Automation

Mazak: Addressing Labour Issues Through Machine Intelligence And Automation

Mazak: Addressing Labour Issues Through Machine Intelligence and Automation

K.S. Chong of Yamazaki Mazak Singapore Pte Ltd speaks about the impact of automation in the metalworking equipment industry. Article by Stephen Las Marias.

K.S. Chong

K.S. Chong, Senior Director, Solution Engineering, Southeast Asia Headquarters, at Yamazaki Mazak Singapore Pte Ltd, speaks with Asia Pacific Metalworking Equipment News during the recent Industrial Transformation ASIA-PACIFIC 2019 event in Singapore, about the latest trends in the machine tool industry, and how automation can help solve bottlenecks and issues on the shop floor.

Give us a brief background on your company, and your role.

K.S. Chong (KS):  Yamazaki Mazak is a Japanese machine tool builder. We produce various types of CNC machines for the metal cutting industry, anywhere from two-axis to nine-axis machines, multi-spindle, multi-turret machines, serving various industries such as automotive, aerospace, semiconductor, and energy, to name a few.

My role is basically to help in before- and after-sales activities such as time study, demonstration, and also turnkey projects. I also help with the proposal of equipment and solutions for the customer’s manufacturing needs.

From your perspective, what are some of the top challenges being faced by manufacturers in the region?

KS:  At this moment, I would say manpower—getting skilled manpower is a big issue for most of the manufacturers in SE Asia. Though they have the jobs or the money to buy the right equipment, getting the skilled manpower or engineers to run the machines or to design or make the fixtures or the process—that is one of the big challenges today.

What about from a manufacturing or technology standpoint?

KS: It is manpower. Humans make machines work. Without good, skilled manpower, it will be difficult to run an efficient manufacturing operation.

What is Mazak doing to help customers alleviate this issue?

KS: We are well known for making machines with our own conversational type CNC controller. We understand that our customers are facing problems to find skilled machinist or engineers to operate eg complex five-axis machines. So, we are building a lot of intelligence into the CNC control to make the machine more intelligent and easier to operate and program. That way, the customer will not need to rely on very high-skilled or high-level engineers to run their manufacturing operations.

 

 

What are Mazak’s latest innovations in metal cutting machines/technologies?

KS: CNC control technology has now advanced to embrace Artificial Intelligence (AI) with deep learning capabilities; making the manufacturing process more intelligent and efficient. More sensors are being employed on machine tools to monitor the operating condition of the machines to improve manufacturing process

What is your approach when it comes to industry 4.0?

KS: Basically, we encourage our customers to try and adopt IoT solutions such as machine status monitoring, in order to collect data on their machine utilization, so that they could address issues such as machine downtime, so as to keep their machines in the optimum operating condition.

By adopting IoT or Industry 4.0 strategies into their manufacturing process or operations, they will be able to get a faster return on investment.

What new industries are emerging right now?

KS: I think at the moment, there’s been a lot of hype on 3D printing and additive manufacturing; this is a very new area. Traditional manufacturing industries who used to use metal cutting machines to produce their products are now trying to explore hybrid additive manufacturing technologies to manufacture those high-value or high-mix, low-volume products.

We saw that trend globally. Therefore, since 5 years back, our headquarters in Japan has already developed several new hybrid additive manufacturing machines.

What is your take on the e-mobility trend?

KS: Our core business is producing CNC metal cutting machines. As far as e-mobility trend is concerned, it is actually using less metal or plastic parts as the traditional engine is replaced by an electric motor.  This means the demand for machining becomes lesser. Actually, I would say it is something that we need to be concerned of—how we are going to find new segments to cover for this shortfall. The manufacturing landscape for the automotive industry will be quite different in the coming years due to e-mobility.

Talks about electric vehicles have been going on for a long time, but there seems to be no massive production or adoption of it especially in southeast asia. Majority of the vehicles will still be those driven by conventional engines.

KS: Correct. Most of these ASEAN countries do not have a good infrastructure yet, such as charging facilities. Also, due to the living conditions of Southeast Asia, which is much cluttered and high density, it is also difficult to implement those infrastructures.

What opportunities are you seeing here in the region?

KS: The opportunities, I would say, would be in the adoption of new technologies such as hybrid additive manufacturing and IoT to complement the current traditional manufacturing processes.

How would you describe the level of manufacturing technology for job shops here in ASEAN?

KS: In Singapore, I would say it is quite matured; but of course, this is a dynamic world. New technologies are coming almost every year, every day. So, industries or SMEs need to be dynamic to adopt these new manufacturing technologies.

What is your outlook for the industry over the next year or two?

KS: There will be a lot of challenges, especially now with this global uncertainty, slow down of the global economy. So, it is anyone’s guess what is going to happen in the next two years. As the saying goes, ‘what goes up must come down, and what goes down must come up’. So, there is a good possibility that those segments that are not doing well today or this year, will slowly recover in the coming years.

 

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Automation To Take Center Stage In The Global Welding Equipment Market

Automation To Take Center Stage In The Global Welding Equipment Market

According to report by Persistence Market Research, the global welding equipment market expects the market to witness strong growth during the forecast period 2017-2024. The global market for welding equipment is estimated to reach close to US$ 19,200 Million revenue.

The manufacturing and fabrication industries are evolving constantly. This is resulting in the companies seeking out new technologies to stay ahead of competitors. Use of new materials in various industries is driving the need for welding automation. Companies are also moving towards acquiring new solutions to offer quality product and increase productivity. In response to this, welding equipment manufacturers are bringing in advanced technologies to help companies’ better serve their customers. Manufacturers are developing welding solutions that can serve both small scale and large-scale companies. Modified short-circuit MIG is being integrated into welding machines, ensuring better control and to create high-quality and uniform welds.

New materials such as high strength steels, advanced high strength steels, and increased use of stainless steel and aluminum in fabrications are creating the demand for new welding technology as per the material being used. Hence, a welding system for specific materials is also being developed by manufacturers in the global welding equipment market. Rising trend towards automation is also resulting in the development automated welding equipment for wide range of application. Information management system for welding is also gaining popularity. This system collects and provides information arc-on time, and performance based on voltage and amperage. This help companies to collect data on the performance of welding in real-time and track both quality and productivity.

 

Arc Welding Technology to Lead the Global Welding Equipment Market

Based on the welding technology, arc welding technology is expected to see a significant growth in the market. By the end of 2024, arc welding technology is projected to surpass US$ 8,500 Million in terms of revenue. Meanwhile, resistance welding is also projected to witness impressive growth during 2017-2024.

On the basis of a level of automation, compared to the manual welding equipment, automatic welding equipment is likely to register the highest growth during 2017-2024. Automatic welding equipment is expected to exceed US$ 13,000 Million revenue by 2024 end.

Based on the application of welding equipment, automotive & transportation sector is expected to gain maximum traction in the global market for welding equipment. Towards 2024 end, the automotive & transportation sector is estimated to reach nearly US$ 3,800 Million revenue.

Asia Pacific to Lead the Global Welding Equipment Market between 2017 and 2024

Asia Pacific is likely to dominate the global market for welding equipment during the forecast period. Asia Pacific is estimated to reach close to US$ 6,600 Million in terms of revenue. Increasing infrastructure and construction activities in the countries like India and China are driving the demand for welding equipment. Moreover, the automotive industry in Asia Pacific is also witnessing a substantial growth, thereby, fueling the demand for welding equipment. Growth in the steel industry owing to the increasing demand for steel in for product manufacturing in different industries is resulting in the growth of the welding equipment market in the region.

Key Players in the Global Welding Equipment Market

Some of the prominent players active in the global market for welding equipment are DAIHEN Corporation, Colfax Corporation, The Lincoln Electric Company, Fronius International GmbH, Obara Corporation, voestalpine AG, Arcon Welding Equipment, Panasonic Corporation, Sonics & Materials, Inc., Rofin-Sinar Technologies, Nelson Stud Welding (Doncasters Group, Ltd.), Amada Miyachi, Inc., and Illinois Tool Works, Inc.

 

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Airbus Opens Automated A320 Assembly Line

Airbus Opens Automated A320 Assembly Line

Airbus has inaugurated its highly automated fuselage structure assembly line for A320 Family aircraft in Hamburg, showcasing an evolution in Airbus’ industrial production system.

With a special focus on manufacturing longer sections for the A321LR, the new facility features 20 robots, a new logistics concept, automated positioning by laser measurement as well as a digital data acquisition system. These will further support Airbus’ drive to improve both quality and efficiency while bringing an enhanced level of digitalisation to its industrial production system.

“By embracing some of the latest technologies and processes, Airbus has begun its journey to set new standards in A320 Family production. This new fuselage structure assembly line is an essential enabler for the A320 Family ramp-up. Increasing the level of automation and robotics enables faster, more efficient manufacturing while keeping our prime focus on quality,” said Michael Schoellhorn, Airbus Chief Operating Officer.

For the initial section assembly, Airbus is using a modular, lightweight automated system, called “Flextrack”, with eight robots drilling and counter-sinking 1,100 to 2,400 holes per longitudinal joint. In the next production step, 12 robots, each operating on seven axes, combine the centre and aft fuselage sections with the tail to form one major component, drilling, counter-sinking, sealing and inserting 3,000 rivets per orbital joint.

Besides the use of robots, Airbus is also implementing new methods and technologies in material and parts logistics to optimise production, improve ergonomics and shorten lead times. This includes the separation of logistics and production levels, demand-oriented material replenishment as well as the use of autonomous guided vehicles.

The Hamburg structure assembly facility is responsible for joining single fuselage shells into sections, as well as final assembly of single sections to aircraft fuselages. Aircraft parts are equipped with electrical and mechanical systems before eventually being delivered to the final assembly lines in France, Germany, China and the U.S.

 

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One Technology—Many Benefits

One Technology—Many Benefits

Here’s a look at punching technology innovations and and the benefits like helping manufacturers toward their Industry 4.0 journey. Article by Trumpf.

Punching encompasses far more than just making holes in sheets. You can manufacture complete parts on a punching machine. Reshaping processes open up new dimensions for you. The versatility of the technology is the result of the wealth of tools used. With appropriate loading and unloading aids, you can even automate your production.

Monotool Punching Head Principle & Rotating Tools

The monotool punching head principle means that different tools can be exchanged into the punching head, and all of them can be rotated 360 deg.

It offers higher process reliability as the punches are always connected to the punching head in a form locking manner. Not only does it perfectly guide the tools down onto the sheet metal, it also guides them off the sheet metal in a controlled manner after the punching process.

Its reduced setup outlay provides easier handling. Tools can be used for multiple applications due to their rotational ability, resulting in fewer tool change and setup operations.

And fewer punching tools mean lower costs. Imagine the ability to create an oblong hole with every conceivable orientation in the sheet metal—with just one tool! This is really easy if the punching head is 360 deg rotatable, this works with all contours that you have a tool for, regardless of whether it is a standard or special tool. The ability of all your tools to rotate multiplies your processing options and reduces your tool requirements, and therefore your costs.

Tooling for Punching

With the increasing complexity of market requirements, sophisticated components can no longer be solved with standard tools. The need for manufacturing highly complex components in shorter amount of time require special tools, and using the right tooling is the prerequisite for successful punching.

For punching, there exists different tooling options. The Classic punching tool system is the leading tool system for punching machines. Due to the broad range of forms, shears, coatings, and accessories, you can use it with flexibility.

Another tooling option is the MultiTool, which integrates up to 10 different punching and die inserts in one tool adapter, increasing flexibility, efficiency, and productivity as different punching operations can be carried out by one tool. Additionally, forming and embossing can be carried out. Another benefit is the reduction of non-productive times due to reduced setup and tool change times.

Scratch Free Processing

When it comes to punching, the end result heavily depends on the right process, and it is crucial that the products are scratch free at the end of the process.

The basis for scratch-free processing is the use of brush tables, which provide soft support to the sheet and thereby preventing scratches and reduces noise. During positioning, the sheet slides over the brushes, which, due to their length, bend in the direction of movement.

Also, through raising brush field and support plates around dies, the contact between sheet and die will be reduced, leading to less scratches during the punching and forming.

  1. Solutions for punching-tools

Adhesive pads are pre-formed, self-stick polyethylene film and can be attached to dies, strippers and intermediate rings to prevent scratches on the workpiece. To avoid imprints and scratches on the sheet surface, a specially coated stripper can be used. The coating is also is wear-resistant and keeps material abrasion chips from sticking to it.

  1. Special die solutions

To reduce scratches for intermediate rings and dies, brushes or Ampco can be used. Ampco is a soft alloy that avoids scratches on the bottom of the sheet because of its softness and lubricant effect. Another option are descending dies that, by moving downwards during the positioning of the sheet, eliminate the contact of metal between workpiece and processing station. Active dies additionally operate a second punching head able to perform an active forming stroke from below, broadening the rage of processing strategies and tool usage and enabling new forming sizes and heights.

  1. Gentle material handling through intelligent automation

By using different automation solutions, scratches can be easily prevented before and after production. A conveyor belt with soft surface, where finished parts are ejected from the punching machine, ensures gentle handling.

Loading, unloading, stacking can be automated as well and by using a vacuum technology during these steps, scratches during part pick up, transport and deposit can be eliminated.

Skeleton free processing

Material usage optimisation not only boosts your production but also helps you save a lot. By implementing skeleton free processing, companies can increase their sheet utilization by 10 percent on average—thereby reducing material costs. Additionally, smaller bits of residual material simplify logistics and yield higher scrap prices.

Another advantage is the enhanced process-reliability achieved through the safe unloading of finished parts and small parts even when the part chute is open and through the automatic cut up and removal of residual pieces of sheet metal. Working without a scar skeleton also increases safety and is operator friendly.

Residual pieces of sheet metal can be sorted by material, and good parts and scrap are sorted to different containers. Other benefits of implementing skeleton free processing are savings in operational time by 14 percent on average, and the energy needed for the process itself: operating a punching machine instead of manufacturing a metal sheet consumes about 30-80 times less power, which in turn leads to energy savings equal to the power needed to operate a punching machine for 40 years.

Simultaneously, companies increase output rate through smaller workpieces and enhance their production, hence, significantly boosting their return on investment.

Programming

The software used to execute punching operations has a great impact on success and efficiency. Technology offers many different processing options and the right software should support users to make use of all these possibilities.

A good software should simplify the nestling process and thereby optimize material utilization and save costs. It should also reduce the effort required to generate the NC program for example by applying automatic repositioning and trimming. Choosing a software that has the option for offline programming can reduce machine down time as programmer can prepare the next programs already while the machine is running.

Additionally, settings can be predefined and adjusted to the specific needs of the company. If Industry 4.0 is a topic for your company, a software with the ability to automate processes and integrate systems to make use of Internet of Things (IoT) should be chosen.

Automation for Punching Machines

Automation can save costs and boost production, but it has to be reliable and safe to do so.

Automation can be applied to the loading of raw sheets or blanks and or pre-cut parts and the consequent unloading of finished parts, micro-joint sheets and scrap skeletons. Also, disposal of scrap skeletons and remainder strips and sorting of small parts and punching slugs can be automated with the right machinery.

There are plenty of benefits that automation in punching operation offers, for example, the increase in productivity due to high machine utilization, and reduced factory lead times. Additionally, automation increases process reliability, enhances efficiency, and improves safety during the punching process.

Automated systems typically perform the manufacturing process with less variability than human workers, resulting in greater control and consistency of product quality

Integrated tool management

Automation can come into play even before the punching process is carried out. Before punching, suitable tools have to be selected and set up in the machine. Tool availability, proper assembly and accuracy of tool data in the machine control have to be checked, which is all very time consuming.

With integrated tool management, these steps can be automated—reducing search and setup times. The central data management makes data available anytime, anywhere, and enables direct data transfer between machines.

Tool management automation also increases efficiency of inventory management, productivity and process reliability, as the tools and tool lengths and changes are recorded, while the punch-stripper and die combinations and tool suitability are checked by the system automatically.

The Future of Punching

Punching technology has continuously developed in the last few years, and high-quality punching tools now do not leave any punching burr. Set up, sorting and removal is easier than ever before.

The demand for customer’s quality requirements is increasing, while the batch sizes are decreasing. It is therefore important to make precise calculations, but this is not exactly easy when a part is manufactured on several machines. The solution? Combining two technologies: punching and laser cutting into a single machine. And the benefits are below:

  1. A combination that pays off

The punching head reaches standard contours and formings, while the laser cuts more complex contours, allowing you to produce a wide range of parts and even complete challenging orders on a single machine.

  1. Lean logistics: Gain freedom

Integrate cutting, punching and forming processes on a single machine will reduce your calculation risk and the floor space required. Reduced waiting times and workflows such as setup and handling allow you to make multiple savings.

  1. Combined processing: Best quality

Combining fits or forming with laser cutting not only reduces the waste you produce but allows you to manufacture high-precision components in a quality that was not possible to achieve when processing on several machines.

  1. Short process chain: Simple logistics

With the right automation, your machine handles all parts automatically—loading, producing, sorting, stacking, unloading, and storing. There are virtually no limits to its loading and unloading capacity, therefore your machine works around the clock as needed.

 

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Bearing Solutions And Dynamic Motion Systems For Robot-Based Automation

Bearing Solutions And Dynamic Motion Systems For Robot-Based Automation

Industrial robots have established themselves in the competition for efficient automation solutions for a wide variety of handling and machining tasks. This development has been accelerated by increasing quantities and the associated fall in purchasing costs and by technical progress regarding rigidities and possible loads. Articulated arm bearing supports play a decisive role in the load carrying capacity, dynamics, and precision of robots. Schaeffler offers solutions for each of the six axes with their specific requirements.

INA XSU-series crossed roller bearings: Ideal for narrow design envelopes thanks to their high load carrying capacity and rigidity with a small bearing cross-section

Swivel joint bearing supports for articulated robots

The lower swivel bearing support for axes 1 and 2 of a robot supports the entire weight and the largest tilting moments. What makes things even more difficult is the fact that tilting in the bearing support is multiplied as far as the tool center point (TCP). This is where Schaeffler offers INA ZKLDF double-row axial angular contact ball bearings with very high tilting rigidity, which are well known from the machine tool sector. Their solid bearing rings are screw mounted to the adjacent construction.

Axes 3 and 4 still support a significant proportion of the robot arm’s weight, however, the installation space in the joint is already significantly restricted. This calls for a high load carrying capacity and rigidity with a small bearing cross-section. Schaeffler’s engineers have optimised INA XSU-series crossed roller bearings especially for the increasing requirements in this application. A particularly high filling level with cylindrical rollers ensures increased rigidity.

Double-row bearing supports, particularly those in an O arrangement, offer major potential for bearing supports with very high tilting rigidity due to their very large support distance and small axial design envelope. INA SGL-series angular contact roller bearings also have a very rigid roller contact. Schaeffler recommends a combination of both types, particularly for axes 5 and 6 with small articulated arm diameters. SGL bearings can be very flexibly integrated into the available installation space between the robot’s gearbox and the housing due to their small cross-section and diameter graduations.

The 7th axis – the extended arm

A so-called 7th axis is frequently used to extend the working area of industrial robots or enable them to move greater distances. The robot is moved between individual machine tools or stations and the magazines and palette systems on a table of the linear axis. The INA KUSE six-row monorail guidance system in X-life quality is particularly suitable as a guidance system here. It offers a very high nominal rating life, reduced lubricant requirement, and extremely small stroke pulsation. In a compressive direction, this six-row monorail guidance system has a particularly high load carrying capacity and is therefore ideally suited for combination with direct drives. In order to maximise the availability of the entire production cell with X machine tools, Schaeffler offers DuraSense as an option for its monorail guidance systems. DuraSense’s integrated sensor system enables automated lubrication or monitoring of the lubrication condition of carriages. The risk of unplanned downtimes due to wear and lubrication failure is significantly reduced.

INA linear actuators and driven linear units can be combined from an extensive range to form cartesian systems. INA MTKUSE telescopic actuators are suitable for transport and handling tasks in workpiece and tool magazines, for example.

Cartesian systems: Cost-effective, dynamic, and precise

It is not always necessary to use an expensive robot for handling workpieces and tools. These tasks can be frequently still performed by cartesian axis systems, which are constructed from linear actuators that can be combined. Schaeffler offers an extensive range of INA linear actuators and driven linear units in this field. Linear actuators with special functions expand the range of applications. MTKUSE telescopic actuators, for example, allow a handover in areas behind protective barriers or in separate workspaces.

 

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Interroll’s New Plant In Thailand Fully Operational

Interroll’s New Plant In Thailand Fully Operational

Interroll (Thailand) Company Limited has moved to a new, state-of-the-art plant in Phantong (Chonburi) in order to seize growth opportunities in Southeast Asia.

Interroll Thailand has completed its relocation to a new location in Phantong (Chonburi) which provides a shop floor of more than 4,800 square meters as well as a 700-square-meter office space in attractive Interroll design.

The construction of the new plant in Thailand is an important part of Interroll’s consistent globalisation strategy. Growth markets in Southeast Asia—especially Indonesia, Philippines, Vietnam and Myanmar—show a good demand for Interroll products, with significant potential for the long-term future. Moreover, an increase in the base of installed material handling systems in the region provides additional opportunities for services in the region.

“We are running a state-of-the-art location with improved capacities here,” says Grisorn Nakapong, Managing Director of Interroll Thailand. “The locally manufactured products are Rollers, RollerDrive, Pallet Flow, and Drum Motors service. Our customers can also count on upgraded Drum Motor services, which we provide at this location.”

 

Increased productivity and shorter delivery times

By the end of 2019, a production line for the Modular Conveyor Platform (MCP) will be added. Moreover, the container loading area has been laid out to support big orders of Pallet Flow for markets in Southeast Asia. The facility also provides an in-house canteen for the employees as well as multipurpose areas for sports and team building activities. Modern office concepts facilitate communication among employees and within project teams.

“By introducing product lines with One Piece Flow and a high degree of automation, we have further raised our productivity significantly,” says Jens Strüwing, Executive Vice President Products & Technology at Interroll. “The new plant enables us to shorten delivery times for our customers in the region by 30 to 50 percent and to produce a much larger range of our solutions in proximity to our Southeast Asian target markets.”

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Bystronic On Flexible Automation

Bystronic On Flexible Automation

With products becoming increasingly customised and batch sizes growing ever smaller, manufacturers need flexible and automated solutions that are capable of processing small batch sizes. Here’s how Bystronic is helping them. Article by Stephen Las Marias.

Bystronic Group is a leading global provider of high-quality solutions for the sheet metal processing business. The focus lies on the automation of the complete material and data flow of the cutting and bending process chain. Bystronic’s portfolio includes laser cutting systems, press brakes, and associated automation and software solutions. Comprehensive services round off the portfolio.

The company headquarters are located in Niederönz, Switzerland. Additional development and production locations are located in Germany, in Italy, and in China. Bystronic is actively represented by its sales and service subsidiaries in more than 30 countries and has agents in numerous other countries.

In March 2018, Bystronic expanded its existing portfolio of technologies with the acquisition of TTM Laser S.p.A, an Italian company headquartered in Cazzago San Martino, which specialises in the development of 2D and 3D laser systems for the cutting of tubes and profiles and for the welding of large-format metal sheets. TTM Laser’s tube processing technology can be applied to a host of industries, ranging from the need for precision components in steel for makers of furniture and exercise machines, to tubes to help construct the chassis of automobiles and agricultural machinery.

Bystronic completed the integration of TTM Laser into the Group last May 2019. This was marked with the opening of a new Experience Centre and the launch of a new laser cutting system ByTube 130. The 3,200-square-metre Experience Centre includes a modern showroom, in which the newest technologies for tube and profile processing will be presented. TTM Laser’s facility in Cazzago San Martino will now be Competence Centre Tube Processing of the Bystronic Group.

The new ByTube 130 is the optimal solution for sheet metal processing companies that want to expand their portfolio to include tube processing, to capture a wider market including automotive and construction industries right through to furniture, machine, and equipment manufacturers. ByTube 130’s automated system reduces the need for manual interventions to a minimum, making the entry into the field of tube processing particularly easy. At the same time, the machine covers a very wide range of requirements: Since 85 percent of the market potential lies in the small tube segment, the ByTube 130 is geared toward the processing of tubes with diameters between 10mm and 130mm. The machine has a loading capacity of 17 kilograms per meter. The 2D cutting head allows a large proportion of customer requests to be processed, since vertical cuts account for 90 percent of the market.

In an interview with Asia Pacific Metalworking Equipment News (APMEN), Norbert Seo, senior vice president, Market Division Asia & Australia, Member of Group Management, ​​talks about the trends he is seeing in the market, drivers for growth, and how Bystronic is helping customers address their manufacturing challenges. He also provides his insights on the Southeast Asian market, and his outlook for the metalworking industry in the coming year.

Norbert Seo

What would you say are the key competitive advantages of your company?

Norbert Seo (NS): Bystronic believes on building long-term partnerships with its customers. We believe in commitment and trust, in highest quality, in lifetime support and in local expertise. It’s crucial for our customers that their production never stops. Beside latest technologies and high-end solutions also service is a very important aspect. It is this full package that gives customers peace of mind. And this is what we have in mind when we are offering “Bystronic. Best choice”.

We are supporting our customers where they are today. We are showing them a clear vision, e.g. regarding Smart Factory, and define together with them the next steps for growth, for getting ahead in the competition, for manufacturing metal products smarter and faster than ever before. That’s Bystronic! That’s our commitment to all our customers worldwide.

What are the major drivers of growth for your company?

NS: Bystronic is always innovating, coming up with higher powered laser cutting machines in increasingly larger formats, and coming up with automation systems that helps increase productivity for our customers.  As the need for quality cutting and faster turnaround increases, so do the demand for bigger, powerful, more efficient systems.

Please enumerate the top three trends in markets that you are serving, and how do these trends affect your business in terms of product development and/or manufacturing?

NS: For many customers, looking ahead to the future of their own sheet metal processing operations means: being able to adapt to fluctuating order situations; mastering cost and time pressure by applying the most efficient processes and systems available; and, positioning themselves on the competitive global or local markets with leading technologies and manufacturing solutions.

A clear trend in the markets of our customers is that big batches and mass production is getting less and less. Products are getting more customised, and batches are getting smaller and smaller. So, our customers do need solutions to produce small batches in a flexible and automated way. That is a big need, because today they have to do that manually. Therefore, flexible automation will be one of the trends in the future.

Another trend is shorter delivery times. People want their products straightway. Nobody wants to produce for stocks anymore or according to forecast, and this is even more challenging. You have to be fast and you have to be automated. Having said all these points, Bystronic is in the direction where the industry is going. We offer concepts and solutions that are very closely designed to the needs of our customers. We enable customers to fully optimize and automate their operations in multiple shifts, as well as end-to-end solutions that cover cutting, bending, material handling, plus process and data management.

When you talk to your customers, what are the biggest challenges that they usually encounter?

NS: About 80 percent of Bystronic customers in Southeast Asia are job shops, whose focus are on individual machines or automated solutions. What these job shops need is a business reliable technology and service provider that they can easily contact, and who can visit their shops at once. That is why we are focusing on strengthening our local expertise. We are talking with our customers about what is bothering them, what solutions Bystronic can develop for them, and what the next step for their production processes could be.

For job shops, the next step could be a powerful fibre laser with an automated loading and unloading solution to increase productivity. Or a fully automated material and data flow to enable virtually autonomous operation in multiple shifts. Advanced users and large metal processing companies also think in other dimensions. Here, we are talking about end-to-end solutions that cover cutting, bending, material handling, as well as process and data management—so called Smart Factory concepts.

How is your company helping your customers address these challenges issues?

NS: There is a lot of talk about Industry 4.0. However, customers do not fully understand this concept and do not yet have a precise idea of what they can achieve with this. Our answer to their demands is our vision of the smart factory.

The Smart Factory is a journey. Step by step the customer achieves the highest level of productivity; where all processes from the initial order inquiry to the delivery of the metal sheets, and right through to the shipping of the finished parts are automated and digital connected.

Most of our customers in Southeast Asia have small job shops with one laser and press break. We will guide them in this journey. It is a growth path to achieve more profit and competitiveness. We will provide suitable solutions for cutting, bending, automation and software. And we will definitely help them step-by-step on the path towards it.

What opportunities and trends are you seeing for the metalworking industry in ASEAN in the upcoming years?

NS: There is a very good reason why everyone is talking about Industry 4.0. Bigger companies and job shops are taking small but forward steps towards incorporating diverse and flexible automation systems such as loading, unloading, storage, sorting, tool changing, etc., into their manufacturing processes. It is only a matter of time before late adopters follow suit.

What is your outlook for the metalworking industry in the coming year?

NS: In general, we can see that the market is getting tougher and the reason is price issue. Normally our customers and their end-users are asking for very competitive prices. Aside from a viable machine price, the equipment must also be effective. For example, you have one hour to produce 50 parts, therefore our machine must be able to manufacture 60 or 70 parts compared to our rivals. Producing excellent products is always a challenge. For this, Bystronic provides productive machines that offer stability, speed and highest quality on the market.

 

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PMR Study: Servo Motors & Drives Sales Continue To Benefit From Rising Factory Automation

PMR Study: Servo Motors & Drives Sales Continue To Benefit From Rising Factory Automation

The global servo motors and drives market was valued at ~ US$ 9 Bn in 2014, and is expected to surpass US$ 12 Bn by the end of 2019. The servo motors and drives market is expected to grow at a CAGR of ~eight percent between 2019 and 2029, and is estimated to reach a global value of ~ US$ 28 Bn by the end of 2029.

A new market study on the servo motors and drives market, which includes the global industry analysis 2014–2018 and forecast 2019–2029. The report studies the global servo motors and drives market and offers an in-depth analysis for the next ten years. The report on the global servo motors and drives market contains vital macroeconomic and forecast factors that are estimated to drive the growth of the global servo motors and drives market. The report on the servo motors and drives market also discusses restraints that are expected to hamper the global market, along with potential opportunities and latest trends in the market across the value chain.

 

Servo Motors And Drives Witnessing Lucrative Opportunities In Non-Traditional Application Areas

By application, the robotics segment is likely to hold a significant share across the globe due to the unprecedented developments in the robotics industry and heavy adoption of robotic techniques in various end-use industries. The printing and packaging equipment segment will also show a decent share hold over the market and is set to register a healthy growth over the forecast period. Moreover, in food & beverages industry, servo motors and drives are playing a vital role to make accurate packages of foods or cold drinks. Thus, servo motors and drives application is not limited to the above mentioned industry but also these motors are gaining healthy traction in other industries such as pulp & paper, and textile, among others.

By technology, the servo motors and drives market is segmented into single axis servo systems and multi axis servo systems, among which, the single axis servo systems segment is expected to attract end users and is likely to witness more traction in the servo motors and drives market. The reasonable cost and efficient performance of single axis servo systems is likely to play a pivotal role for the substantial growth in the market of single axis servo systems.

By product type, the global servo motors and drives market is segmented into linear servo motors and rotary servo motors, and both the segments are projected to have near about equal sales with linear servo motors gaining a slight edge in terms of market share. Linear servo motors are manufactured by several manufacturers, which provides customer liberty to choose a product best fit for their purpose. Due to this scenario in the market, linear servo motors have a slightly more sales across the global market. Moreover, linear servo motors and drives are used for repetitive operations such as assembly and arrangement on XY table, CNC machine, etc.

 

AC Servo Motors & Drives Account for 75 percent of Total Sales

By motor configuration, the global servo motors and drives market is segmented into AC servo motors and DC servo motors and to provide a more specific outlook AC servo motors and drives are further categorised into industrial type and asynchronous type. On the other hand, DC servo motors are categorised into brushless DC motors, separately excited DC motors and permanent magnet DC motor. On the global perspective, AC servo motors are more likely to be preferred in the market due to its ability to operate with the AC current as well as it also pick up frequently light load and heavy load. Almost 3/4th of the market is estimated to be held by the AC servo motors and drives across the globe. Meanwhile, synchronous type AC motors are going to be the top choice of customers among other offerings of servomotors. In the DC servo motors and drives market, all the three sub-segments are expected to attract the target customers in the market.

By rated power capacity, the global servo motors and drives market is segmented into 400 – 750 W, 750 W – 1 kW, 1 – 5 kW, 5 – 15 kW, 15 – 50 kW, and 50 – 100 kW. The demand for these products depend on the requirement of end users. Although, the servo motors and drives 750- 1Kw segment is expected to remain paramount share holder in the market over the forecast period. However, the demand for servo motors and drives entirely depends upon its requirement and applications.

By region, the servo motors and drives market has been segmented into six regions, namely North America, Latin America, Europe, East Asia, South Asia, and Middle East & Africa. In these regions, The Europe market is estimated to grow with a noteworthy share in the global servo motors and drives market over the stipulated time period. However, East Asia & South Asia regions are estimated to grow with significant collective share throughout the forecast period. Moreover, the North America region is expected to account nearly 10 percent share in the global servo motors and drives market owing to the rising awareness of end user towards accuracy and precision, coupled with the factory automation.

 

Competition Analysis

The global servo motors and drives market is characterised as a fragmented market, owing to the significant presence of well-established and small-scale manufacturers of servo motors and drives across the globe. For profound analysis, Study has analysed the global market in three categories: Tier-1, Tier-2, and Tier-3. Here, Tier 1 players are estimated to account for large share in the global market. Furthermore, increasing number of full-fledged companies mainly from emerging regions such as in China, are making competitive structure in the global servo motors & drives market.

Moreover, renowned players in the global market are adopting business expansions, acquisitions, collaborations, and product launch strategies, in a bid to promote substantial growth to the servomotors and drives market.

  • In April 2019, Siemens AG launched an enclosed IEC motor for industrial and construction application, which highlighted the product innovation performance of the company.
  • In June 2019, Mitsubishi Electric Corporation inaugurated its new office in Boston, U.S. to improve its presence in the market of North America.

Some of the key players identified across the value chain of the global servo motors and drives market includes Siemens AG, Panasonic Corporation, Parker Hannifin Corporation, Nidec Motor Corporation, Delta Electronics, Inc., Fuji Electric Co., Ltd., Hitachi Industrial Equipment Systems Co. Ltd, Mitsubishi Electric Corporation, Schneider Electric, Rockwell Automation, Inc., ABB, Applied Motion Products, Inc. Altra Industrial Motion Corp., etc.

 

These insights are based on a report on Servo Motors and Drives Market by Persistence Market Research

 

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LVD Announces Acquisition Of Italian Industrial Automation Firm, COMPAC S.r.l.

LVD Announces Acquisition Of Italian Industrial Automation Firm, COMPAC S.r.l.

LVD Company nv has acquired COMPAC S.r.l. of Urbino, Italy, an industrial automation solutions provider. LVD has partnered with COMPAC since 2016 to produce automatic warehouse systems for numerous LVD laser cutting equipment installations in Italy. The acquisition expands LVD’s portfolio of automation systems for flat sheet and tube laser cutting machinery at a time when sheet metal fabricators are increasingly automating their production processes to improve overall efficiency.

A 30-year-old, family-owned business, COMPAC S.r.l. specialises in the design, manufacture and integration of high-tech automatic warehouse systems, input and output handling systems, load and unload devices, and custom automation systems for industry. COMPAC has steadily grown its business and automation products. Its automation solutions are diverse, including handling systems for magazine and cardboard industries and conveyor lines for metal cleaning machines.

With the acquisition, COMPAC becomes part of the LVD Group. LVD will add COMPAC systems for metal fabrication to its automation offerings, broadening the choice of solutions for its punch press, fiber laser and tube laser cutting machines for customers worldwide. The metal fabrication systems will be branded as LVD. COMPAC will retain its brand for automation solutions supplied to other markets. All COMPAC products will continue to be manufactured at its leading-edge 7000m2 production site in Italy.

“COMPAC is an innovative manufacturer with a strong engineering mindset and a proven history of advanced automation solutions,” explained LVD President and Managing Director, Carl Dewulf. “Our acquisition of COMPAC was driven by our interest in securing a strong future for our automation product line, to offer our customers the most advanced and reliable automation technology to keep pace with the advances of fiber laser cutting. With COMPAC as part of the LVD Group, we gain additional automation know-how and systems experience.”

 

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Sustainable Manufacturing Thanks To Fiber Lasers And Automation

Sustainable Manufacturing Thanks To Fiber Lasers And Automation

A fiber laser cutting system, a matching automation solution, and innovative software enable companies to increase their productivity while simultaneously saving energy. The Haslach Group, based in the Allgäu region in Germany, shows how this can be done.

Twice the output for the cutting process with the same electricity consumption – fiber lasers are considerably more efficient than CO2 lasers. This saves resources while simultaneously increasing output. And this is why the transition was an obvious step for the Haslach Group: “We want to be able to fulfil our customers’ increasing demand and we have found a reliable partner with Bystronic,” says Managing Director Marita Haslach-Dann.

In order to meet the growing demand while simultaneously saving resources, two ByStar Fiber 4020 fiber laser cutting systems have been in operation in the Haslach Group’s production halls since December 2018. Each equipped with a laser output of six kilowatts, they can cut metal sheets up to a size of four by two meters – ideal for Haslach, a medium-sized company well-known for its ability to process large-format metal sheets.

Wide Range Of Applications

On the outside, the ByStar Fiber 4020 stands out thanks to its attractive design. On the inside, there is patented laser technology: a cutting head developed by Bystronic that precisely adapts the focal point of the laser beam to match the sheet thickness and material. This enables the fiber laser cutting system to consistently achieve the optimal processing quality in spite of varying sheet metal thicknesses and materials.

The ByStar Fiber 4020 cuts up to 30 millimeter thick steel and guarantees clean cutting edges in a wide range of sheet metal qualities. This makes it possible to cut intricate contours in the best possible quality. Complex geometries can also be implemented with ease. Moreover, the range of applications is broader in comparison to CO2 laser cutting machines: The new systems can handle a wide variety of sheet thicknesses and an extensive range of materials, including non-ferrous metals, such as brass and copper. The Haslach Group benefits from this added flexibility, because many of its customers have very specific requirements.

Customised Automation Solution

In order to ensure the rapid loading and unloading of the fast machines, the Haslach Group uses a matching automation solution on both of its fiber laser cutting systems: the ByTrans Cross 4020. “An ideal match,” Marita Haslach-Dann explains. “The automation helps us to work more ergonomically and to increase our throughput. This enables us to produce efficiently.” In spite of the fully automated material supply, operators can manually feed in sheets whenever required.

The inflow and outflow of materials is connected to a high-bay warehouse. The Haslach Group had specified an automated warehouse system, but only one supplier was able to meet their specific demands: “Bystronic rapidly implemented a customised solution for us,” Marita Haslach-Dann says. It was the overall package of cutting systems, automation, software, and service that convinced her.

Software Brings Transparency To Manufacturing

Cutting plans are created using the Bystronic BySoft 7 software, where programmers work in a 3D CAD environment. The 3D models provide a tangible idea of the parts that are to be produced. The BySoft 7 software automatically selects the best possible cutting technology and helps optimise cutting processes. It also ensures optimal use of the raw sheets based on the highly sophisticated nesting of parts.

Thanks to the touch screen, operators always maintain an overview: Production and machine data are retrieved in real time. Operation is so user-friendly that one employee can supervise several machines at the same time. “With the previous systems, we had one operator for every machine,” says Marita Haslach-Dann. The staff have been assigned to new tasks because the high cutting speed of the ByStar Fiber 4020 results in the output of more cut parts that require sorting.

In order to ensure all employees have an overview of the production process, the Haslach Group also relies on planning software from Bystronic, the Plant Manager. The programmer is enthusiastic: “We can always see at what capacity the machines are running,” he explains. “This allows us to flexibly coordinate individual steps of the workflow to accommodate short-term change requests.” Virtually real-time access to all the relevant production and machine data makes it possible to adapt production processes to be able to accept last-minute customer orders.

Doubled Productivity

Programming and planning software has transformed production into a digitally networked manufacturing landscape. Employees can constantly monitor the flow of information and quickly implement plans. “Our path from the incoming order to the end product has become faster and more efficient,” Marita Haslach-Dann explains. The Haslach Group’s head of the cutting department confirms this: “We have successfully increased productivity by 50 to 60 percent when processing thin sheet metal.” The results are impressive: The perfect cutting edges satisfy even the most demanding customers.

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