ZEISS’ investment in Senorics marks the start of a technology collaboration with the sensorics startup based in Dresden, Germany. The partnership aims to further the joint development of small and cost-effective sensors for industrial use in quality assurance and in process monitoring, e.g. on production lines for foodstuffs, agricultural products, plastics and medicine.
ZEISS can draw on its longstanding, extensive knowledge in the development, manufacturing and marketing of optical and photonics systems, as well as the digital solutions that go with them – particularly in quality measuring technology. At the same time, the company is actively shaping global markets in the field. Senorics now stands to benefit from this expertise.
And ZEISS will get the chance to use the Senorics technology to tap into new applications that it was previously harder to do with the technologies in its portfolio.
“We will begin by examining common application cases. Senorics’ innovative technology has the potential to create compact, cost-effective sensors for applications such as compositional analysis. The investment is a way of consistently implementing our strategy in the field of Advanced Sensor and Data Solutions,” says Dr. Philipp Strack, Head of ZEISS Ventures.
“The fact that ZEISS has approved the quality of our technology and would like to use it in the future considerably increases our customers’ trust,” says Dr. Ronny Timmreck, CEO of Senorics GmbH. “Moreover, the collaboration with ZEISS supports us with both the development and marketing for our technology. What’s more, the collaboration with ZEISS following the closing of our seed funding round in late 2018 was a further milestone in the long-term advancement of Senorics.”
To even better meet the needs of its Asian customers, Leuze electronic opens a new central logistics center in Singapore for the Asian market.
Following the groundbreaking ceremony in June for its central, global logistics center in Unterlenningen, near the company’s headquarters in Owen in southern Germany, Leuze electronic now opened its new distribution center in Singapore.
“The high number of orders over the last years has been a positive challenge for us and requires a new form of global warehouse logistics,” explains Ulrich Balbach, CEO at Leuze electronic.
In 2018, the positive growth trend of the recent years continued at Leuze electronic internationally. Leuze electronic therefore continues to invest in new global structures – including in Singapore.
“By focusing on our target industries of intralogistics and lab automation as well as our regional expansion in Southeast Asia, we were able to achieve enormous growth on the Asian market,” says a pleased Matthias Höhl, Vice President Asia, at Leuze electronic.
The optical sensor manufacturer sees Asia as an important growth market for the future as well. The new central Leuze distribution center in Singapore will operate in the local time zone and thereby even better meet the needs and requirements of its Asian Leuze customers.
“For Leuze electronic, the opening of its new central logistics center in Singapore is an important step for continuing to participate in the high growth rates of the Asian market in the future and further expanding our market share in Asia,” says Balbach.
OMRON Corporation has launched the E2EW Series Full Metal Proximity Sensors, which boast the world’s longest sensing distances. The sensors enabled both detection stability for different material components and durability with the full metal body. They help enhance productivity in the automotive industry, where downtime leads large production opportunity losses, by reducing risks of sudden stoppages due to sensors occurred in the welding processes for automobiles.
Automotive industry needs lighter weight of automobiles in accordance with the trend of electric vehicles and low fuel consumption, encouraging the material change in automotive components from iron to aluminum. This will increase mixed production lines containing iron and aluminum. Full metal proximity sensors are mainly used in harsh welding processes. However, previous full metal proximity sensors have short sensing distances. In particular, the sensing distance for aluminum is shorter than the one for iron. Therefore, higher accuracy is required for installing proximity sensors for aluminum than iron, making the design, start-up, and maintenance of production lines complicated. With skilled labor shortages becoming severer, however, demand is growing for ways to maintain and enhance facility operation rates without relying on human experience or skills.
The sensing distance are approximately twice as long as previous models for iron, and six times as long as previous models for aluminum, meaning equivalent sensing distances to detect iron and aluminum components. In addition, OMRON’s technologies prevents coating abrasion which allows 60 times longer-lasting spatter resistance than previous models. The E2EW Sensors with its durable body and long sensing distance increase sensor installation flexibility, and they help enhance productivity by streamlining production lines which require skills from the start-up, operation, to maintenance.
The application of the acoustic emission (AE) sensor for monitoring can supply valuable information regarding the discontinuity in material. By Tim Wood, international sales manager, SBS
Changes in micro-stresses within CNC machine tool structure, caused by contact between tooling and work-piece, generate high frequency signals known as acoustic emission, or AE.
It’s best described as the phenomenon of radiation of acoustic waves in solids that occurs when a material undergoes irreversible changes in its internal structure.
It also generally refers to the generation of transient elastic waves produced by a sudden redistribution of stress in a material. When a structure is subjected to an external stimulus (change in pressure, load, or temperature), localised sources trigger the release of energy, in the form of stress waves, which propagate to the surface and are recorded by sensors.
Detection & Analysis
AE signals can be detected using an Acoustic Emission Monitoring System (AEMS), and used for advanced machine process control. With the right equipment and setup, motions on the order of picometers (10 – 12 m) can be identified. vDetection and analysis of AE signals can supply valuable information regarding the origin and importance of a discontinuity in a material. Because of the versatility of Acoustic Emission Testing (AET), it has many industrial applications (eg: assessing structural integrity, detecting flaws, testing for leaks, or monitoring weld quality) and is used extensively as a research tool.
In the case of grinding machines, this high frequency structure borne noise is created when the grinding wheel touches the part, or the diamond dresser. AE signals travel through solid materials, for example, tooling, with high velocity, meaning they are an ideal parameter for the detection of grinding wheel contact within milliseconds of time, or microns of axis travel.
Double disk grinding (DDG), a form of face grinding, is no exception. The recent application of the AE system to a DDG grinding process for rolling element IR (Inner Race) bearing faces resulted in 0.5 seconds saving on a 3.6 second grind cycle – a 14 percent reduction. In this case, the saving was made by using the system to detect contact between grinding wheels and work.
Eliminating The Gap
The process, also known as GapElimination or GE offer the ability to detect part contact in less than 1 millisecond. It also allows higher machine feed-rates, and less air grinding time, typically saving anywhere from 10 percent to 20 percent of cycle time.
Correct AE sensor location and mounting on the machine is critical. To achieve maximum sensitivity, best AE signal path and biggest cycle time reduction, a non-contact acoustic sensor was mounted on the rotary loader spindle. The corresponding stator was mounted on the guard door of the loader.
For Monitoring Purposes
Acoustic emission sensors can also be used for dressing monitoring on double disk grinding machines — either point or rotary diamond units — giving dresser touch detection, accurate machine indexing and monitoring of dressing profile.
For maximum efficiency gains the system can be interfaced with the machine CNC or PLC via hardwire, profibus or Ethernet protocols.
The SBS AEMS system is a permanent installation on a machine tool, and is available to machine manufacturers or as a retrofit package to end users. SBS can combine acoustic emission signals with other measurable machine parameters such as spindle power and work-piece RPM using a system called ExactControl.
The CyberCon4 sensor system by Heimatec can be used to measure various tool parameters such as operating time, rpm, temperature or humidity. Collected data is forwarded to a monitoring station after a defined time cycle via Bluetooth technology and can then be used for evaluation and maintenance activities.
A moisture sensor detects entry of liquids, such as cooling lubricants, into the tool and the machine, so that major damage or machine failures can be prevented. Monitoring software allows for tools equipped with the sensor system to be monitored, hence maintenance cycles can be managed.
While using acoustic data in machine maintenance is not new, the use of airborne acoustics is. We speak to Amnon Shenfeld, co-founder and chief executive officer, 3DSignals, on the role this plays in predictive maintenance.
Trends of manufacturing precision, miniaturisation and cost reduction are taking place across almost all industries. Asia Pacific Metalworking Equipment News speaks to Optical Gaging (OGP) president Stephen Flynn on the importance of utilising such trends in Asia’s rapidly-developing industries.
Q: What is the outlook for the multi-sensor measuring system industry in Asia?
Stephen Flynn (SF):The market for multi-sensor metrology in Asia continues to grow rapidly as products being manufactured become more sophisticated. The trends of precision, miniaturisation, cost reduction and rapid development continue across almost all industries, and these trends drive the needs for more and better metrology to manage and control manufacturing processes and improve quality.
Q: Can you give us the insight into which sectors of the metalworking industry in Asia that could see the demand for measuring products?
SF: Both subtractive and additive manufacturing sectors are seeing increased use of high-end metrology. Traditional metal cutting such as grinding, milling and turning continue to rely on in-process metrology to set-up, monitor and control their processes.
Multi-sensor systems are ideal because they can handle more measurements in a single setup, saving time and lowering overall uncertainty. 3D metrology software is ideal for more sophisticated prismatic parts and the use of articulating probes and single or dual rotaries provide 5- and 6- axis capabilities.
Additive manufacturing systems are still in their infancy, but in general have similar needs for first article inspections and in-process monitoring of finished products to manage processes.
What is unique about 3D printing is the degree to which processes are material dependent. Multi-sensor measuring systems are particularly well-suited to characterising parts produced using 3D printing because the array of sensors offers choices to handle the demands of the various materials.
Q: Can you discuss OGP’s goals in Asia for the next few years?
Quicker integration of metrology data into manufacturing and design workflows can enable manufacturers to qualify and stabilise processes more quickly.
SF:Our company is well-positioned throughout Asia to welcome new manufacturing growth, particularly in countries such as Vietnam and Indonesia where OGP has had a strong presence for several years.
The influx of manufacturers in the automotive, aerospace, medical and electronics sectors are quickly adopting multi-sensor technology throughout their quality metrology operations.
South Korea, China and the Singapore, Malaysia and Oceania regions are also continuing to grow more manufacturing industries. We are adding staff, locations and partners to meet the additional needs of customers throughout the Asia-Pacific region.
In addition, OGP will introduce a raft of new sensor and software technologies worldwide over the coming two years—some in the mid-market and some in the very high end of the precision spectrum—but all with a focus on practical implementation and ease of use in everyday manufacturing.
Q: With accelerating advances in software and component design, how does OGP stay on top of such changes in discussions with customers?
SF:The acceleration of data-driven manufacturing models (Industry 4.0, Smart Manufacturing, etc) highlights the need to continually engineer our measurement systems and software so they are practical, useful and easy to use in everyday manufacturing settings.
Obviously more complex measurements require more complex solutions, but in general our range of measurement systems and software covers a broad spectrum of use cases, so that regardless of a component’s design or manufacturing process, chances are we have a system that is a good fit with the needs of the user.
We use the full range of optical, sensor, software and mechanical configurations available from OGP to help solve each customer’s process metrology needs.
Q: Is there an identifiable technology uptake pattern in Asia in regard to metalworking and sensor technology?
SF:Historically, the nature of manufacturing process in each country or region has been in proportion to the overall economic activity level of the region.
The more developed economies had the more sophisticated and high value added production, while the less developed regions had more basic industries.
That trend has changed due to many factors, and today we see advanced manufacturing being located closest to where consumer demand is expected to be the highest in the future. In effect, there are very few, if any boundaries, anymore as far as technology adoption is concerned.
Q:How do you go about building a customer base in Asia?
SF: Our view has always been that a quality product that solves real problems, offered at a fair price with excellent locally-based customer support, will be successful. The key for us has been our local support team who are instrumental in serving our customers throughout Asia.
We located our Southeast Asia regional business centre in Singapore (and branched out from there) because of the ease of conducting trade in the region and its convenient access to major markets in Asia.
Q: Finally, can you discuss industry-wide manufacturing trends — such as factories of the future and how this may work in the global supply chains of areas of focus such as the automotive, aerospace, metalworking and other industries?
SF:The trend across all advanced manufacturing today is to reduce time to market. The vision of Industry 4.0 and other Smart Manufacturing models is to use manufacturing data (CAD, CAM, PMI, Inspection and Evaluation data) efficiently.
For OGP, that means providing ways to quickly integrate production metrology data upstream into the manufacturing and design workflows to enable manufacturers to qualify and stabilise processes more quickly.
We are developing software tools that do exactly that — integrate metrology data with both manufacturing CAM software, and upstream to CAD design workflows so that it is possible to model, simulate and adjust designs and machining programmes quickly on the basis of real data.
Ditzingen, Germany: Trumpf, a manufacturer of machine tools, has bought 60 percent of shares in France-based BeSpoon—a provider of sensors, system components and software for position-tracking processes.