Friday, January 18, 2013

Synthetic-fiber producer ENKA de Colombia SA, Medellín, Colombia, replaced dc and ac motors with advanced ac versions coupled to efficient variable-frequency drives on a fiber spinning line. The strategy saves the company more than $883,000 annually in electricity and downtime.

The spinning line extrudes nylon and polyester filaments from melted resins. Before the upgrade, motor and drive efficiency was about 50%. Part of the production line used an uninterruptible power supply (UPS) meant for protection from power outages, but the UPS ran at 80 to 93% efficiency at best.

One outcome of the inefficiencies was that the old equipment produced enough heat to demand its own a/c system. Elevated temperatures led to more breakdowns and repairs.

The new variable-frequency drives, Yaskawa F7 and G7 ac VFDs, have a nominal 98% efficiency. They create so little heat that ENKA was able to remove nine a/c units formerly needed to cool its factory. The new ac motors are also smaller than the dc motors they replaced. Old electrical equipment and a/c required for the spinning line took up almost 3,500 ft2. The new a/c-less electrical installation occupies only 1,163 ft2, And the updated UPS relies heavily on battery banks and works at near 100% efficiency.

Yaskawa VFDs were installed in a common-bus configuration, so a drive that is slowing its load can provide power to drives that need it. This reduces the power drawn from the mains.

In addition, the new VFDs let certain machines turn out up to 18 different filament types simultaneously with little modification.

The combination of energy saved from using more-efficient equipment, eliminating a/c, and introducing regenerative braking works out to $806,131 in annual kilowatt-hour savings. ENKA also figures it saves about $77,000 annually on technician time because of the new gear. All in all, payback time for the new installation was less than a year.

Depending on the drive style, a high-tonnage mechanical press can stamp out metal parts at up to 1,000 strokes per minute. Even so, it’s a remarkably durable machine. The steel frame will long outlive the motor and electronic controls that drive the flywheel.

And therein lies a problem. Most mechanical presses built in the 1980s or earlier were powered by DC brush motors. And they are expensive and difficult to replace, retune and maintain. A new DC motor can take weeks to get. Once installed, it must be tuned with potentiometers and jumpers. The process requires considerable tweaking, even if the original motor’s “pot” settings are known.

“We have several customers where engineers used a paint marker to note how the potentiometers were set,” says Steve Spero, service engineer with Yaskawa America Inc. “We have other customers where no one knew how they were set, and it can be all sorts of fun turning those knobs to get the motor back in working condition.”

To avoid such issues, a growing number of manufacturers are using AC motors to replace DC motors in mechanical presses, transfer systems, extruders, slitters, cutters, feeders, winding machines and other equipment.

Compared with DC motors, AC motors offer many advantages. For one thing, AC motors are readily available from numerous manufacturers, including Baldor and Marathon Electric. And, of course, AC motors have no brushes to wear out or commutators to rewind.

More importantly, today’s digital drives, like the A1000 from Yaskawa, vastly simplify the process of configuring and maintaining AC motors. Rather than tweak a series of “pots,” engineers simply enter the motor’s operating parameters via a keypad, laptop or digital network, such as DeviceNet, Ethernet or CC-Link.

“You can back-up all the parameters, so if you lose a drive, it’s easy to restore them and get back up and running,” says Dave Cecil, Yaskawa’s director of engineering and service.

The A1000’s keypad interface has application presets to make programming simple, and it has built-in memory for backup purposes. In addition, a USB copy unit can be plugged into the drive so configuration information can be transferred between an office environment and the factory floor.

“If you lose a drive, you can unplug the keypad, put in a new drive, reinstall the keypad, and it will automatically download the parameters,” explains Cecil. “If you had 10 identical presses, you could take that keypad from press to press and download the parameters.”

The drive’s removable I/O terminal board also provides backup memory for the drive. All parameter changes are automatically saved to both the main control board and I/O board. Engineers can leave the I/O connected when replacing a drive—configuration information will download automatically to the replacement.

The A1000 has several features to simplify preventive maintenance. The cooling fans snap in and out for easy replace-ment. Onboard monitors track drive temperature, precharge relay, and the remaining life of the cooling fan, bus capacitor and insulated gate bipolar transistors. The drive can use this information to trigger alarms or send status reports to managers across a network.

“There are also monitors on the drive that electronically look at the output current, output voltage, DC bus voltage and other variables without having to hook up an analog meter,” says Spero. “You just push a button, and there it is.”

“A lot of companies are moving to a ‘predictive failure’ philosophy,” adds Cecil. “The idea is to predict when the drive will fail. Instead of waiting until the drive breaks, you look for indicators that it’s getting ready to break and take action be-fore it fails and causes downtime.”

Yaskawa Electric Corp. and Yaskawa America Inc. celebrated the start of U.S. manufacturing for the Yaskawa MV1000 in a ceremony at the Yaskawa America Oak Creek, Wis., plant on Nov. 30. Yaskawa offered the medium-voltage drive (for motors up to 5000 hp) earlier this year, but ordering and shipping from Japan takes about 6 months. That’s expected to be reduced to 8 weeks or less after more than $3 million is invested by 2014 for new manufacturing and testing areas in the 30,000-sq-ft plant. By late 2013, models serving up to 5,000 hp are expected to be available, including UL and CSA listings.

Yaskawa MV1000 is said to be the smallest 1000 hp drive available, with 30%-60% smaller volume compared to the last generation of Yaskawa product. It also has the longest mean time between failures (MTBF) at 200,000 hours, a number expected to increase, said those involved. Yaskawa Smart Harmonics Technology reduces input harmonics, meeting IEEE519-1992 and eliminating the need for other filters. Total harmonic distortion (THD) is less than 2.8%. Energy savings for customers derive from 97% or better power conversion efficiency at rated load and by motor speed control, particularly on variable torque loads such as fans, blowers, and pumps.

Employees, customers, and guests were invited to the plant for a Kagami-Biraki sake ceremony commemorating the new beginning. They celebrated next to the first MV1000 units made there, two of which were ready to ship to a pipe manufacturing customer in Ohio. Another will remain at the Oak Creek plant for demonstration, display, and continued testing.

Yaskawa Oak Creek now employs 115 and will augment engineering, application support, manufacturing, and testing as needed, the company said.

The MV1000 drive uses open-loop vector control, meaning it is highly resistant to load fluctuations, enabling stable continuous operation without using an encoder. High-performance vector control can be used with synchronous motors as well as induction motors. The available user interface is the same used with Yaskawa 1000-Series low-voltage drives, for easy setting and operation. The Yaskawa DriveWizard Plus MV helps with setup, maintenance, and troubleshooting. A USB copy device aids with the transfer of parameters from drive to drive. Communications options include RS485 (Modbus), DeviceNet, Profibus-DP, and Ethernet. The drives are available at2.4 kV power lines (up to 2750 hp) or 4.16 kV (up to 5000 hp). Multiple induction motors can be run with one drive, reducing overall system size. Other options, including input integral input switchgear and engineered bypasses, will also be available.

Lincoln Electric introduces the new UltraCore® SR-12 gas-shielded flux-cored wire. This 75% - 80% Argon / balance CO2 gas-shielded flux-cored (FCAW-G) wire is capable of meeting AWS E71T-12M-JH8 requirements in as-welded and stress-relieved conditions.

UltraCore SR-12 is an excellent choice for pressure vessel fabrication and many other applications requiring post-weld heat treatment (PWHT) of mild steel.

Key Features:
  •     Robust Mechanical Properties - Exceeds AWS E71T-12M-JH8 strength and low-temperature impact toughness requirements in as-welded and stress-relieved conditions with impacts of 110 - 200 J (80-150 ft•lbf) @ -40°C (-40°F).
  •     Operator Friendly - Premium arc performance and bead shape makes SR-12 easy to use for welders of all skill levels.
This flux-cored wire conforms to AWS A5.20/A5.20M: E71T-1M-JH8, E71T-9M-JH8, and E71T-12M-JH8 classifications.

Available in 15 lb. and 33 lb. packages, UltraCore SR-12 wire comes in the standard .045 in (1.1 mm) diameter.

Safety is a critical component of welding, and thanks to The Lincoln Electric Company, now welders of all skill levels can access the safety information they need anywhere, anytime.  The company’s new Welding Safety Interactive Guide converts Lincoln Electric’s award-winning Welding Safety Interactive DVD into an online format that is easily accessible and viewable on computers, tablets and mobile phones.

Designed to educate arc welders about potential arc welding safety hazards and the safe practices they should follow, the guide offers information on a wide variety of topics, including how to avoid electric shock, prevent fire and explosions and choose appropriate personal protection equipment. The guide also provides safety insights from the American Welding Society (AWS) and the Occupational Safety and Health Administration (OSHA).  The program’s content is designed to be understood by welders at all experience levels, providing a valuable resource for everyone from welding students to professional welders out on the jobsite.

“Lincoln Electric is proud to be the first welding equipment provider to offer an intuitive, informative and concisely packaged online welding safety guide,” said John Petkovsek, Director Environmental Health and Safety at Lincoln Electric. “We’re excited to deliver a mobile-ready platform on the best welding safety practices for the welder and present critical safety insights for everyone from weekend project warriors to professional welders in fabrication or construction.”

The DVD that inspired the new online guide recently received the 2012 André Leroy Prize from the International Institute of Welding (IIW). The prize is given annually to recognize an outstanding large-circulation, multimedia document (including videos and computer programs), intended for use in Education and Training in any aspect of welding and allied processes.

FABTECH 2012 marks the launch of a new look to Lincoln Electric’s VRTEX® 360, as well as the release of the fourth upgrade in its VRTEX® Extensions™ software upgrade program. The software upgrade includes GMAW (MIG) stainless welding support, including appropriate visual and audio sound differences; shielding gas selections specific to aluminum welding; and enhanced THEORY functionality including visual and text definitions.

With the new upgrade, users will see the addition of stainless GMAW in multiple configurations.  The stainless upgrade includes new visuals and audio, discontinuities, equipment settings, tolerance levels, and the expansion of the THEORY function. An additional feature to the upgrade program is Demo Weld functionality. The Demo Weld feature allows the student or instructor to view an example weld or a demonstration of a proper technique for a specified weld, prior to the weld being made.  Finally, the VRTEX® Extension™ 4 also expands support and includes 0.052 in. (1.3 mm) solid wire and SMAW (Shielded Metal Arc Stick Welding) on thinner material support.

All VRTEX® Extensions™ software upgrades are offered as an ongoing program designed to enhance and supplement the VRTEX® 360 with new features and functionality. 

“The VRTEX® upgrade program release of aluminum GMAW earlier this year and stainless GMAW now, continues to increase the cost savings and value proposition of Lincoln Electric’s virtual reality welding simulators,” said Deanna Postlethwaite, VRTEX® Business Unit Manager. “Our goal is to continue to expand and enhance the virtual welding training system for multiple training environments, based on customer feedback and input.”

With the recent changes made to the VRTEX® Extensions™ program, customers have the flexibility to choose only what they want, when they want it. The program now offers independent or a la carte upgrade releases and enables users to purchase VRTEX® 360 software upgrade releases based on their specific needs. Each upgrade contains bundled features that the customer can review and evaluate prior to purchasing. Users have the option to purchase or skip the upgrade if it does not fit into their welding training program.

The VRTEX® 360 upgrade program is produced under the continued development partnership of Lincoln Electric and VRSim. VRSim Inc. of East Hartford, Conn., is a leader in the development of training software and graphic simulation for industry and academia. The VRTEX® 360 is a software-based welding training system powered by the software expertise of VRSim and the welding innovation of Lincoln Electric.

Any customer with the base software version 1.1.10 or Upgrade 1 can purchase the releases that best complement their welding curriculum. VRTEX® 360 Extensions™ upgrade packages include supporting literature – materials useful in any welding training environment.
Lincoln Electric continues to lead the industry in the innovation of virtual reality welding training through the VRTEX® program. The Company also continues to spearhead programs and products dedicated to the improvement of resources and materials for the training of effective, productive and quality welders.

Lincoln Electric announces the official launch of the VRTEX® family of virtual reality arc welding (VRAW™) training products, which includes the respected VRTEX® 360 and the new, easily portable VRTEX® Mobile – ideal for on-site training and recruitment events. These solutions are just two of the offerings in the VRTEX® virtual reality arc welding technology product line – training that’s engaging, realistic and cost effective.

These interactive teaching tools work equally as well for introducing new welders to the trade in a traditional classroom or in a manufacturing facility – both as an HR screening tool or for existing workforce training. VRTEX® virtual training systems from Lincoln Electric allow students of any age to learn and train in a safe, virtual environment with realistic imagery and scenes, thanks to a specially equipped virtual reality welding helmet and rich, vivid graphics.

Key Features:
  •     Two Models Available – The new, easily transportable VRTEX® Mobile, featuring a basic GMAW (MIG) (SMAW stick add-on package available), is compact and assembles quickly. It’s easily movable from place to place in a classroom environment, an industrial facility or recruitment event. The VRTEX® 360 delivers best-in-class virtual reality welding with 360-degree immersion in environments and applications, including SMAW, pipe welding, GMAW (including aluminum and stainless) multi-position welding and a continuing expansion of features with the VRTEX® Extensions™ software upgrade program.
  •     Real-World Welding Experience, Fun “Gaming” Approach – The VRTEX® family of VRAW™ training systems delivers hands-on training that’s consistent with standard industry methodology and evaluation criteria. Featuring actual machine set-up replication and a realistic welding puddle, sounds and effects, the system measures and records students’ training results in real time, allowing trainers to identify welding deficiencies. When students walk away from a VRTEX® machine into a real welding training booth, they can put on their helmets and pick up their welding guns feeling confident about set-up and welding procedures.
  •     Reduced Costs, Improved Safety – VRTEX® virtual reality welding systems eliminate the cost of hands-on initial learning – material waste and scrap – while creating a more proficient student. They can practice repetitive welding without the time needed to tack plate and toss scrap because the coupon isn’t real – it’s virtual, appearing with a press of a button.  VRAW™ training with Lincoln Electric’s VRTEX® system also allows students to become comfortable with using a welding gun and with the various body positions needed for even the most challenging welding applications, increasing confidence and overall safety in the real welding booth.

Lincoln Electric’s newest addition to the VRTEX® family of virtual reality arc welding (VRAW™) training products, the VRTEX® Mobile, delivers a basic, hands-on entry-level training and skills solution that’s consistent with standard industry methodology and evaluation criteria – all in an easily transportable, virtual package. The portable VRTEX® Mobile is ideal for use in classrooms, the human resources department or at off-site training or recruitment events.

Key Features:
  •     Welding Applications – With a universal gun handle design (unigun), the VRTEX® mobile offers a pre-installed basic GMAW (MIG) package and an optional SMAW stick add-on package, providing training for flat plate, 2F and 3F joints and 1G, 2G and 3G grooves. The virtual SMAW device is at a fixed 90° angle.
  •     Portable Design Features – Designed for roadtrips and tabletop use, the VRTEX® Mobile comes with a monoscopic, face-mounted display with touchscreen user interface and a tabletop coupon stand.
  •     Real-World Welding; Fun “Gaming” Approach – Like its more sophisticated partner, the VRTEX® 360, the VRTEX® Mobile requires students to learn actual machine set-up replication and features a realistic welding puddle, sounds and effects. All VRTEX® training systems measure and record students’ training results in real time to assist educators in identifying welding deficiencies and strengths. When students complete their virtual training, they can walk into a real welding training booth, put on their helmets and pick up their welding guns feeling confident about set-up and welding procedures and technique.
  •     Safe, Cost-Efficient Learning – Both of the VRTEX® virtual reality welding systems – the VRTEX® 360 and the VRTEX® Mobile – eliminate the cost of hands-on initial learning. Students practice repetitive welding without the time needed to tack plate and toss scrap because the coupon isn’t real – it’s virtual, appearing with a press of a button. This eliminates costly waste. Lincoln Electric’s VRTEX® systems also help students to become comfortable with using a welding gun and with the various body positions needed for even the most challenging welding applications, increasing confidence and overall safety in the real welding booth.

Lincoln Electric introduces an enhanced Robotic Welding Education Cell 2.0 for use in schools, colleges and private manufacturing training centers. The compact new robotic cell is intended to help the manufacturing industry respond to a critical shortage of skilled labor. Training available workers on advanced automated welding delivers the productivity and quality the U.S. manufacturing industry must have to remain successfully competitive.

For instructors and students, the new cell provides access to robotic technology and advanced training, allowing students to develop skills that meet the needs of the industry’s developing manufacturing environment.  The mobile nature of the Education Cell, including a collapsible work space, allows it to be used as a training tool in multiple classrooms and welding labs. It also can be easily transported to recruiting events to attract students.

"The future of manufacturing lies in motivating students to consider science, technology, engineering and math careers," said Deanna Postlethwaite, marketing manager, Lincoln Electric Automation Solutions. "The enhanced Robotic Welding Education Cell is a key to addressing these educational targets and building a workforce with the right skills for manufacturing.  The robotic system design caters to industrial, welding education and robotic training needs.”

The Robotic Education Cell Program gives students a foundation in robotic welding basics, as well as more sophisticated technologies, preparing them to succeed in industries ranging from building and fabrication to automotive, transportation, and structural steel.  The welding cell supplements coursework in any math or science-based curriculum, including CAD, electronics, machining, and computer science and information technology.

The Robotic Education Cell offers the following benefits:
  •     Collapsible work surface area (2000 sq. in. maximum work surface area)
  •     Lightweight, mounted on wheels and fits through a standard doorway, allowing it to be moved easily from classroom to classroom and positioned for optimal demonstration purposes
  •     Ready to go out of the box. The packages include integrated shielding gas bottle rack/storage, fume extraction system mounting and integrated safety devices.
  •     Equipped with a “production ready” welding robot packaged with numerous software options from FANUC® Robotics
  •     A single power drop for the complete cell - simplifying connection of the FANUC® ARC Mate® 50iC/5L robotic arm and Power Wave® R350 welding power source
 The Robotic Welding Education Cell features:
  •     Lincoln Electric Power Wave® R350 welding power source
  •     Lincoln Electric Power Wave® and Production  Monitoring™ Software Capability
    •         CheckPoint™ cloud-based production monitoring software
    •         Production Monitoring™ 2.2 server-based software
  •     Lincoln Electric AutoDrive® 4R100 wire feeder
  •     Lincoln Electric Magnum® PRO robotic welding torch and consumables
  •     Lincoln Electric SuperArc® L-56® GMAW welding wire
  •     FANUC® ARC Mate® 50iC/5L
  •     FANUC® R-30iA Mate Controller
  •     FANUC®  LR ArcTool® Software

Lincoln Electric has introduced its new 2013 Equipment Catalog (E1.10) detailing the company’s MIG, TIG, and multi-process equipment, as well as plasma cutting systems, welding automation, fume control systems, training product solutions, orbital welding systems, accessories and welding gear products.
New in 2013, the Lincoln Electric Equipment Catalog can be downloaded and viewed on Apple® iOS and Android® smartphones and other devices. Appropriate apps are available in the Apple® App Store or Google® Play Store.

The catalog also features a bound-in, removable copy of the company’s expanding Welding Gear catalog, including Red Line™ apparel, VIKING™ auto-darkening helmets and Radius™ tools.

New product sections include:
  •     Training Product Solutions – including the VRTEX family of virtual welding training systems.
  •     Orbital Welding Systems – for automated pipe and tube welding.
  •     Automated Solutions – including systems offered by new Lincoln Electric company Wayne Trail®.
  •     Expanded Accessories Section – featuring an improved layout and reference to a greater number of equipment accessories, allowing distributors and customers to more easily locate the items they need to complete a welding system.
With an updated appearance and easy color-coded navigation, the catalog displays all of Lincoln Electric’s key products, including those introduced over the last year, to help its customers reduce costs, increase quality and improve productivity.

The catalog also includes a postcard allowing users to register for the company’s iWeld™ email newsletter and enter to win one of two welding packages – a stick welder, helmet and welding gear or a compact wire welder, helmet and welding gear.

Ideal for shipbuilding, offshore, construction or pipe welding operations, the Activ8™ portable wire feeder from Lincoln Electric is the smallest, lightest wire feeder on the market and is now available in a One-Pak® configuration that includes a Magnum® PRO Curve™ 300 gun. With the One-Pak®, welders can enjoy the convenience of receiving a wire feeder and gun matched for most applications in the shipbuilding, construction or pipeline industries.

The Activ8™ One-Pak® includes the following:
  •     Activ8™ Wire Feeder with internal contactor, gas solenoid, arc-sensing lead and clip [15 ft (4.5 m)] and a K1500-2 Gun Bushing.
  •     Magnum® PRO Curve™ 300 Gun with 15 ft (4.5 m) gun cable, 1/16 inch (1.6 mm) liner, and K466-10 Gun Connector Kit.
Key features of the Activ8™ include:
  •     Designed specifically for 8 in. (200 mm) spools.
  •     Compatible with any DC CV and/or CC power source.
  •     Simple controls include front WFS knob and internal-booted Cold Feed and/Gas Purges, Trigger Interlock and CV/CC switches.
  •     Across-the-arc operation (voltage sensing) uses a sense lead and contactor to enable weld current.
  •     Standard shielding gas apparatus can be used for FCAW-G and GMAW processes.
  •     Tough plastic case, molded from high-impact, flame-retardant material, is durable and lightweight enough to withstand repeated drop testing.
The portable wire feeder is capable of feeding self-shielded FCAW or FCAW-G and GMAW (MIG) gas-shielded wires at 50-800 IPM (1.3 – 20.3 m/min). It will handle GMAW wires .023 - .052 in. (0.6 – 1.3 mm) in diameter and FCAW wires of .035 – 5/64 in. (0.9 – 2.0 mm) in diameter. The Activ8™ is rated at 330 amps at 60 percent duty cycle and weighs in at only 27 lbs. (12.2 kg).

At the heart of the Activ8™ wire feeder is the MAXTRAC® Drive System, which features the following:
  •     Dual gear-driven drive system to ensure positive feeding performance.
  •     Patented wire drive with tool-less drive roller and wire guide changes for quick spool replacement.
  •     Tachometer-controlled motor to power drive rolls for smooth, steady feeding without wire slippage.

Lincoln Electric introduces Metalshield® MC®-80Ni1, a premium, low-alloy, metal-cored wire.  This metal-cored wire is designed to produce high strength and toughness and H4 diffusible hydrogen weld deposits required in such applications as structural and heavy fabrication or other high-strength welding applications that require a tensile strength of 550 MPa (80ksi).

Key Features:
  •     H4 diffusible hydrogen levels.
  •     Low spatter and excellent arc stability.
  •     Deoxidizing agents to minimize pre- and post-weld clean up.
  •     Enhanced silicon island management.
  •     Low temperature impact properties – Charpy V-Notch test results capable of exceeding 40 J (35 ft•lbf) @ -51° C (-60° F).
  •     Excellent bead shape and profile.
Metalshield® MC®-80Ni1 delivers low spatter and excellent arc stability and is great for semiautomatic and robotic applications.  Enhanced silicon island management minimizes slag and eases slag removal.

Metalshield® MC®-80Ni1 is available in standard diameters of .045 in., .052 in., and 1/16 in. and packaged in 500 lb. Accu-Trak® drums and 33 lb. plastic spools.

Friday, January 04, 2013

The new HARTING PushPull Signal connectors meet the demands of industry for the reliable transmission of energy, signals and data in all power ranges, consistently and in a uniform connector system.

HARTING PushPull Signal has 10 contacts to transmit rated currents of 5 A with conductor wiring gauges of up to 0.75 mm². To ensure EMC interference immunity, the contact inserts are fully screened, as they are with RJ45 data connectors. Screened cables can be connected. The connectors have PushPull locking for reliable and intuitive connection. Perfect locking is indicated by an acoustic signal (a click).

Hybrid applications can also be created with PushPull Signal. For example, one part of a connector face can be used for energy transmission, whereas other contacts are available for communication. PushPull Signal connectors are obtainable in the PushPull 14 and 4 version series in accordance with IEC 61076-6-107.

Han® PushPull version 14 is the preferred connector for decentralized automation in the field for data transmission and energy supply subject to the guidelines of the PROFIBUS user organization PNO and the automation initiative of German automobile manufacturers (AIDA).

In the form of the Han-Yellock® 10, HARTING is now introducing a new, compact connector. Based on the established Han-Yellock® 30 and 60 sizes, functionalities have been adapted to meet the requirements of compact units and systems.

Universality and efficiency are the keynotes of the uses the new Han-Yellock® 10 can be put to. Currently with 25 different contact inserts, it meets all needs from energy supply to data transmission. Consequently, one size can reliably transmit power of up to 40 A / 690 V and sensitive data signals, as in Ethernet applications, for example. In addition, multipole varieties with up to 21 contacts are also available. Contact inserts are also possible for optical data transmission.

The key features are ease of handling and operation. The locking mechanism integrated in the housing locks both housing halves reliably during the connection process. Unlocking is a similarly intuitive process. A brief push on the activation button is all that is required. The robust stainless steel locking mechanism is deactivated, allowing both connector halves to be separated from each other.

Data transmission has a particular need for clear solutions to ensure ideal EMC properties (electromagnetic compatibility). Han-Yellock® from HARTING provides this, thanks to the nesting of both housing halves and the direct electrical connection between the housing and the adjacent surface. Even the use of larger diameter sheathed cabling was addressed by having an M25 cable input.

HARTING is expanding its product portfolio with the introduction of a new straight D-Sub SMT connector series. This will complement the already globally established angled D Sub SMT range.  The optimized design allows for easy handling and a long working life. The new series is compatible with other surface mount components which results in a simplification of PCB design and manufacture and opens up new application opportunities.

100% co-planarity is achieved by combining stamped contacts with our uniquely designed insulator. This concept provides a robust solution capable of effortlessly withstanding all stresses encountered during normal assembly procedures. The straight D Sub SMT connector is available in two mounting formats, with flat grounding pads or with the addition of two PIHIR pins for an increased retention performance. The black insulator ensures good positional camera recognition and the two plastic locating pins included in the molding prevent the connector moving following placement. A removable grip for 10mm vacuum pipettes is also available.

The straight D Sub SMT can be supplied with 9 to 37 contacts, M3 or 4-40 UNC threaded inserts and can be supplied with non-removable M3 or 4-40 UNC female screw locks. Performance level 2 and 3 are standard with performance level 1 available on request. They are supplied on reels, quantity 140 pcs. per reel with other packaging formats available on request.

Since its launch, Han-Quick Lock® termination technology has found a firm footing in the market and is installed in numerous HARTING products. The new feature is that most connectors are available for two wire gauge ranges. This is shown by the different coloring of the Han-Quick Lock® actuators. The termination wire gauge ranging from 0.25 mm² to 1.5 mm² has a black actuator, whereas the actuator for the 0.5 mm² to 2.5 mm² range is blue.

The innovative termination technology makes it possible to connect a stranded wire to a connector contact without having to use any special tools such as a crimping tool. The contacts are already pre-assembled in the connectors with Han-Quick Lock®. With its space-saving design, the patented termination technology boasts very high contact density, making it ideal for integration in various types of connectors. For example, many HARTING connectors are available with two alternative termination technologies, though of course they are still mutually compatible despite their different termination methods.

The portfolio includes connectors from a wide range of HARTING series:
for Han-Modular®, Han A®, Han D®, Han® Q, Han® PushPull and Han-Yellock®, numerous modules and connectors with termination technology suitable for assembly in the field are now available.

With the Han® Q 3/0 and Han® Q 4/0, HARTING is expanding its portfolio in the smallest Han® 3A size range. An area measuring 42 mm² is enough room for 3 power contacts and the protective earth contact (Han® Q 3/0) or 4 power contacts (Han® Q 4/0). This makes them both the most powerful in the compact industrial connector class.

The connector boasts the following performance data: clearance and creepage distances with the Han® 3/0 allow a 400 V rated voltage, which increases to as much as 830 V with the Han® Q 4/0. Both have roughly similar current load capacities – this is approx. 40 A given an ambient temperature of 40°C and a connection wire gauge of 4 mm². Because connectors with standard Han® C contacts can be used with a wire gauge of up to 10 mm², currents of over 80 amps are possible but in these cases the diameter of the cable entry need to take into account.

Both connectors are used in industrial environments. They are ideally suited to the needs of the semi-conductor industry, for example. The Han® Q 3/0 with protective earth contact is designed for 3-phase earthed networks and is used in three-phase motors. It can fit all housings in the 3A size, i.e. all plastic and metal varieties, EMC and also the extremely robust HPR and stainless steel housings. The Han® Q 4/0 comes with 4 power contacts and is used to enable equipment such as ventilators, fans or extraction units to be connected. Because these consumers are very common in the semi-conductor industry, the Han® Q 4/0 is the ideal solution to reduce costs because two of the consumers can be connected with one connector. The connector is also ideally suited for DC applications. However, in this case, it can only be used in 3A size plastic housings.

HARTING is expanding its space-saving har-link® metric product range with a version equipped with solder bucket contacts. Up to now, connectors were supplied on the cable side only with an insulation displacement termination. The new har-link® with solder bucket contacts now enables fast and easy harnesses prototyping for test purposes for example without the use of a special dedicated tooling. With this new contact style, now wires from the AWG 30 up to the AWG 24 can be mounted on the cable side of the har-link® connection, providing a high flexibility and compatibility with a large range of cables available on the market.

HARTING’s modular and compact har-link® interface connectors with 2.0 mm spacing can transmit data of up to 2 GBit/s per twisted conductor. Also equipped with a special screening concept, har-link® reliably delivers optimum functionality in areas affected electromagnetically. har-link® is manufactured in accordance with IEC 61076-4-107 and is a compact, robust cable connector which guarantees excellent data transmission to the PCB in high frequency networks and telecommunication applications.

The HARTING Technology Group is creating new standards in the PCB field with har-flexicon®, the new miniaturized and field-assemblable individual conductor connection technology with 1.27 mm spacing.

Flexible individual conductor wiring of industrial devices with PCBs as their key component is one of the principal requirements in modern device technology – and it will always stay that way. Because sensoric and actoric subassemblies need to be connected on site rapidly, PCB connection technology must continue to be universally applicable. What is required is flexibility in the connection of I/O signals with tool-less individual conductor wiring – which enables on-site assembly in the field.

It is always the overall, not the individual, costs of components which are paramount in the development of industrial subassemblies. The use of reflow and SMD solderable components in automated assembly and soldering processes leads to manufacturing costs which are lower than those for the manual assembly and wave soldering of wired components.

There is a universal demand for units to become ever more compact. Efficient device design and more powerful components with higher efficiency and greater power density lead to innovative devices, which deliver a growing variety of functions and performance coupled with reduced device volume. So, even with classical PBC connectors, miniaturization continues to march ahead with components in this segment constantly getting smaller and smaller. Despite this reduction in size, users still expect to operate connection technology just as conveniently and quickly as conventional products with higher spacing measurements.

har-flexicon® meets all these requirements consistently and is a model for rapid and convenient wiring of ever more compact devices whilst addressing the economics of the assembly process.

HARTING's har-flex® product family connectors with 1.27 mm contact pitch are expanding the design options for industrial devices. The flexibility and performance requirements for controllers and drivers have grown rapidly in recent years. At the same time, miniaturization is advancing unabated. har-flex® accommodates both trends.

Straight and angled connectors are available as PCB models. Together with the connectors for flat ribbon connection, PCBs can be combined into complex systems perfectly adapted to their surroundings. All har-flex® connectors are available with from 6 to 100 contacts, in increments of two. In addition to the connectors for flat ribbon connection, HARTING also offers assembled cables.

The compact but rugged design of har-flex® also guarantees reliable operation under adverse conditions. Two large holders ensure that the connectors are firmly held in place after the soldering. A low-wear insertion and withdrawal procedure is achieved by a very smooth contact point between the male and female contacts. This is the result of special follow-up treatment during the punching process which HARTING applies based on its extensive experience with punching technology.

For an uninterrupted production chain, the connector is delivered in packaging suitable for machines and can be processed in the SMT solder process. In spite of the rugged design, har-flex® connectors are also suitable for high data rates, which means that they can handle modern transfer protocols such as Gigabit Ethernet or PCI Express.

HARTING has successfully tested energy data acquisition with smart Power Networks in its own production area. Now the company is presenting the application at this year’s SPS in Nurnberg. HARTING has created its own software for data handling and data visualization.

The HARTING solution provides users with the necessary energy flow transparency, which represents the foundation for energy policy decisions. Data transparency is therefore the first step for successful energy management. HARTING has consequently created the database that ISO 50001 demands. 

The acquired transparency is consulted for the analysis and then transferred into actions for improvement. The company operating a machine or system consequently gains an insight into the state of the machinery and is able to identify energy peaks, form operating figures, control the consumption depending on the energy costs and prepare benchmarks for individual machines.

RFID technology makes it possible to identify goods and substances with the help of electromagnetic waves within certain frequency ranges. HARTING regards UHF RFID technology as the right choice for the transportation, automation, machinery and energy markets. This technology stands up to the harsh environmental conditions that prevail in these markets and also reliably registers rapidly moving objects with metal surfaces, such as railway cars. A read range of from 5 cm to 12 m ensures the greatest flexibility for the applications.

Thanks to its special patented transponder properties, the HARTING portfolio is optimally suited for these conditions. The High Performance Reader, which is capable of registering and processing more than 300 transponders per second, is joined by a selection of reading antennas. These allow HARTING to offer modular solutions for the widest range of applications in the RFID field.

In the age of the "Internet of Things" in which goods or even living beings are represented in a virtual Internet structure, UHF RFID is one of the most interesting interfaces. The next logical step in this context is the integration of sensors into passive transponders to enable goods to register additional information about their environmental conditions such as the temperature. This also means an additional step forwards for today's software architecture as industrial processes will achieve a higher level of automation and become more transparent and controllable.

At SPS/IPC/Drives HARTING will be presenting a passive UHF transponder with temperature registration implemented in a real application that demonstrates data acquisition and visualization in a Web interface.

The HARTING Technology Group has rounded off the HARTING RJ Industrial® series with new RJ45 female connectors with integrated tranformers for 10 Gbit. The highly compact dimensions of these RJ45 connectors enable convenient and simple integration into all established IP 65 / 67 interface types, from PushPull through to Han® 3A.

The reduced height is also an advantage in scenarios involving plug-in cards, allowing the realization of very flat assemblies and modules. In addition to the new 10 Gbit types, versions for 10/100 Mbit and 1 Gbit are also available. Versions for PoE as well as individual adaptations to specific customer wishes are possible and can be rapidly executed. In connnection with SMD LEDs on the customer PCB, integrated optical fibers enable signalling of the port status. These industrial female connectors can be processed in all standard soldering methods such as wave-soldering or SMT reflow.