“cobots�) that work around or together with humans. There’s a newer trend involving mobile cobots - lightweight and compact enough to move between worksites or areas of factories. A 2018-2026 market analysis values the global cobot market reaching more 28
Image courtesy of: Kuka
than $4.4 million by the end of the period, indicating a CAGR of 33.4%. A Kverneland Group factory in Denmark produces agricultural machinery and uses a mobile cobot to move pallets of components around the factory. It relies on the robot so much that this model of cobot travels the equivalent of 30 miles in any 24-hour period. The machine is the same size as a pallet, and when fitted with a lifter, it handles more than 1,100 lbs. at a time. Kverneland relied on trucks for internal deliveries, before adopting the mobile cobots. However, due to the constant movement of people around the factory, there were various minor injuries incurred by human workers collisions with those vehicles. The cobots should minimized that problem, significantly.
Worcon | September 2019
AUTOMATION
Softer robots Work is also underway to build robots with softer components. When covered with a material like plastic or rubber that could endure the stress of a robot’s constant movement, such machines would present less danger to humans that come into accidental contact with them. Some of the experiments happening now involve building soft, animal-inspired robots based on things like an elephant’s trunk, caterpillars, or worms. These are early-stage projects, and notably the progress to date has involved robots that lift only comparatively light loads.
Image courtesy of: Ryan L. Truby/Harvard University
However, there’s one example of a robotic arm that weighs about 1 kilogram and can lift about five times that weight. If scientists figure out how to strike the all-important balance between softness and power, the influence on industrial robotics applications could be consequential.
Heavy-duty robotic arms Heavy-duty robotic arms can keep the workflow moving smoothly and prevent accidental injuries resulting from human fatigue or strain. Market analysts predict the demand for heavy-duty robotic arms will grow to $14.7 billion by 2026, representing a combined annual growth rate (CAGR) of 4.73% for the forecast period beginning in 2017.
Image courtesy of: Fanuc
Over that time, people who work with robots will see more opportunities to use these types of arms in their workplaces. One example is the Fanuc M-2000 Series robots. The arms on these machines can lift 2.3 tons, and the developer has demonstrated the arms’ strength, reach, and functionality by lifting entire cars as an example for a way to use them. 29
EMO FAIR
Worcon | September 2019
Belotti S.P.A. FLA Series
5-axis CNC machining centers for high-speed milling of aluminum and resin moulds and trimming of plastic and composite materials
Image courtesy of: Belotti
FLA means maximum productivity and flexibility into a series of high-speed, movable bridge machining centers able to answer the manufacturing needs of any specific application filed. Among the end-users, there are internationally well-known producer of the automotive and aerospace sectors as well as suppliers of plastic components and moulds.
X -Y -Z axis acceleration represent the necessary requirements for trimming plastic and composite materials as well as for machining light alloys and resin moulds. Several options, such as modular tool changers (8-48-position) and automated loading/unloading systems (rotary tables or parallel shuttles), could also improve the operating time and efficiency, allowing quicker ma80 m/min rapid speed and up to 0.8 g of chining center’s setup and equipment. 30
Worcon | September 2019
EMO FAIR
FLU Series
5-axis CNC machining centers for high-speed milling and trimming of composites and aluminum FLU is the compact and flexible solution for composite and aluminum that can guarantee constantly high performances in several application fields such as automotive, aerospace, design, medical, pattern- and mold-making.
ty, this Belotti range assures enhanced accuracy during high-speed milling operations and long-lasting stability, thanks to its monolithic structure. Equipped with a motorized, suspended bridge sliding on the two extremities, this solution has also a particular Following the ultimate goal of helping design giving easy access of the total customers increasing their productivi- working area through over-head crane.
Image courtesy of: Belotti
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EMO FAIR
Worcon | September 2019
Chiron • Premier: the double-spindle CHIRON DZ 25 P five axis with 800 mm spindle distance • Automated and highly-productive: new variants of the 16 series • New: STAMA MT 733 one plus - trend-setting in complete machining
Image courtesy of: Chiron
CHIRON: new variants of the 16 series and world premier of DZ 25 P five axis
The highly-productive 5-axis double spindle machining center has already convinced those visiting the CHIRON OPEN HOUSE because of its unique At EMO, CHIRON is combining the new combination of dynamics and precision. FZ 16 S five axis with VariocellPallet pallet automation for the first time. The The CHIRON DZ 25 P five axis is celebratnew automation solution is aimed at ing its world premier at EMO, designed machining small batch sizes and com- for productive machining of large complex workpieces autonomously. Fur- ponents in the automotive industry and thermore, the new DZ 16 W five axis will aviation. With the 25 series, CHIRON is be presented live in action in Hanover. achieving a combination of productivi32
Worcon | September 2019
Image courtesyof: Chiron
er been seen in this class before. With a spindle distance of 800 millimeters, the DZ 25 P five axis is predestined for double-spindle machining of aluminum structural components. It is operated and loaded on separate sides, which allows ideal access to the work area and a good insight into the process. The machine only requires a small amount of floor space thanks to its compact design. Furthermore, its optimal dynamics make it a compelling offering in this competitive environment. Visitors can experience the DZ 25 P five axis live in a new light in CHIRON’s interactive showroom.
EMO FAIR joy its world premier in Hanover. Like all models of the MT 733 series, it has a gantry design: this allows the machining process to gain a significant amount of stability on a thermal, mechanical and static level. The Galaxie® drive system in the B-axis bolsters this effect with its extreme power density, stiffness and positioning precision. The final result is highly dynamic and highly precise milling/turning and drilling operations, simultaneous 5-axis machining and integrated automation. These are the best conditions for a successful “first part good part” strategy. The MT 838 TWIN, presented by STAMA, is a HSK-A100 milling and turning machining center that is unique in double-spindle milling and turning of chuck components with a spindle distance of 600 mm.
STAMA MT – trend-setting in complete machining for complex workpieces that are difficult to machine Whether from the bar or the chuck, STAMA keeps setting new milestones in complete machining with the MT 7 and MT 8 systems’ milling and turning machines offering innovative machining solutions. Since September 2018, STAMA has been offering new machining centers for 6-side milling and turning in one set-up in the form of the MT 733 series, especially for complex components and materials that are difficult to machine. The MT 733 one plus will en-
Image courtesy of: Chiron 33
EMO FAIR
Worcon | September 2019
Hainbuch GmbH Centrotex S - Hainbuch launches small quick change-over interface on the market! exchanged for another clamping device in less than a minute. Thus long set-up times are a thing of the past.
Easier operation
Image courtesy of: Hainbuch
Hainbuch has set new standards with the Centrotex quick change-over interface. The proven system is now also available in a version for smaller spindles. Thus, today Centrotex S is the smallest system available on the market for setting up clamping devices in a matter of seconds. With its diameter of just 224 mm, it is the ideal quick change-over system for machines with a small work space.
The smallest Centrotex version does indeed incorporate the proven technology of its big brother, however it is clearly superior in terms of convenience. The Centrotex S is actuated via just one radial locking screw and ergonomic operation has been significantly improved, thanks to the fewer tightening turns required. In addition, the Monteq changing fixture offloads the machine operator and contributes to a faster clamping device set-up.
No compromises in performance With repeatability to ≤ 0.002 mm on the interface – without having to align – the latest version of the Centrotex quick change-over system can also meet the most rigorous requirements. The machine adapter is mounted on the spindle, and the clamping device equipped with the adapter counterpart can be 34
Image courtesy of: Hainbuch
EMO FAIR
Worcon | September 2019
Image courtesy of: Hainbuch
Key advantages:
Benefits:
• Interface between machine and clamping device • Only one radial locking screw • Suitable for spindle nose KK5, KK6, AP140, and AP170 • Repeatability to ≤ 0.002 mm on the interface - without having to align • Ergonomic handling • Resistant to contamination • For easier handling, the Monteq changing fixture can be implemented for heavy clamping devices
• Clamping device change-over in less than one minute • No compromises in the selection of clamping devices, job-oriented manufacturing • No loss in rigidity, in comparison with clamping devices that are bolted directly on the machine • Higher machine availability • Short return on investment
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EMO FAIR
Worcon | September 2019
Heller
Image courtesy of: Heller
“Over many years, HELLER has worked on developing a partner network of suppliers from the automation sector. In addition, HELLER has in-house automation experts providing extensive know-how. The engineering expertise for evaluating the suitable automation solution extends over several technical departments specialising in mechanics, fluidics, electrics, hardware and software,” explains Jochen Kern, Head of Application Industrial at HELLER.
provided by the suppliers Fastems and Fanuc. Moreover, digitisation will be one of the key topics at EMO 2019. After the potentials for increasing the productivity of machine tools using conventional means have almost been fully exploited in recent years, HELLER’s goal is to combine information and production technology using Industry 4.0 solutions to create added value. The ‘HELLER4Industry’ concept comprises complementary machine functionalities, on-demand services and expanded service Two of the exhibits at EMO will therefore solutions, linking digital solutions with be equipped with automation solutions the customers’ manufacturing reality. 36
Worcon | September 2019
EMO FAIR
5-axis machining centre model HF medium to large batch sizes. At EMO 2019 in Hannover, HELLER will place 3500: productivity in five axes With the 5th axis provided by the workpiece, their powerful dynamics and the horizontal spindle for shortest chip-tochip times, the 5-axis machining centres from the HF series deliver a significant reduction in idle times. With these machines, HELLER guarantees high productivity in series production and for universal application when machining
the spotlight on model HF 3500, first presented in 2016 and at EMO 2017 together with the HF 5500, providing a work envelope of 710x750x710 mm and a maximum pallet load of 550 kg. Model HF 3500 is equipped with an automation solution using a collaborative robot type CR-15iA supplied by Fanuc, equipped with a Schunk Co-act gripper.
Image courtesy of: Heller
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EMO FAIR
Worcon | September 2019
high rigidity also in case of high loads. Combined with the 5th axis provided by the workpiece for dynamic 5-sided and simultaneous 5-axis machining, HELLER’s typical horizontal spindle, ensuring quick tool changes and short idle times, offers substantial advantages as far as productivity is concerned. The HF provides a wide choice of spindles to suit different applications. Image courtesy of: Heller
The HF series comprises 5-axis machining centres proving once again that HELLER DNA like productivity, performance, reliability and availability form the foundations of each and every new development conceived in Nürtingen. The HF series combines proven qualities with innovative features. This is also true for the kinematics with three linear axes in X, Y and Z, equipped with absolute measuring systems and two direct driven, dynamic rotary axes in A and B integrated into a swivel rotary table. What makes them dynamic is the fact that the high speed of the A and B rotary axes is achieved through minimised mass moment of inertia and the use of direct drives. Optionally, the powerful dynamics can be increased further with the ‘Speed Dynamics Package’. Contrary to comparable machines on the market, HELLER has equipped the new series with a counter bearing as a unique selling point. The use of the counter bearing in combination with a YRT bearing results in a 38
Moreover, the HF series provides large workpiece interference contours. Contrary to conventional 5-axis machining centres, HELLER’s concept is not only based on single-part clamping, but provides the possibility of multiple clamping or the clamping of large components. With the HF series, HELLER is also presenting its new HELLER Operation Interface, the new operating panel with 24” screen technology and touch controls, quick access technology in the control and XTENDS – optional expansion applications to support the user.
Image courtesy of: Heller
EMO FAIR
Worcon | September 2019
Liebherr
Image courtesy of: Liebherr
In hall 26, booth A90, visitors can discover innovations in the field of gear technology. With the LC 80 WD worm milling machine, Liebherr offers a solution for the productive and economical production of worms that is perfectly suited for series production of automotive steering worms and for a variety of industrial worm applications. In addition, the worms can be chamfered or brushed during machining. The LK 180/280 DC is the new generation of gear skiving machines, which is characterized by a machine-integrated tool changing system with up to 12 storage locations. In addition to chamfering during machining, this offers the option of additional SkivingPlus functions such as turning,
drilling, milling or measuring. Liebherr also has a lot to offer in the field of shaping: The LS 180 E gear shaping machine with electronic shaping head stands out due to its enormous flexibility, as it can machine straight and helical gears in one clamping device and can therefore shape several gears on one workpiece. Anyone who appreciates fast setup and short idle times during generating grinding will be interested in the LGG 180/280 generating gear grinding machine. This series offers topological generating grinding with galvanically bonded CBN tools. The dressing-free grinding tools combine high tool quality, simple handling and a very long tool life. 39
EMO FAIR
Worcon | September 2019
Tezmaksan Makina Turkish technology which ensures 24-hour working without any operator TEZMAKSAN which will introduce its two domestic and national products, Cubebox and Kapasitematik which it has developed with its new generation technology to the sectoral professionals within the fair scope aims to have a word in the world with its technologies increasing the efficiency. Cubebox which is defined as the R&D and innovation excellence increases the speed of the production in cooperation with the machinery-operator in the smart factories. Cubebox presents 24-hour operator-free and fault-free system to the companies. Cubebox which pro-
vides 50 percent of efficiency for the companies during the night shifts is drawing attention because of being in compliance with all CNC benches with its standard structure. The software which is 20 percent more affordable compared to the special robot systems for the companies takes only one day to be installed and activated. Besides, parts and sections might be replaced without requiring any robotics programming knowledge thanks to the system. TEZMAKSAN aims to realize system export for 5 million Euros annually to Europe in 2025 with Cubebox.
Export aim is 1 million Euros with Kapasitematik Kapasitematik, another completely domestic product of Tezmaksan ensures the communication between machinery and operators in 7/24. Aiming to prepare Turkish industry for Industry 4.0 with Kapasitematik, TEZMAKSAN presents the easiest way to increase the facility efficiency. TEZMAKSAN aims to realize software export for 1 million Euros in 2023 with Kapasitematik.
Image courtesy of: Tezmaksan 40
Worcon | September 2019
EMO FAIR
WFL Increasing productivity with the MILLTURN The MILLTURN will be centre stage for WFL at this year’s EMO. Three demonstration models will be on show at the trade fair from 16 to 21 September: an M30-G MILLTURN / 1800mm with automation cell, an M50-G MILLTURN / 3000mm with a focus on turbine blade machining and an M80X MILLTURN /3000mm with an integrated diode laser. In addition, the spotlight will also be on pioneering monitoring and recordImage courtesy of: WFL ing functions for all machine processes. To complete the package, WFL has de- of gripper systems and gantry loaders veloped intelligent tools and integrated with peripheral transport and storsensors for the MILLTURN machines. age systems for workpieces, tools and jaws. Automation is even becoming increasingly essential to provide productivity benefits in small-series production. In cases where there is a lack of staff for night and weekend shifts, automation can be used to increase machine utilisation and therefore remedy the problem of staff shortages. Image courtesy of: WFL The M30-G MILLTURN / 1800mm is also equipped with a Kuka KR Quantec roFlexible automation solutions bot, which has a load bearing capacWFL Millturn Technologies and its sub- ity of 120 kg and a nominal working sidiary FRAI Robotic Solutions have de- radius of 2896 mm. The machine also cades of expertise and offer a variety uses an automatic gripper exchange of automation variations for different system with 2 different gripping heads requirements to maximise productivi- and a workpiece tray for chucks and ty. The comprehensive range of prod- shaft components. Another further ucts includes straightforward loading highlight is the integrated visualisausing articulated robots, a wide variety tion of the cell on the machine display. 41
EMO FAIR
Worcon | September 2019
Erdwich Zerkleinerungs-Systeme GmbH The formation of removal material in the form of swarf is inevitable in metalworking processes such as turning, drilling, milling or grinding. The mostly very long, spiral and sharp-edged metal swarf has to be collected outside the work areas in order to be delivered as scrap to recycling companies for recycling or to be processed in the company’s own facilities. Due to the large volume of the balls of swarf and the swarf itself, however, intermediate storage requires a lot of space, which can be a problem especially in smaller companies. The recycling special-
ists at Erdwich Zerkleinerungs-Systeme GmbH have therefore set themselves the task of designing single-shaft and twin-shaft shredders for as many space conditions and metallic challenges as possible. The portfolio ranges from plants that can be integrated directly into the production process to standalone solutions. At the trade fair EMO 2019 in Hanover, Germany, Erdwich will present a selection of its portfolio of single-shaft shredders M400/1- 400 and M600/1-600 as well as twin-shaft shredders M350/2- 410 in the field of demand-oriented swarf shredding.
“According to our experience, it is primarily the volume that poses the greatest problem during storage and further processing of the balls of swarf,” explains Harald Erdwich, Managing Director of Erdwich Zerkleinerungs-Systeme GmbH. “The space requirement for the installation of a suitable shredding plant, which must meet the local conditions both in terms of dimensions and in terms of throughput and the material to be shredded, ranks directly in second place”. Since both the operational floor space and the swarf itself represent valuable resources, it is necessary to find the optimum solution for each application. The range of applications extends from small wastes in laboratories, which have to be shredded in interval operation, to 24/7 continuous use in the automotive industry with correspondingly high throughput quantities. “The plants can be configured either for pure volume reduction or perfect breaking-up of materials, so that the metal swarf can be further processed by briquetting or oil separation in a centrifuge,” explains Erdwich.
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Single-shaft solutions for “everyday swarf” “Our single-shaft shredders are suitable for processing the metal swarf that accumulates in everyday operations during machining,” explains Erdwich. “Due to the special pressure angle, the swarf and metal pellets are drawn in and shredded at the stator by the individually inserted, removable knife disks on the cutting rotor.” As with all Erdwich systems, the knives of the M400/1-400 and M600/1600 single-shaft shredders shown at the EMO are made of fully hardened steel and can therefore be reground several times, which significantly increases their service life. Replacing individual knives is thus also possible in a short time. The particle size and the throughput of the machines are determined by the various possibilities of inserting the knives on the cutting rotor as well as individual perforated sieve geometries. Depending on the type of swarf and appearance, throughputs of 70 to 1,650 kg/h are possible with the single-shaft shredders from Erdwich.
EMO FAIR shaft machines are also better suited for continuous throughputs of large volumes and quantities of up to 4,000 kg/h,” Erdwich explains. Depending on the material, the cutting gear geometry of the twin-shaft shredders can also be perfectly configured using adapted blade shapes and individual knife insertion options on the hexagonal shafts. Due to the variability of the cutting gear, the optimum feeding behaviour is generated for each material in order to achieve the highest performance. In addition, a specially developed stripping system with self-cleaning effect ensures that the metal swarf does not wrap itself around the shaft making it necessary to interrupt operation to remove the swarf. A PLC control with automatic reverse and cut-out control protects all single- and twin-shaft shredders from Erdwich from damage due to overload or massive parts.
Greater cutting force due to twinshaft design Thanks to their higher cutting force, twinshaft shredders such as the M350/2410 are suitable for shredding larger quantities of swarf or swarf with large cross-sections. “In the case of special chip geometries, the force of a single-shaft shredder may not be sufficient to achieve the desired result,” says Erdwich. “Twin-
Image courtesy of: Erdwich 43
INTERVIEW
Worcon | September 2019
100 Years Of Existence Is The Quality Assurance Of The Hoffmann Group On the occasion of the 100th anniversary of the Hoffmann Group, we talked with Mr. Marko Gajsak, Sales Director, from the company ROTOMETAL ALATI d.o.o. which became a partner of HoG in 2010. Can you tell us something about the history of the company and how it is organized? The ROTOMETAL group is divided into 3 parts: • metalworking - ROTOMETAL d.o.o., • wholesale of fastening technique ROTOMETAL-ING d.o.o., • wholesale and representation of i-dustrial tools from Hoffmann Group ROTOMETAL ALATI d.o.o.
Image courtesy of: ROTOMETAL Group
Everything started in 1986 as a metalworking craft, and in 1990, Rotometal d.o.o. was founded. By establishing the company ROTOMETAL PROMET d.o.o, in 1995, the group is expanding its activities and wholesale of fastening techniques and becomes one of the largest wholesalers of this assortment in the Republic of Croatia. In 2010, ROTOMETAL Group re-ex44
panded its activity on wholesale and representation of industrial tools, and in 2011 a new company ROTOMETAL TOOLS d.o.o. was founded. In 2016, a new company ROTOMETAL-ING d.o.o. which continues the activity of Rot-metal promet and extends it to the countries in the region of Bosnia and Hercegovina, Serbia and Slovenia. How many employees do you have? Rotometal Group currently employs 120 people, of which 50 are in metal processing, 35 in the fastening materials department, which is also the 2nd largest distributor of screwdrivers and fittings in Croatia, and 35 employees in the tooling department. In which sectors are you represented as a machine-processing company and what kind of machinery do you have? Rotometal d.o.o does machining and processing of metals. It is mostly represented in the electrical industry and shipbuilding. Today, the company offers a complete service thanks to the equipment it has from CNC cutting (gas and plasma), CNC bending and cutting (electro-hydraulic), machining – classical and
Worcon | September 2019
INTERVIEW
CNC, welding – manual and robotic, industrial cleaning and metal protection. Our CNC machine park has more than 30 machines, and the total machine park has more than 50 different machines.
month in Samobor (ToolTruck event), where we will present the latest industrial innovations and tools for 2020!
Can you tell us more about your partnership with the Hoffmann Group? The Hoffmann Group, which we represent is the largest tools sales compay in Europe and always in the first three in the world. The cooperation started in 2011 after the Slovenian company Merkur, who represented it before us, issued a letter of insolvency and lost the representation rights in the Republic of Croatia.
In 1936, his son, Franz Hoffmann, joined the company and for the first time combined the tools of various manufacturers to create a catalog related to the company. It was then that the idea for Hoffmann’s catalog was born.
History of the Hoffmann Group The company was founded in Our specialty is welding and processing 1919 by Josef Hoffmann in Muof parts in the electrical industry, es- nich, which was similar to ours, pecially generators and transformers. doing welding and locksmithing.
In 1952, the first fully-produced, designed and printed catalog is issued, which contains the entire range of products. The catalog is intended as a “reference with technical advice” for clients, but also for company employees. “Tool That same year, ROTOMETAL ALATI take Bible”, as it is still called today, is orange on a partnership that we nourish today. and is published every year since 1978. ROTOMETAL TOOLS d.o.o. is one of a total of 18 Hoffmann Group partners. Since 1973, with the introduction of the After our excellent results, this coop- brand GARANT - premium tool from Hofferation further expanded to the coun- mann Group, Hoffmann is no longer only tries in the region, and companies in a trader, but also a tool manufacturer. Bosnia and Hercegovina and Serbia The products impress with their innovawere soon opened. This year, on the tion, functional design and top quality. occasion of the 100th anniversary of HoG, with our partners, we are orga- GARANT cutting tools since 2001 are nizing a big event last week in the 9th constantly found in the TOP 5 largest
Image courtesy of: Hoffmann Group 45
INTERVIEW
Worcon | September 2019
hard metal cutting tools manufacturers today a system partner that offers in Germany. a complete service to its customers. In 1983, the brand HOLEX was present- Can you highlight the services the ed, offering customers good industrial group makes the difference between quality at an attractive price. the competition? I would cite three main competencies: In 1993, based on the cooperation with German partners, the Hoffmann Group 1. TRADE is founded. Hoffmann Group offers the widest range of products on the market with the most State of the art logistics powerful logistics for reliable tooling. In 2009, Hoffmann Group opens its We own the largest warehouse in Eulogistics center in Nuremberg - now rope, where there are always more than the largest and most efficient logis- 70,000 tools worth more than 120M €. tics center in the industry anywhere TÜV certification guarantees that 99% of in Europe, size 40,000 m2. In order to the products are in stock and that there maintain its state-of-the-art logistics will be no errors in delivery. So fast and standards, in 2018, the company be- efficient logistics sends over 60 000 pogins construction of the LogisticCity. sitions per day. In addition to its brand The new logistics center will be more tools, Garant and HOLEX, Group repthan the “only” warehouse and marks resent the world’s leading 500 brands. the first step towards digital-connected logistic operations with the total space 2. PRODUCTION of 125 000 m2. LogisticCity thus em- In order to achieve the competence bodies Hoffmann’s competitive spirit. in the production of the tool, GARANT is developing in constant dialogue Hoffmann Group today? with customers and leading world inToday, the Hoffmann Group has 4500 stitutes. It is produced in the stateemployees, 1.4 billion euros of annual of-the-art factories in the world and turnover, it is represented in 65 coun- it is tested in 12 of its own test centries around the world and is constant- ters. The Garant tools are constantly expanding and internationalizing. ly in the top 5 brands in the world. In addition to cutting tools, we also offer clamping tools, measuring tools, hand tools, industrial furniture, clothing and footwear for safety at work.
3. SERVICE COMPETITION With more than 1300 sales representatives, our consultants are also available to our customers. So today we have specialists for cutting, clamping, meaFor this reason, Hoffmann Group is suring, grinding tools, specialists for in46
INTERVIEW
Worcon | September 2019
dustrial furniture (digital visualization enables the factory to be reviewed and virtual production is planned). We also offer buyers post-sales services from re-sharpening, tool rolling, calibration of measuring tools‌ We also have various e-tools, and one of the important tools is Tool Scout, which greatly facilitates tool selection and helps the customer to select processing parameters.
Also the software of the future - Software Tool 24 is embedded in our smart cabinet for issuing tools that enable automatic ordering – when the amount of a certain tool is at the minimum level, warns the system and automatically orders the new one which will arrive in one day period. The software also enables monitoring of consumption statistics and brings significant savings in purchasing and tool consumption itself.
Image courtesy of: Hoffmann Group
For the end, can you tell us how your company Rotometal follows the Hoffmann Group development trends? All sales representatives in ROTOMETAL ALATI d.o.o. are engineers with mechanical engineering degree. Also everyone has undergone basic training since offering over 80,000 tools is not easy. The training lasts for one month and consists of lectures and exercises.
of the specializations has several levels of education that literally need years to complete. We send our employees to a minimum of one training per year, mandatory catalog training, and to participate and visit industrial fairs, which means continuous training and tracking trends in the market. After that, we share our newly acquired knowledge with our customers, and we do our own training and presentations for our customers and participate Also after that training we have spe- in tool testing to help our customers cialty training for machine process- speed up production, improve their ing, measuring tools, abrasive tools, quality and ultimately make savings. hand tools, automated cabinets‌ Each 47
MACHINES
Worcon | September 2019
A CNC Made Of Wood The Holzfraese CNC is the world’s first heavy-duty wooden CNC router for professional users.
Image courtesy of: cnc-holzfraese.de
Holzfraese says its router is an automated solution that can realize just about any custom project - requiring no marker pencils, rulers, or T-squares. It can also handle a variety of clamping systems, including vacuum clamping.
quiring a high-degree of customization and precision, like scale models, housings, instrument building and molds. Two models are offered: A compact model focuses on versality, featuring automation for contour and prefabricated component milling. A speed model is suited for nesting, featuring a “single-mill principle” and focusing on extremely high speed, material optimization, and very low emissions. The speed model is “virtually maintenance-free”, says Holzfraese. Another benefit to the Holzfraese are its vacuum pads, says the company. Most are typically designed to use protruding vacuum pads or multi-hole plates. A risk to this is that workpieces can buckle.
“Our vacuum table has several vacuum The machine is made from Koskisen pads, which are placed flush in the millplywood and polymer concrete - and ing bed. Thus, our system ensures preciinnovative German engineering, of sion from the first to the last workpiece.” course. Bessler saw the need for a machine for small shop owners nervous The Holzfraese is currently on display at about getting into CNC. Holzfraese re- Ligna, the world’s largest woodworking quires minimal setup time, offers a show, where it has attracted crowds each good price-performance ratio, and pro- day. Stretched across more than 1.4 milduces few emissions. Bessler says its lion net square feet, and featuring disideal for woodworking operations spe- plays by more than 1,500 companies, the cializing in small-series production, en- biennial LIGNA runs through May 31 at graving, and any other application re- the Fairgrounds in Hannover, Germany. 48
MACHINES
Worcon | September 2019
FPS - Universal Milling Machines For Flexible Use FPS Werkzeugmaschinen GmbH will present their three-axisuniversal milling machines - the FPS 620M-NC and 420M-NC - among other products at EMO.
FPS offers its universal milling machines with two different high-end CNC systems: Heidenhain TNC 620 FS or Siemens 840D sl. Both control systems are clear and easy to use thanks to their workshop-oriented work step programming and convenient touch screen. As well as ensuring that their products are easy to use, FPS places importance on operator safety.
handwheels. The display includes models with purely manual operation modes and others that feature straight cut control for practical applications.
Image courtesy of: FPS
Image courtesy of: FPS
The machine tools from this Bavarian company are a great first step into modern manufacturing; as a result, they are frequently used in training organisations, vocational schools, universities and higher education instiAs a result, the compact mill- tutions, the company explains. Howing machines are equipped with ever, industrial companies also make the latest CNC safety technology. good use of the 620M-NC machine in individual and prototype production. When set to manual operation, the 620M-NC and 420M-NC, which are de- Their key customers in industry include signed for milling and drilling, aim to im- technology companies from the aviapress users with their accessible work- tion, mechanical engineering, automoing space and ergonomically positioned tive engineering and optics industries.
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MACHINES
Worcon | September 2019
EU Machine Tool Orders Dropped In The First 3 Months European machine tool producers’ new orders declined again in the first quarter of 2019, according to the latest quarterly report by CECIMO - the European Association for the Machine Tool Industries and Related Manufacturing Technologies. Production of machine tools in Europe is expected to be flat in 2019, according to the same report. European machine tool producers’ new orders declined again in the first quarter of 2019, according to the latest quarterly report by CECIMO – the European Association for the Machine Tool Industries and Related Manufacturing Technologies. Production of machine tools in Europe is expected to be flat in 2019, according to the same report. The eight largest European machine tool manufacturing nations registered a -14% drop in orders volume during Q1, compared to comparable period of last year. Foreign demand has been affected to a larger extent (-17%) than domestic orders (-10%.)
(-12%), Germany (-9%), and Italy (-9%.) U.K. machine-tool manufacturers reported a +10% increase in domestic demand. Demand from foreign customers dropped sharply in Czech Republic (-31%) and Germany (-26%). U.K. manufacturers posted a +19% increase in foreign demand, while Austrian producers reported +3% growth in orders from outside the country.
According to the CECIMO report, weaker trade volumes, low business confidence, and geopolitical risks are weighing on demand for the European machine tools. Manufacturers are starting to Within individual nations, the sharp- see the consequences of slower trade est declines in total orders were reg- on their business, the report indicated. istered in the Czech Republic (-27%), Germany (-20%) and Spain (-16%). In its forecast for the remainder of More moderate declines were re- 2019, CECIMO expects 2019 machine corded in Italy (-7%) and Switzerland tool production to rise by just 2%, down (-4%). The U.K. saw a +15% increase. from the +9% in 2018, and machine-tool Domestic new orders declined in Spain consumption to grow 1-2%, com(-49%), Austria (-20%), Czech Republic pared to the 9% expansion for 2018.
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MACHINES
Worcon | September 2019
Image courtesy of: Worcon
About CECIMO The European Association of the Machine Tool Industries and Related Manufacturing Technologies (CECIMO) is comprised of the trade associations for 15 countries, which represent approximately 1,500 business in Europe (EU, plus EFTA and Turkey), and 98% of the total machine tool production in Europe and about 33% worldwide. Over 75% of CECIMO production is shipped abroad, and half of it is exported outside Europe. Within individual nations, the sharpest declines in total orders were registered in the Czech Republic (-27%), Germany (-20%) and Spain (-16%). More moderate declines were recorded in Italy (-7%) and Switzerland (-4%). The U.K. saw a +15% increase.
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TOOLS
Worcon | September 2019
Garant Xtric Centering Vise The Garant Xtric centering vise from Hoffman Group is equipped with a new chuck jaw quick-change system enabling easy, tool-free changeover. A click mechanism gives the vise an interchange accuracy in the micrometer range, the company says. Because the center can be adjusted precisely, multiple Xtric devices can be used.
Clamping technology
move and rethread the spindle nut.
The new Garant Xtric is suitable for clamping both blanks and finished parts. In addition, pre-stamping components is not required.
With its rotating top jaws, the Garant Xtric provides a clamping range of 0 to 144 or 194 mm, depending on the model. All models are alternatively available with pivot jaws.
The vise’s top jaws can be replaced or rotated 180 degrees by hand without using any tools. The top jaws are inserted into a dovetail and pushed down via two spring plates until they engage, eliminating the need to reGarant Xtric main features
In order to clamp larger workpieces using multiple centering vises, the center can be adjusted with micrometer accuracy. If required, it can be shifted by up to 0.5 mm on each side (1 mm total).
intermediate plate. • Jaws can be changed without us • Very good accessibility and per ing tools. Changing the jaws may fectly symmetrical. result in a change of clamping ca • All functional faces hardened, pacity. hard milled or ground. • Easy-to-use, jaw-change system, • Central alignment delivers perfect no tools required. ly centred clamping. • Clamping force up to 25 kN at 90 • Clamps raw materials and finished Nm torque. parts with the least possible lifting • Quick to use and intuitive in oper of the jaws / component. ation. • Supplied with holes for LONG po • Repetition accuracy <0.01 mm. sitioning system, can be adapted • Perfect for 5-face machining. Cen to GARANT ZeroClamp using an tred clamping. 52
TOOLS
Worcon | September 2019
New Cutting Tools By Walter AG Walter AG introduces a variety of new cutting tools for a multitude of uses across different industry sectors. Walter AG, one of the world’s leading metalworking companies, has reinforced its status by announcing a flurry of developments in milling cutter technology – all designed to generate a raft of cost-savings and improved process integrity benefits, for users across all industry sectors. A new PCD cutter able to machine both aluminium and bi-metal (grey iron-aluminium) workpieces by utilising a number of indexable inserts, each optimised for different applications. The M2127 PCD milling cutter features standard indexable inserts, with correspondingly varied possible applications without changing the tool and excellent availability of the inserts while minimising storage costs.
ture seating grooves and are fixed in the insert seat with wedge clamps secured against centrifugal forces. This ensures extremely high speed stability and process reliability. Axial cutting edge adjustment makes it possible to adjust the runout with an accuracy of 1–2 μm, resulting in time savings for the user. This makes mass production in the automotive industry an interesting area of application for the PCD milling cutter, which is available in diameters up to 160 mm. Two new long-life solid carbide cutters (MC319 and MC320 Advance) are specifically for roughing.
An expanded range of M4000 cutters of up to 315 mm diameter for larger workpieces and the next generaThe PCD grades themselves have tion Xtra·tec XT (Xtended Technology) been optimised for each specific ap- shoulder and face mills for increased plication. All indexable inserts fea- productivity and process reliability.
Image courtesy of: walter-tools.com 53
TOOLS
Worcon | September 2019
Mikron Tool - Drilling In One Stroke
Image courtesy of: mikrontool.com
Small, deep and fast, these are the char- small diameters as well as deep bores. acteristics of the Crazy Drill Cool SSTInox. With a special cooling design, the The range includes through coolant drill aims to take on tough challenges. drills in six different working lengths: up to 6 x d, to 10 x d, to 15 x d, to 20 x Small, deep and fast, these are the d, to 30 x d and to 40 x d. In addition, characteristics of the small drill Cra- there is a short i.e. pilot drill for a max zy Drill Cool SST-Inox. Due to inter- bore depth of 3 x d. Up to a bore depth nal coolant ducts, improved geome- of 20 x d these tools are available from try and special coating, the machining dia. 0.039” (1 mm), the longest one of stainless steels, nickel based super from .078” (2 mm). The entire range alloys and Crco-alloys has become goes to a max diameter of .236” (6 mm). simpler and process stable, accord- Because drills with spiralised coolant ing to Mikron Tool. This goes also for ducts are available already; also in the 54
TOOLS
Worcon | September 2019
small diameter ranges. However, many get into trouble with tough-elastic materials or with the poor heat conductivity of super alloys. Here the cooling through “classic” round ducts is even with high pressure insufficient.
sible diameter and are drop shaped. These ducts are located in an area with little stress and therefore the stability of the tools is not jeopardised. Comparing to the conventional round diameter, these ducts afford a 4-time higher coolant flow. At diameters under A premature edge chipping, pack- .118” (3 mm) a power chamber in the ing of chips, buildup of the flutes pre- shaft reduces the length of the ducts vents a process stable drilling. Exactly and provides higher coolant pressure. this is important for industries which produce from valuable material even The advantage of the efficient supmore valuable finished parts. Markus ply of coolant to the drill tip, increasSchnyder, head of Mikron Tool In- es tool life because an overheating of ternational and one of the initiators the cutting edges is avoided right from of the new tool, knows all about the the beginning. Combined with the inproblematic: “For many years our cus- novative tip geometry, the cooling tomers reached the limit when drill- helps greatly to break and flush out the ing stainless steel. The process was chips from the flutes. All these characnot stable and too slow; thus, machin- teristics make it possible to work with ing became extremely expensive.” higher cutting parameters (speed and feed) and to drill in one single stroke. The coolant ducts have the largest pos-
Image courtesy of: mikrontool.com 55
MARVEL OF ENGINEERING
Worcon | September 2019
The Golden Gate Bridge History Of Golden Gate Bridge
cables is 129,000 km that was spun in six months, and is enough to go around The Golden Gate Bridge that was com- the world approximately 6 times. pleted in 1937 is a suspense on bridge connecting the San Francisco Bay Design considerations of The with the Pacific Ocean. The Golden Golden Gate Bridge Gate Bridge is considered to be a globally renowned representation of San The design of a suspension bridge is a Francisco and California. It is an en- complicated work that needs considgineering wonder created in 4 years erable mathematical proficiency and due to the admirable human vision, engineering capability. The design has persistence, and technical expertise. multiple aspects that require extensive The weight of the bridge when built deliberations since all materials deform was 894,500 tons, length 8,981 feet, on the application of loads. It is essenwidth 90 feet, and water clearance tial to determine the deck movement 220 feet. Two primary cables pass over range at numerous locations caused the tower tops, and are fixed in con- due to the varying load conditions. The crete anchorages located at each end. different load conditions are heavy The length of wire in the two primary traffic, traffic with intermittent stops and movements, and reduced or no traffic. The designer of this bridge deliberated in detail numerous engineering factors, including the deck movement due to its weight, environment temperature range, velocity of wind, deck sag between suspension cables, elongation of suspension cables, etc. It may be appreciated that the engineering technology prevalent in that era did not encompass these important features of bridge design. Still, the Golden Gate Bridge is considered to be an engineering wonder because of the precise engineering planning, design, and conImage courtesy of: Pixabay struction processes that were applied. 56
Worcon | September 2019
Forces and loads on The Golden Gate Bridge The foremost engineering problem that existed in the design of this bridge was the structure that was exposed to withstand the high speed windstorms coming from the Pacific Ocean. Accordingly, the bridge was designed to withstand the most improbable condition of wind at a speed of 100 miles an hour, at which the mid-span swing could attain a maximum limit of 27 feet. The vehicles and bridge deck weight is transmitted upwards by the suspender rods to the major suspension cable that transfers the forces to the anchor blocks and bridge
MARVEL OF ENGINEERING towers. The forces from the suspender rods create tensile forces in the major suspension cable. These are the forces that try to elongate the cable. The major suspension cable that sags in a parabolic shape consists of several small-diameter steel cables wound jointly to create a huge stranded steel cable. The tensile forces from the cable create compressive forces in the tower that attempts to compress the tower. The tower has been designed to withstand these compressive forces without buckling. Thus, we see that numerous design considerations were deliberated to produce a robust bridge that could be claimed as an excellent engineering marvel.
Fun Facts: • The Golden Gate Bridge has only been closed three times because of
weather • The U.S. Navy originally wanted the bridge to be painted black with yellow stripes, instead of its unique “International Orange” • In 1965, paint corrosion on the bridge sparked a program to remove the original lead-based paint and replace it with an inorganic zinc silicate primer and acrylic emulsion topcoat • There are approximately 600,000 rivets in each tower • When original rivets become corroded, they are replaced with ASTM A-325 high-strength bolts of equal diameter • The speed limit on the bridge has been 45 mph since 1983 • There are 80,000 miles of wire in the main cables • As of January 2014, approximately 2,025,883,491 vehicles have crossed the Golden Gate Bridge (includes northbound and south bound) since opening to traffic on May 28, 1937 • Recently (January 2015), a moveable median barrier was successfully installed on the Bridge
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