Industrial Factory Automation

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 ...

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,...

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 fil...

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 sta...

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 ...

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 incl...

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...

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...

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, ...

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™ aut...

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 i...

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 ma...

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...

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...

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...

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...

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 i...

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 c...

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 manu...

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 con...

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 li...

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.