Nidec Drive Technology Corporation unveils Smart-FLEXWAVE, a groundbreaking precision reducer for robots and machine tools, integrating torque, temperature, and angle sensors to enhance efficiency, reduce size, and enable remote monitoring.

Nidec Drive Technology Corporation, a member of Nidec Corporation’s group companies has developed Smart-FLEXWAVE, the world-first product that combines FLEXWAVE, an existing precision control reducer for robots and machine tools, with built-in torque, temperature, and angle sensors.

FLEXWAVE, the currently available precision reducer with a wave gear mechanism, is used chiefly in industrial robots’ joints for its ability to achieve a high reduction ratio with a single axis, among other features such as light weight, compact size, high rotation accuracy, and super-low backlash. The Smart₋FLEXWAVE, the newly developed reducer that combines torque, temperature, and angle sensors in its mechanism, can detect output torque, temperature inside a reducer, and input axis angle while maintaining an existing reducer’s space. This feature enables Smart₋FLEXWAVE to contribute to making smaller and lighter collaborative robots, detect a robot crashing into an obstacle, and monitor screw tightening torque, overheat, stopping place, etc., all remotely via a network, boosting productivity.

This new reducer of the series will be exhibited at International Robot Exhibition (iREX) 2023 to be held at Tokyo Big Sight (Tokyo International Exhibition Center) from November 29 – December 02, 2023 (The Company’s booth will be E2-27 of Hall East 1-3).

The Company stays committed to providing a variety of fields with its high-efficiency industrial machines based on its reducer- and continuously variable transmission-based knowhow to contribute to productivity enhancement and automation.

The southern region will focus on key enablers of growth that would propel the economic growth of the southern states, with the theme ‘Transformation through Competitiveness, Growth, Sustainability, Trust and Globalisation’ for 2023-24.

The Confederation of Indian Industries (CII) is set to drive the transformation of South India through nine pivotal tracks, aiming to propel the region’s economic growth by 2047. CII’s Southern Region Chairman, Kamal Bali, unveiled this comprehensive plan during the inauguration of a new CII office in Mangaluru. These transformative tracks encompass a wide range of areas, from rejuvenating people and culture to embracing energy transition, innovation, and startup ecosystems, ensuring South India’s development and competitiveness. 

CII will set up state-level task forces on digital transformation to support industries in their digitalisation initiatives. The CII will hand-hold 2,000 MSMEs, which will be serviced and sensitised on various elements of competitiveness in collaboration with CII centers of excellence. CII’s commitment to working closely with state governments and empowering MSMEs underscores its dedication to fostering economic growth and sustainability in the region.

CII Karnataka Chairman, Vijaykrishnan Venkatesan, highlighted , the inauguration of a new office in Mangaluru has expanded CII’s office network in South India to 17 locations. This extension allows CII to provide specialized support for MSME development in the Mangaluru region. He said that this network expansion enables CII to serve its members at the grassroots level in Karnataka.

Image Courtesy – Economic Times
https://economictimes.indiatimes.com/news/economy

GAM Coating, headquartered in Oss, Netherlands, is a highly reputable coating specialist offering powder coating, wet painting, shot blasting, and more. Their flexible and eco-friendly approach has led to increasing demand from various industrial sectors. They recently expanded their capabilities with a new spinner hanger blast machine to meet growing requirements for wet painting jobs.

Because of rapidly increasing demand for powder-coated and wet-painted components GAM Coating had to increase its shot blasting capacity. With a spinner hanger blast machine from Rösler the company purchased a highly flexible “workhorse” that excels through excellent shot blasting qualities and low energy consumption.

The practically identical residential buildings at the Ijsselstraat 29a location in Oss,  Netherlands, where the brothers Arnold and Marc Princen reside, along with the adjacent manufacturing facility transmit the impression of integrity and reliability. This is the headquarters of GAM Coating, short for Gerrit, Arnold and Marc. The company was founded by the father, Gerrit, in 1972 as an automotive paint and body shop. Over the past 50 years 

GAM evolved into a highly professional specialist for powder coating, wet painting, shot blasting, glass bead blasting and grinding. Marc Princen, dressed in an overall covered with paint spots, welcomes us with a smile: “Demand for our services is very high. We would have no excess capacity, even if our facility was twice its current size”. 

A sure recipe for success: Quality, flexibility and reliability  
Over time the company replaced the automotive paint operation with a variety of industrial work. Today’s customers come from industries like automotive, machinery building and agricultural equipment. In addition, components pre-dominantly used in internal areas are powder coated and painted with wet paint. Marc Princen explains: “Between large orders  we can handle small jobs or quickly help out customers who received an unexpected purchase order. Many coating job shops have a very rigid, inflexible work organization. For example, on Mondays the color black is applied and on Tuesdays it is the color blue. If a  customer needs a black component on a Tuesday, he must wait until next Monday. We are  a lot more flexible and provide our service to our customers as they need it.“ Exactly this flexibility, combined with a high coating quality and on-time deliveries, is the reason for the continuously increasing demand from different industrial sectors. 

Shot blasting as an eco-friendly paint preparation  
GAM Coating knows that excellent surface preparation is a key prerequisite for high-quality coatings. Marc Princen comments: “Since it is much more eco-friendly than chemical pre-treatment, we are employing shot blasting for paint preparation”. As blast media the company is using corundum because it does not react with the substrate of the workpieces.  Large components are blasted manually in a blast room. “This allows optimally pre-treating hot-dipped steel, stainless steel and other non-ferrous metals. The blast media is added to the compressed air in precise quantities. Broken-down media and other contaminants are continuously discharged through a dust collector. Our operators are equipped with approved pressure breathing protection devices fed by cleaned air, and they are dressed in special protective clothing”, describes Marc Princen.  

While GAM Coating still had sufficient capacity for powder coating jobs, rapidly increasing demand for wet painting required a capacity expansion. After careful evaluation of the pros and cons of an additional blast room vs. the purchase of a shot blast machine, the customer decided to go with the option of purchasing a new blast machine.  

Spinner hanger blast machine: A highly productive and flexible workhorse 
GAM Coating chose a spinner hanger blast machine from Rösler. These machines are ideal for de-scaling, de-rusting, paint stripping, surface texturing and de-sanding of large or heavy components, including complex steel fabrications. A special overhead rail system transports the components, hanging on special trusses, into the shot blast machine. The blast process takes place with the work pieces moving in the blast chamber continuously or indexing. The overhead rail system is designed as an open “Y”. This allows to load/unload workpiece at two stations so that unproductive times are kept at a minimum. A special feature of the  Rösler shot blast machine is its excellent wear protection: The blast chamber consists of 8  mm thick welded manganese steel. In addition, the blast area is specially protected by easily exchangeable 10 mm wear plates, also made from manganese steel.  The blast chamber with a height of 2,700 mm and a width of 2,200 mm allows the fully automatic shot blasting of components with max. dimensions of 2,000 by 2,000 mm, such as shelves, machinery components, door frames and tables. Such components represent about 75 % of the component range handled by GAM Coating. „Programming of the Rösler machine is very simple, as we only have to set the blast time and turbine RPM”, adds Marc  Princen. Besides its high productivity, the shot blast machine is also characterized by its high energy efficiency. In this respect the Gamma G turbines with “Y” shaped throwing blades play a key role. Compared to conventional turbines the special curved blade design in the Gamma G turbines produces a 20 % higher blast performance with a lower energy consumption. Marc Princen concludes: „Energy considerations definitely play an important role in today’s industrial environment. On the one hand lower energy consumption is good for the environment. On the other hand the price for energy is an important cost factor”.

Emerson unveils Fisher™ Whisper™ Trim Technology, for reducing valve noise in industrial applications. With innovative additive manufacturing, it delivers up to 20 dBA noise reduction for rotary valves and a 20 percent increased flow capacity for globe valves, offering cost-effective and space-saving solutions.

Emerson offers new Fisher™ Whisper™ Trim Technology for use in both rotary and globe valves, providing an extension to Emerson’s current portfolio of Whisper noise solutions. This next generation of Fisher Whisper Trim technology addresses noise issues by using additive manufacturing and other advanced techniques to create trim designs with increased capabilities.

Control valve noise is often problematic in industrial applications. It is created by high pressure drops across a valve, which generate high velocities as the fluid moves through the narrowed passages in the valve body. This aerodynamic noise has a strong dependence on the gas velocity, so high flow and high pressure drop applications tend to reach high sound levels very quickly. This type of noise can damage hearing, and over time it can destroy tubing, sensitive equipment, nearby piping connections, and valve components.

Rotary valves are typically less expensive than globe valves, but they are inherently prone to higher noise levels due to their trim configuration. It is difficult to incorporate a large amount of noise reduction into the trim because of the limited available space and other factors, so rotary valves are not usually employed in high noise applications.

The new rotary style Fisher Whisper Trim Technology addresses this issue, with additive manufacturing used to provide up to 20 A-weighted decibels (dBA) of sound level reduction, a 10 dBA improvement compared to traditionally manufactured solutions. These noise reduction levels are achieved while largely maintaining the high flow capacities common with rotary valves, and this solution saves significant costs as compared to globe valve alternatives.

A wide selection of low noise trims is currently available in globe valves, each using a progressively more complicated trim configuration to produce higher levels of noise reduction. Usually, the more complex the trim style, the higher the noise reduction and cost, and the lower the flow capacity. If high flow capacities are required, a much larger valve body has been necessary when using traditional low noise trim designs.

The new globe style Fisher Whisper Trim Technology addresses this issue by using additive manufacturing to create trim designs with increased flow capacity. Globe valves using this technology have a 20% increased flow capacity as compared to traditional trim designs, while still offering up to 30 dBA noise reduction. This enables the use of smaller valves where larger sizes were previously required, saving space and cost.

Each of these solutions provides significant noise reduction without the drawbacks of traditional designs, giving end users more choices to solve issues related to valve installations where noise is problematic.

The European standards DIN EN 60034-30-1: 2014-12 (mains operation) and DIN VDE 0530-30-2: 2019-02 (frequency inverter operation) define the four efficiency classes for electric motors from IE1 to IE4+. Based on the underlying criteria, even more efficient drives are known as IE5 within industry. 

The new high-efficiency IE5+ synchronous motors series from NORD requires significantly less rare earth elements than its predecessor. Image: NORD DRIVESYSTEMS 

The IE5+ permanent magnet synchronous motor from NORD DRIVESYSTEMS significantly exceeds the highest efficiency class IE5. The especially compact and energy-efficient motor offers a constant high efficiency of up to 93 percent and more over a wide torque range and thus also develops optimal energy performance in partial load and partial speed ranges. 

Significantly lower CO2 emissions than IE3 
This means that the IE5+ motor not only saves energy, but also emissions. In comparison to a conventional IE3 asynchronous motor, an IE5+ synchronous motor reduces emissions by around 0.15 t CO2 per year. This applies to one single motor. In large systems, for example in intralogistics with hundreds or even thousands of drives, this adds up to an impressive total saving. This model calculation is based on the following assumptions: 

• IE3 asynchronous motor with 0.75 kW, 83% motor efficiency and helical bevel gear unit • IE5+ synchronous motor with 0.75 kW, 93% motor efficiency and helical bevel gear unit • Period: 16 operating hours per day, which corresponds to 4,000 operating hours per year • Energy savings of the IE5+: around 400 kWh per year 

• Reduction of emissions: 0.15 t CO2 per year (with a CO2 emissions factor of 366 g/kWh) 

Savings not only in energy – also in material 
The IE5+ motor from NORD can also impress with another sustainability factor: material efficiency. “Various innovations in the motor design help us to realise significant material savings with our new IE5+ series”, Jörg Niermann, Head of Marketing at NORD, emphasises. NORD DRIVESYSTEMS designed the IE5+ as an 8- pole synchronous motor in an IPM design. This reduces the size of the motor’s active components, which not only results in material savings in the sheet metal package but also in the magnet material. 

Less rare earth elements 
In the course of material savings, it was also possible to reduce the proportion of rare earth elements in the 1/3

magnet material. Rare earth elements are mainly found in Russia, China and Brazil and can only be mined with great environmental impact. “We are glad that we were able to significantly reduce the use of this material”, Niermann explains. 

With 8-pole synchronous motors, the stator can also be manufactured with the so-called single-tooth windings. As a result, valuable material such as copper is only used where it is actually productive, and inefficient use in the winding head is reduced. 

“Our IE5+ synchronous motor combines energy efficiency with material efficiency and thus scores twice in terms of sustainability”, Niermann highlights. Of course, this not only applies to the IE5+ motor itself but also to the DuoDrive geared motor, in which the IE5+ is integrated. 

Bringing Service Support advancements for efficient CNC solutions to empower its customers and facilitate high-quality and stress-free manufacturing.

Mitsubishi Electric is a global pioneer of CNC Technology and it offers it’s wide range of product and services in India. With a manufacturing base in Bangalore and sales and service network across all major industrial cities in India, Mitsubishi Electric CNC is a frontrunner in machining technology with a mission to make India a global manufacturing hub. In order to empower its customers and facilitate high-quality and stress-free manufacturing, the company has launched anExtended Warranty Contract.

The Extended Warranty Contract includes the Field support, online technical support over the phone and email by the staff members of the company, provision for Spare parts, and assurance for Lifetime support. The CNCs covered under the extended warranty contract are listed below:

• Economical: For Economical controller (E70/E80 series with Turning/Grinding/Gantry Machines)
• Standard: For Standard Controllers (M60/M70/E70/M80/E80 series) and for MAZATROL (M64 series that is, Yamazaki Mazak Corporation’s Customized Controllers)
• Custom: For Windows/Customized Controllers of Japanese Machine tool builders (Yamazaki Mazak Corporation /DMG MORI CO., LTD. / CITIZEN MACHINERY CO., LTD. / Kitamura Machinery Co., Ltd. etc.) including C70/C80 series and of Taiwanese Machine tool builders (SHE HONG INDUSTRIAL CO. LTD. etc.)

The Extended Warranty Contract accompanies a brief discount and special payment terms. The contract covers detailed parts & services. It also includes specific selected parts for Spindle motor, Servo system, CNC unit, Amplifiers and others.

The characteristics that enable the Extended Warranty Contract to stand out are mentioned below:

Priority Response: The Extended Warranty Contract ensures that the moment you notify the service team about a breakdown, Mitsubishi Electric service team of highly trained service engineers will swing into action to provide a solution to that particularproblem.

The extended warranty contract assures to minimize the downtime and increase machine lifetime.

The extended warranty contract offered by Mitsubishi Electric India comes with a cost which is comparatively lower and affordable in the market. And, highly trained and well-equipped engineers keep a record of installed products and restore the machines in shorter time durations.

Mitsubishi Electric CNC conducts free of cost machine evaluation on the purchase of this Extended Warranty Contract. This benefits the customer in knowing the machine’s health and helps to plan production and maintenance proactively.

Travel & lodging of Engineers, Freight charges for shipment and return of parts are covered under this contract. There are no hidden charges involved.

Round the clock Telephone support through a dedicated Toll-Free line is available for the users for immediate action on the desired issues. It also covers Troubleshooting & Counselling over phone and email along with dispatch of parts and engineer on the immediate next working day.

Extended warranty contract for the CNC system enables proper functioning of the machinery, also it tends to enhance the after-sales service experience for the clients across the country which can ultimately help to gain trust of the India manufacturers.Mitsubishi Electric India is on a journey with its partners and customers to help them achieve their goals and strengthen the expertise of machine tool manufacturers. It lives up to the government’s ‘Make in India’ initiative which will help the country become self-reliant.

The UNITED GRINDING Group has intensified its Southeast Asian business and established its own subsidiary in Singapore.

The UNITED GRINDING Group has been present in the Southeast Asian region for many years through representatives and the WALTER EWAG Asia Pacific subsidiary. Now the specialist for grinding, eroding, laser, and measuring machines bundles and intensifies its activities in this region by founding a group subsidiary in Singapore, United Grinding Asia Pacific Pte. Ltd.

“Southeast Asia is a strategically very crucial region for us. Establishing a UNITED GRINDING subsidiary is the logical step to intensify our activities in this region,” explains Stephan Nell, CEO of the UNITED GRINDING Group. The potential is high, and the number of customers is continuously increasing. “Proximity to our customers has always been important to us to ensure fast and uncomplicated support,” adds Nell. The ability to offer the group’s bundled technology and application know-how from a single subsidiary offers customers many advantages.

Michael Schmid, CEO of the new UNITED GRINDING branch and already responsible for the Southeast Asian business of the WALTER and EWAG brands for more than 20 years, adds: “We can bundle the strength of our powerful team in the joint group subsidiary and serve our customers even better. In the future, we will offer all three group technologies, surface and profile grinding, cylindrical grinding, and tool machining, under one roof. I am convinced that bundling and intensifying our activities in this region is a win-win for all parties involved.”

HARTING, the Technology Group, establishes a new production facility in Vietnam, strategically positioning itself in Southeast Asia to maintain high-quality connector production and enhance customer support.

HARTING set up a new production site in Vietnam. China’s neighbour is a strategically important location in Asia for the Technology Group. As from now, a well-trained core team will have connector production up and running on the over 2,500 square metre factory premises. “It is important to us that we also ensure our high-quality standards here in Vietnam,” as Andreas Conrad, member of the board of the HARTING Technology Group, stated. “With our globally standardised processes and production facilities, we are guaranteeing our customers the HARTING quality they are accustomed to – around the globe. Whether in Germany, Romania, Mexico or now also in Vietnam – our customers can rely on HARTING being at hand worldwide.”Philip Harting, the CEO of the Technology Group, was on location in person to open the new production plant. “With our newly acquired site in Vietnam, we are creating an important building block in the growth region of Southeast Asia. Here in Hai Duong, we are close to our customers and producing directly on site. We are reducing the delivery routes to a minimum and will record significant CO2 savings in this way. Together with the management team, we have already set the course for further expansion.”

Tata Motors delivers the first batch of cutting-edge Ultra EV electric buses to Srinagar, marking a step towards sustainable public transport for Srinagar and Jammu Smart City projects.

Tata Motors, India’s largest commercial vehicle manufacturer, has announced the delivery of the first batch of state-of-the-art Ultra EV air-conditioned electric buses to Srinagar Smart City Limited. This delivery marks the initial step in a larger order to supply, maintain, and operate 100 electric buses in Srinagar and 100 electric buses in Jammu for a 12-year period as part of the Jammu and Srinagar Smart City projects. The collaboration is part of the Housing and Urban Development Department’s initiative to establish an environmentally and financially sustainable public transport network for Srinagar, Jammu & Kashmir.

The zero-emission electric buses are built on a next-generation architecture, featuring cutting-edge technology and advanced battery systems. They are designed to provide a safe, comfortable, and convenient intra-city commute across Srinagar, ultimately contributing to a more sustainable urban mobility solution.

Shri Manoj Sinha, Hon’ble Lieutenant Governor of Jammu & Kashmir, lauded the initiative and highlighted the transformative impact of the electric buses on the city’s public transport system. He expressed gratitude to Prime Minister Narendra Modi for the support in making the project a reality.

Shri Prashant Goyal, Principal Secretary of the Housing & Urban Development Department, J&K, emphasized the significance of the project in improving the last-mile passenger transport system in Srinagar, easing traffic congestion and promoting sustainable urban development.

Shri Athar Aamir Khan, CEO of Srinagar Smart City Ltd, stated that the project marked a massive transformation in public transport in Srinagar and would decongest the city while providing reliable, affordable, and comfortable public transport options.

Mr. Asim Kumar Mukhopadhyay, Chairman of TML Smart City Mobility Solutions (J&K) Pvt Ltd, expressed his excitement about Tata Motors’ role in providing transformative, eco-friendly, and emission-free transport solutions for the region. He emphasized the company’s commitment to safer, smarter, and greener mobility solutions.

Tata Motors has a strong track record in supplying electric buses across India, with more than 1,000 electric buses deployed in various cities, collectively covering over 9.6 crore kilometers and maintaining an uptime of over 95%. The Tata Ultra EV sets new standards for urban city commuting, offering low energy consumption, operational efficiency, and advanced safety and comfort features.

The project reflects the commitment to cleaner public transport and contributes to the development of sustainable transportation solutions for urban passenger needs.

A new report by the Energy Efficiency Movement (EEM), founded by ABB, reveals how industries can reduce global carbon emissions by 11 percent and save $437 billion annually by 2030.

As industry is facing the unprecedented challenge to meet global decarbonization targets while addressing growing demand, a new report from the Energy Efficiency Movement (EEM) demonstrates how businesses can start acting immediately. The EEM is a global forum founded by ABB, and now consisting of more than 400 organizations, that shares ideas, best practices and commitments to create a more energy-efficient world.

The report published, “The Case for Industrial Energy Efficiency” aims to give corporate leaders key insights into 10 measures that rely on mature technologies, have a meaningful impact on costs and emissions and can be deployed quickly without complex or expensive projects. Building on the “Industrial Energy Efficiency Playbook,” published in 2022 by the EEM, the new guide helps corporations address one of the biggest barriers to energy efficiency: building their own business cases. In some instances, the savings arising from efficiency measures mean that transformation projects can be self-funding. Elsewhere, the report reveals investments in efficiency can serve as a valuable hedge against energy and carbon price volatility, while helping to meet voluntary targets and regulatory goals.

Doubling efficiency by 2030 could cut greenhouse gas emissions by almost a third compared to today’s levels, according to the International Energy Agency (IEA). And for industrial players, the opportunity is immense. The Energy Efficiency Movement estimates that if applied across industry, the 10 simple measures in this guide could save 1.5 gigatons of carbon emissions a year by 2024, and 4 gigatons by 2030, the equivalent of taking around three-fifths of the world’s internal combustion vehicles off the roads. These estimates are based on mid-range scenarios, yet still equate to an 11 percent reduction in annual global carbon forecasts by 2030. Using the more ambitious scenario, the savings would go up to 5.3 gigatons, or nearly 15 percent of total 2030 emissions. For five of the 10 actions where financial savings can be meaningfully calculated, industry could be saving around $172 billion a year in 2024, and roughly $437 billion annually by 2030. Using the more ambitious scenario, the savings go up to $590 billion annually by 2030. Actions highlighted in the report include conducting energy audits, rightsizing industrial assets, bringing connectivitiy to physical assets, using high-efficency motors, among others.

“Ahead of COP28, it is important to demonstrate that there are mature and concrete technology solutions readily available to address the global warming issues we are facing,” said Tarak Mehta, President, Motion business area at ABB. “Since renewables can only provide a part of the answer, the critical role energy efficiency plays in accelerating the energy transition toward reaching net-zero emissions by 2050 is undeniable. The urgency is for the private sector to act now. This new report is designed to help speed the adoption of best practices by showing businesses how to realize the full potential of environmental and financial benefits.”

Recently, the IEA called for a ramp-up on annual energy efficiency progress from 2.2 percent today to over 4 percent annually by 2030 and recommends tripling annual efficiency-related investment for an energy-efficient future. Furthermore, the IEA stated that achieving this goal of doubling the rate of progress will require a tripling in annual efficiency-related investment, from $600 billion today to $1.8 trillion by the end of the decade. The EEM sees this guide as a contribution to this important call to action from the IEA.

The results for emissions reduction, industry savings and gross domestic product (GDP) growth are based on modeling commissioned by the EEM from Development Economics, an independent economic impact assessment provider. From May to October 2023, Development Economics undertook rigorous modeling of the economic and emissions outlook for each action in the guide. The modeling incorporated the best available data and included input from subject matter experts at leading industrial players including ABB, Alfa Laval and Microsoft. Expert advice was also provided by the IEA.

Valeo and Qualcomm Technologies have joined forces to explore innovations for India’s 2-wheeler and 3-wheeler markets. Their collaboration aims to enhance safety and provide connected digital experiences for riders.

Valeo and Qualcomm Technologies signed a memorandum of understanding (MoU) to explore opportunities to work together to innovate for the 2-wheeler and 3-wheeler segments in India. These collaborative efforts are an extension of the two companies’ long-term working relationship to deliver advanced computing units for telematics and advanced driver assistance systems (ADAS) for software-defined vehicles (SDVs). 

In addition to helping deliver enhanced safety to 2-wheelers and 3-wheelers, the companies will leverage their rich and complementary portfolios to accelerate the adoption of cloud-connected digital services, leading to greater safety and an always-connected digital experience for riders. They will couple Snapdragon® Digital Chassis™ solutions for 2-wheelers and new vehicle classes from Qualcomm Technologies with Valeo technologies for display, telematics and sensors as well as the Group’s software expertise to develop a comprehensive solution that includes embedded cellular modems, connected displays, driver assistance features and connected clusters. 

These new features will enable riders to remain focused on the road while connected in real time to their favorite smartphone applications, navigation systems or cloud-based entertainment. Connectivity will also enhance the safety of the vehicle and the passengers on and off the road with real time traffic and potential risk on the road information as well as with software and cybersecurity updates and tracking monitoring of the 2- and 3-wheelers 

In India, 2-wheelers and 3-wheelers are fast-growing markets. Valeo and Qualcomm Technologies acknowledge the importance and value of the Indian ecosystem and market, with the presence of strong India-based players that are expanding abroad. The extended collaboration intends to leverage the strong local R&D presence of the two companies and the local manufacturing capabilities of Valeo. By working together, the companies expect to offer OEMs complete solutions based on the best-in-class automotive technologies. 

“We are excited to extend our work with Qualcomm Technologies to 2-wheelers and 3-wheelers. It is an important new step forward in our long-lasting collaboration. Valeo’s engineering and manufacturing presence in India coupled with Snapdragon Digital Chassis solutions for 2-wheelers and new vehicle classes will allow us to locally design, develop and produce a new generation of a connected display matching to local requirements, and serve our local customers thus contributing to making mobility in India safer and more connected,” said Marc Vrecko, President of Valeo’s Comfort and Driving Assistance Systems Business Group. 

“For many years, Qualcomm Technologies has worked with Valeo to anticipate the needs of OEMs and deliver ADAS and advanced telematics systems to their vehicles. We are pleased to extend our collaboration endeavors to accelerate the digital transformation of the dynamic 2-wheeler and 3-wheeler markets in India by offering rider solutions with advanced safety features and highly personalized and safe user experiences,” said Nakul Duggal, senior vice president and general manager, automotive & cloud computing, Qualcomm Technologies, Inc.

Having a local proximity is key to efficiently support customers in the design of complex systems for higher safety and enrich the riders’ digital experience. Valeo’s presence in India started 25 years ago to support Automotive OEMs and develop local technologies. Valeo now has more than 6500 employees including 3.200 engineers, 8 production sites and a global R&D center. Valeo India HQ is located in Chennai.

Microsoft and Siemens have partnered to introduce Siemens Industrial Copilot, an AI-powered assistant aimed at enhancing human-machine collaboration in manufacturing, offering potential benefits to various industries.

Microsoft and Siemens partnered to bring the benefits of generative AI to industries worldwide. As a first step, the companies are introducing Siemens Industrial Copilot, an AI-powered jointly developed assistant aimed at improving human-machine collaboration in manufacturing. In addition, the launch of the integration between Siemens Teamcenter software for product lifecycle management and Microsoft Teams will further pave the way to enabling the industrial metaverse. It will simplify virtual collaboration of design engineers, frontline workers, and other teams across business functions. 

“With this next generation of AI, we have a unique opportunity to accelerate innovation across the entire industrial sector,” said Satya Nadella, Chairman and CEO, Microsoft. “We’re building  on our longstanding collaboration with Siemens and bringing together AI advances across the Microsoft Cloud with Siemens’ industrial domain expertise to empower both frontline and knowledge workers with new, AI-powered tools, starting with Siemens Industrial Copilot.”

“Together with Microsoft, our shared vision is to empower customers with the adoption of generative AI,” says Roland Busch, CEO of Siemens AG. “This has the potential to revolutionize the way companies design, develop, manufacture, and operate. Making human-machine collaboration more widely available allows engineers to accelerate code development, increase innovation and tackle skilled labor shortages.”

A new era of human-machine collaboration

Siemens Industrial Copilot will allow users to rapidly generate, optimize and debug complex automation code, and significantly shorten simulation times. This will reduce a task that previously took weeks to minutes. The copilot ingests automation and process simulation information from Siemens’ open digital business platform, Siemens Xcelerator, and enhances it with Microsoft’s Azure OpenAI Service. Customers maintain full control over their data, and it is not used to train underlying AI models.

Siemens Industrial Copilot promises to boost productivity and efficiency across the industrial lifecycle. Using natural language, maintenance staff can be assisted with detailed repair instructions and engineers with quick access to simulation tools. 

The vision: Copilots for all industries

The companies envision AI copilots assisting professionals in various industries, including manufacturing, infrastructure, transportation, and healthcare. Numerous copilots are already planned in the manufacturing sectors, such as automotive, consumer package goods and machine building.

Schaeffler AG, a leading automotive supplier, is among the first in the automotive industry to embrace generative AI in the engineering phase. This helps its engineers to generate reliable code for programming industrial automation systems such as robots. In addition, the company intends to incorporate the Siemens Industrial Copilot during their own operations, aiming to significantly reduce downtimes, and also for their clients at a later stage.

”With this joint pilot, we’re stepping into a new age of productivity and innovation. This Siemens Industrial Copilot will help our team work more efficiently, reduce repetitive tasks, and unleash creativity. We’re excited to partner with Siemens and Microsoft on this project”. Klaus Rosenfeld, CEO of Schaeffler Group.

In industrial manufacturing, sustainability takes centre stage. It’s not just about eco-friendly materials; it’s also about optimising processes. These sustainable practices enhance efficiency, cut costs, and minimise machine downtime, safeguarding valuable resources, including employee work hours.

Connectors play an important role in the design of sustainable processes. It is not only the function of quickly connecting or disconnecting a machine or an attachment that is of interest. Modern connectors support the production worker in making a secure and error-free connection. This is particularly important with modern modular systems where reconfiguration is frequent. An error-free connection helps to conserve important resources such as energy and time.

SmEC – Connector concept for modular machines and systems
One of the most important additional functions of a connector is the signalling of the mating state. The mating state contains different parameters depending on the application and the connector. The plug-in state usually answers questions like whether the connector is plugged into the correct mating connector. Is the connector fully electrically connected, or whether it is completely mechanically locked? Is the connector electrically overloaded, and are the environmental parameters (temperature, humidity, etc.) within the permitted range?

The plug-in status is signalled to the employee using an LED, a light ring or also acoustically. In the simplest case, a red/green display is sufficient for the machine operator to recognise whether a fault is present. Modern full-colour LEDs with additional flashing patterns or animations indicate other states, such as the presence of voltage. In addition to visual or acoustic signalling, a digital interface also transmits the information in greater detail to a control centre. The SmEC from the HARTING Technology Group transmits the data via MQTT or OPC-UA PubSub. The data is available in a JSON format and can be received and processed by any controller. Among other things, the Asset Administration Shell also provides the live data of the connector as a digital twin.

In addition to signalling the mating status, The SmEC actively prevents unintentional disconnection of the connector with the help of the integrated locking mechanism. This ensures that the components are not damaged and that there is no danger to people. The connector can only be disconnected after it has been de-energised and the active lock has been released. For this purpose, the SmEC has integrated voltage and current measurement that also monitors the connected machine. In this way, the current carbon footprint can be calculated based on the energy consumption data.

Data diode – Protection against sabotage
The measurement of the carbon footprint can also be easily retrofitted to old machines. A data diode protects the measuring device (e.g. the SmEC) against sabotage, allowing the data signals in only one direction. This allows data to be sent from a protected network to an unprotected network, e.g. to a dashboard – the protected network is safe from attack. For this purpose, HARTING has developed a data diode for a connector. With a data rate of up to 1Gbit/s, the usual IoT protocols such as OPC-UA, MQTT or Modbus-TCP are transmitted. Integrating a real hardware data diode, which consists of the laser diode on the transmitter side and a photodiode on the receiver side, makes it impossible for the data to flow back.

Functionality of a data diode in the connector

Smart ix – Small connectors with identification function
To determine whether a connector is plugged into the correct mating connector, it must be possible to identify the connector. In the simplest case, this is solved with additional electrical contacts as coding pins. Unlike mechanical coding, the machine control system determines which attachment is now plugged in. However, this method reaches its limits with large, flexible systems. An unnecessary number of contacts are consumed for electrical coding with coding pins. A more suitable variant is identifying the connector with the help of a bus system and a small microcontroller or via NFC (Near Field Communication). This gives each connector a unique ID assigned to a corresponding component (e.g. attachment or tool). This method also works with very small connectors, as seen on HARTING’s Smart ix. The Smart ix is a small 10-pole connector in which a microcontroller is integrated. With the help of the microcontroller, precise identification is possible. The ID is used in the unit/machine control to establish a link to the connected component. This way, even simple components such as lamps, door contacts or analogue sensors can be identified. The control signals to the user whether the components are plugged into the correct port.

HARTING Smart ix Industrial – Identification of small connectors

Han Protect – Han® 3A – Simplified repair processes
During the production process, there are often unwanted downtimes because the necessary skilled personnel are off-site. For example, a defective fuse can only be changed by a suitably trained person. Since the fuse is located in the control cabinet, other people do not have access. One way to make the fuse accessible from the outside is to integrate it into a connector, such as the Han Protect. As the connector has to be disconnected to change the fuse, the work is also possible for instructed persons, especially when low voltage is involved. This speeds up the repair processes and reduces downtimes – which has a lasting effect on resources.

Han Protect -Han® 3A connector with integrated fuse

More information at: https://www.harting.com/IN/en-gb

Recent technological advancements have revolutionised metal joining processes, leading to a shift in welding technology trends. SumonMitra, COO, Cloos India Welding Technology affirms Cloos is at the forefront of the innovations with comprehensive solutions.

What are the latest solutions in welding technologies developed by Cloos that are revolutionising the manufacturing industry?
Advancements in technology have ushered in substantial transformations in metal joining processes. Consequently, emerging welding technology trends are slowly shifting away from traditional materials and manual methods towards cutting-edge arc welding, automated processes, and the latest metals and alloys. Moreover, there has been a notable enhancement in welding training and welding safety measures, ensuring a secure welding environment and handson practice. In this context, Cloos has already pioneered numerous comprehensive welding technology solutions.

Cold Weld by QineoNexT AC Premium for precise welding with optimum heat input. It achieves
excellent results when welding challenging materials using the directionally stable MIG/MAG AC pulsed arc of Cold Weld. Cold Weld combines a pulsed arc with AC technology. Due to the adjustable AC part you can individually control the heat input into the component. Cold Weld enables higher welding speeds by increasing the deposition rate while maintaining an optimal heat input, which positively impacts the component and material characteristics. The reduced heat input preserves the original material properties, minimising distortion and the need for extensive rework. Additionally, Cold Weld can compensate for material tolerances thanks to its excellent gap-bridging ability.

‘Do you wish to reduce your production costs for demanding materials and to increase the quality at the same time? Then rely on Cold Weld by CLOOS!!

To advance automation, Cloos has pioneered robotic welding systems with ARC seam tracking technology, tactile sensing, and adaptive capabilities. These technologies automatically detect and rectify any deviations in welding seams or variations in groove preparation. Cloos’ technology eliminates the need for re-teaching. It also boosts productivity and ensures consistent weld quality, even when dealing with variations in pre-weld products.

How does automation technology address the shortage of skilled welders in the industry?
Many companies need more proficient welders and the need for non-repetitive welding tasks. To address this challenge, Cloos introduces the Arcbot as their initial foray into automation solutions.

The QINEO ArcBot includes all the essential components for automated welding, designed to work perfectly together and easy to mount. This compact “Ready to weld” package arrives fully operational, facilitating its smooth integration into current production workflows. The integrated safety components guarantee essential personnel protection. An electrically adjustable protective screen can be added to the optional welding table. This shields the surrounding area from the UV radiation generated during welding.

“It is ready with all types of Mig&Tig welding machine and innovative welding process of Cloos and also with Fume extraction torch with filter unit to maintain the floor environment.”

QiroxRoboscan solution efficiently automates welding for even the most petite batch sizes. In steel and metal construction, creating automated welding programs for small batches can be time-consuming and costly. With the IRPS Instant Robot Programming System, you can generate automated welding programs quickly, making it cost-effective to weld even individual workpieces. That implies that automated welding of workpieces in batch size 1 pays off now.

The IRPS benefits
This system minimises the programming effort, resulting in significant time savings, enhanced system efficiency, and eliminating the need for a CAD workstation. However, recognising the position and tolerances of the workpiece provides excellent weld quality and saves time because re-teaching is optional. Moreover, eliminating clamping devices reduces investment costs and minimises non-productive time.

In these ways, planning times are shortened, allowing for just-in-time production, reduced personnel and resource allocation, and quicker delivery periods. The intuitive operation allows for a flexible use of personnel with minimal training expenditure.

How is welding technology adapting to embrace digitalisation and data-driven processes in the era of Industry 4.0?
Cloos has integrated its Industry 4.0 software, C-gate, to offer the necessary signals for Industry 4.0. The C-Gate IoT platform enables realtime access to welding production data, which is centrally entered and processed within an integrated information and communication tool. This empowers users to oversee and manage their production processes with precision closely. The platform includes multiple modules users can activate based on their unique digitalisation strategies.

Cloos India Welding Technology Private Limited
Ground & 1st Floor, Plot No. 114/1/3, General Block, MidcBhosari, Pune,
Maharashtra 411026 India Website:- www.cloos.de
Email :- contact@cloos.in
Mobile:-7003545907 / 9168383939

Pranjal Mathur, Research Manager, DataM Intelligence, explores the significance of Go-To-Market strategies in market entry, stating that it involves several key elements, enabling an organisation to establish a strong presence for their product globally.

Please talk about DataM Intelligence.
In 2017, two passionate visionaries embarked on a journey fuelled by their unwavering belief and determination. They ventured into the realm of market research, creating and selling customised reports as a modest team. Taking on various roles, from researchers and marketers to salespeople and content creators, they gave birth to DataM Intelligence.

What initially started as an idea has now become a dominant market research force. Challenges that once seemed impossible became notable achievements as they attracted a loyal client base seeking expert guidance. Over these six years, the duo effectively converted uncertainties into solutions, proving their capabilities. It is crucial to emphasise the pivotal role played by their clients, who placed their trust in newcomers like them. This trust ignited DataM Intelligence’s rise in the market research industry. This story is a testament to the values of hard work, loyalty, and an unwavering commitment to delivering excellence, all encapsulated in the heartwarming saga of DataM Intelligence’s remarkable growth.

Please discuss about what is Go-To-Market (GTM).
GTM is a market entry strategy required to capitalise on the market at launch in any region and industry. A successful GTM strategy involves several key elements that enable an organisation to establish a strong presence for its product. These elements include considerations related to the target market, the intended customer base, brand positioning, product offerings, sales channels, budget planning, and marketing strategy.

A robust GTM strategy is indispensable because a company can only sustain itself with adequate research and a well-thought-out approach. In India, according to NASSCOM, a staggering 99% of startups fail annually due to the absence of thorough market research and a GTM plan. Many entrepreneurs are reluctant to invest in market research in India, leading to the downfall of their businesses due to a lack of understanding of ground realities.

New companies and existing ones in the market require a GTM strategy when introducing a new product to capitalise on opportunities and thrive in the business ecosystem. For instance, launching a new car model without a GTM strategy can result in significant failures and substantial financial losses for automotive manufacturers.

What role do advanced analytics and AI play in staying at the forefront of industry trends and market opportunities?
DataM Intelligence stands out in the highly competitive market research and consulting sector through its commitment to precision, customisation, and innovation. With an experienced team of analysts, we deliver accurate and actionable insights tailored to each client’s specific needs. Our global outlook, enhanced by advanced analytics and AI, allows us to uncover emerging industry trends and market opportunities on a global scale.

Furthermore, our team’s dedication to ethical standards ensures client confidentiality and fosters trust. Notably, DataM Intelligence excels in developing go-to-market strategies creating effective plans for businesses aiming to enter new markets or expand their existing presence. We take pride in facilitating many companies’ direct entry into their desired industries. This expertise, combined with our team’s personalised approach and technological proficiency, positions DataM Intelligence as the preferred choice for clients, establishing us as leaders in the industry.

How does DataM Intelligence plan to continue delivering on its commitment to precision, customisation, and innovation in the competitive market research and consulting?
Government initiatives such as “Make in India” and the “Automotive Mission Plan 2026” aim to enhance the automotive sector and contribute 12 percent to India’s GDP by 2026. This has led to a significant transformation in manufacturing, marked by the establishment of numerous new companies each year. Furthermore, with various schemes facilitating the establishment of new factories across various sectors and a robust foreign direct investment (FDI) infrastructure, the manufacturing industry is experiencing substantial growth.

Starting from January 2022, India’s Manufacturing PMI has consistently remained above 50, and on occasions like August 2023 and May 2023, it even surpassed 58, underscoring the strength and expansion of India’s manufacturing capabilities. In contrast, China’s Manufacturing PMI fell below 50 for 13 out of 21 months between January 2022 and September 2023, and it did not exceed 52 in any month since January 2022.

Manufacturing is becoming the bedrock of India’s economy. India already holds the status of being the world’s largest manufacturer of packaging and plastics. It ranks among the top three nations globally in textiles, processed food, construction products, automobiles, and other industries. The “C+1” (China +1) concept positions India to benefit significantly, particularly in the automotive industry, where companies like Mercedes and BMW have already established manufacturing facilities in the country. Additionally, Tesla, Kia, and MG have plans to set up their factories in India, further propelling the growth of the manufacturing sector in the nation.

In an evolving off-highway tire industry, BKT Tires stands out with its unwavering commitment to quality, sustainability, and innovation. Ashok Chhajer, Sr. General Manager at BKT, explores how BKT shapes the future and addresses industry challenges.

In the evolving and competitive off-highway tire industry, what strategies and values have ensured the enduring strength and relevance of BKT Tires?
Through strategic initiatives and ingrained core principles, BKT Tires maintains its enduring strength and relevance in the highly competitive off-highway tire market. Its prominence is primarily attributed to its steadfast dedication to quality. It is demonstrated through rigorous standards and an ongoing commitment to improving all aspects of the organisation.

Through strategic initiatives and deeply ingrained core principles, BKT Tires maintains its enduring strength and competitiveness in the off-highway tire market. A primary factor contributing to its prominence is its unwavering commitment to quality, evident in rigorous standards and an ongoing dedication to enhancing every aspect of the organisation.

Innovation plays a pivotal role in BKT’s success, with significant investments in research and development that sustain its position as an industry leader. This commitment results in cutting-edge tire solutions tailored to meet the evolving needs of the industry.

What sets BKT apart is its customer-centric approach, actively engaging with clients to create solutions that align with their specific requirements. These insights help generate genuine value for clients. BKT’s global presence is further solidified by a robust distribution network, ensuring its products are accessible worldwide and can be reliably delivered. Sustainability is an integral part of BKT’s operations, focusing on eco-friendly practices that reduce fuel consumption and environmental impact, aligning with industry trends and responsible corporate practices.

A long-term vision guides BKT, enabling the company to proactively adapt its strategies and products to anticipate changes in the market, ensuring continued relevance and success. Collaborations with original equipment manufacturers (OEMs) and industry stakeholders play a significant role in fine-tuning BKT’s tire solutions to meet the demands of modern equipment and applications, further bolstering its position in the market.

BKT’s enduring resilience and competitiveness result from unwavering quality commitment. Innovation, customer-centricity, global reach, sustainability, forward-thinking, and collaborative partnerships are other key elements. These values uphold BKT’s strength and relevance in a dynamic and competitive market.

Please discuss the unique features of rubber tracks and how they enhance the performance and durability of machinery in these sectors.
The rubber tracks designed for compact track loaders are essential for the construction and industrial sectors. Rubber tracks tailored for compact track loaders in the Indian market enhance machinery performance and durability. They provide superior traction for stability in diverse terrains, ensuring longevity through robust construction. Reducing rolling resistance boosts fuel efficiency and supports sustainability objectives. Likewise, minimising vibration and noise levels enhances operator comfort, improving productivity. These features are vital for various sectors, offering improved performance and cost savings.

What are the latest innovations in off-highway tires that BKT has introduced recently?
BKT Tires strongly emphasises research and development, striving for continuous innovation in off-highway tires. Recent innovations include environmentally friendly tires that reduce fuel consumption and minimise environmental impact.

How can the choice of tires reduce fuel consumption and overall operational costs on construction and infrastructure sites?
Fuel efficiency is a cost-saving concern. The choice of tires is pivotal in reducing fuel consumption and operational costs on construction and infrastructure sites. Choosing tires engineered for better fuel efficiency, featuring reduced rolling resistance and advanced tread designs, lowers the energy needed to operate equipment. This, in turn, cuts fuel consumption, decreases carbon emissions, and lowers operational costs. Additionally, durable tires with substantially longer lifespans minimise the frequency of replacements, further reducing maintenance expenses and downtime.

How can innovations such as emerging tire technologies benefit construction projects, and are there any challenges in adopting these technologies?
Emerging tire technologies, like smart and sensor-equipped tires, offer substantial benefits for construction projects. They provide real-time data on tire pressure, temperature, and tread wear, enhancing safety and efficiency. However, challenges include initial implementation costs and specific equipment and training requirements. Additionally, ensuring data security and dependability in harsh construction settings remains challenging. Despite these hurdles, the potential gains in safety, cost savings, and productivity make adopting these technologies worthwhile.

In the context of company’s sustainable practices, how are you working to develop eco-friendly tire solutions while maintaining high-performance standards?
As a global tire manufacturer, BKT is committed to sustainability, aligning with evolving industry demands. Our tire products prioritise eco-friendliness and high performance. We have made substantial progress by adopting sustainable materials and processes.

We work with Kultevat, Inc., a U.S. company that makes TKS rubber from Russian dandelions. This rubber is a sustainable alternative to rubber from traditional rubber tree farms, and it helps us keep our commitment to using eco-friendly materials in our tire production. BKT is committed to being eco-friendly, even when it comes to tire recycling. We recycle old tires to create useful materials like reclaimed rubber, Crumb Rubber, and recovered carbon black. Additionally, we use coarse friction fabric made from scrap calendered fabric in our tires.

Our efforts showcase a commitment to sustainability and the circular economy, where materials are reused and repurposed, minimising waste and environmental impact. At BKT, we are taking significant steps toward a more sustainable future and pioneering eco-friendly tire solutions. These meet the industry’s evolving needs.

What is your perspective on the future of the off-highway tire industry in India, and what aspirations does BKT have in shaping its growth and development?
The future of the off-highway tire industry in India holds promising opportunities. With rapid urbanisation, infrastructure development, and increasing mechanisation in agriculture, the demand for high-quality off-highway tires is expected to surge. BKT aims to be a key player in this growth by providing innovative, sustainable, and tailored tire solutions. We will continue to invest in research and development, local collaborations, and expanding our distribution network. Our commitment to quality, sustainability, and customer-centricity allows us to meet the evolving needs of Indian customers. All these attributes contribute to advancing the off-highway tire industry in India.

Anil Mighlani, Managing Director of Angel India CAD CAM, explores innovation in the metal forming industry guided by cutting-edge technology, robotics, and sustainable practices. He asserts additive manufacturing represents the future of metal forming.

What latest advancements in laser cutting are impacting the metal fabrication industry?
The evolving market demands are presenting significant challenges to the industry. Embracing our role as industry leaders, we have harnessed new technologies to address these challenges. Our company has risen by introducing advanced bevel-cutting solutions for high-thickness materials. This transformation has simplified a cumbersome task into a streamlined process, resulting in substantial time and material savings. 

How have the metal-forming processes evolved in your facility over the years?
India is striving to reach a five trillion-dollar economy, and in recent years, metal forming has emerged as a significant contributor. The scope of metal forming has expanded substantially, driving growth in various factories by adding specialized machinery. These dedicated machines, such as CNC technology, have simplified complex tasks, making processes like creating cones much more efficient and accessible than before. 

Please talk about new sheet metal working and forming equipment and robotic and automation solutions.
The market’s demand for increased production is growing steadily. To address this, we are enhancing our production capabilities, and robots have emerged as valuable assets in meeting these challenges. Additionally, there is a range of customized machinery available to support daily production needs. These new machines and robots not only enhance the quality and efficiency of our work but also contribute to the refinement of designs and shapes, meeting the industry’s evolving requirements. 

In what ways digital sheet metal forming technology is impacting the automotive sector? 
The automotive sector is an engine for a country’s economic growth. In today’s highly competitive landscape, companies vie for a larger market share. To retain their standing, they must continually introduce new, appealing models. Metal forming is pivotal in meeting the automotive sector’s escalating demands, increasing the need for customized machinery. As a result, manufacturers of metal forming machines encounter fresh challenges daily, and we are consistently delivering new machines to meet these requirements. 

Can you discuss sustainable practices to address the environmental implications of metal-forming and laser-cutting processes?
Excessive industrialization has posed a significant sustainability challenge across various sectors. Laser cutting is a valuable solution to mitigate pollution and offers excellent sheet coverage. Additionally, transforming numerous conventional machines into CNC machines has enhanced productivity, quality, and efficiency.

How do metal forming and laser cutting technologies contribute to the manufacturing of complex metal components?
Laser-based additive manufacturing is serving as a crucial component in the manufacturing process. It has simplified and expedited the production of intricate designs, offering a high level of precision, which was previously challenging to achieve. Due to lasers, these tasks are accomplished with greater ease and speed, approaching near-perfection. Shortly, additive manufacturing is expected to gain momentum, replacing traditional machinery. Additive manufacturing represents the future of metal forming. 

According to Dr. T.J. Prasadarao, Executive Director, D&H Sécheron, welding technology is pivotal in pharmaceutical manufacturing, embracing advanced materials, sustainability measures, and automation for contaminant-free connections. As the pharmaceutical sector continues to expand, the demand for specialized welding consumables is set to witness substantial growth.

What are the latest trends in welding technologies that are revolutionising the pharma manufacturing industry?
Welding technologies have a substantial impact on pharmaceutical manufacturing, with current developments focusing on using advanced welding materials to achieve precise, contamination-free connections. Specialised consumables designed for pharmaceutical applications help reduce the potential for product contamination. This is crucial in ensuring product quality and adherence to stringent regulations.

Please provide insights into the role of advanced materials and techniques in modern welding processes.
Utilising state-of-the-art materials and methods in welding is crucial for upholding the highest quality standards in contemporary manufacturing. Specialized consumables featuring characteristics like minimal carbon and exceptionally low sulfur content are used to minimise the likelihood of contamination. Approaches such as orbital welding and laser welding are becoming increasingly prominent due to their accuracy and the absence of impurities.

How are you addressing environmental and sustainability considerations associated with welding technologies?

D&H Sécheron Electrode is committed to sustainability. We offer consumables with reduced emissions, low spatter, and minimal waste. Sustainable welding techniques and consumables help reduce the environmental footprint of modern manufacturing while maintaining high production standards.

With the rise of Industry 4.0, how is welding technology evolving to integrate with digitalisation and data-driven processes?
The advent of Industry 4.0 has resulted in the fusion of welding technology with digitalisation and data-driven procedures. D&H Sécheron Electrode is investing in intelligent welding consumables and data monitoring solutions. These technologies allow for the real-time tracking of welding parameters, thus ensuring uniform quality and traceability to meet regulatory requirements.

Please discuss implementing automation in welding to improve productivity and product quality.
Automation is increasingly being integrated into welding processes. D&H Sécheron Electrode is at the forefront of this trend, offering consumables optimised for robotic and automated welding. Automation enhances productivity and ensures consistent weld quality, which is crucial for industrial applications.

What emerging welding technologies and applications should we watch for shortly? 
Shortly, there are several emerging welding technologies and applications. These developments promise innovation and efficiency to various industries, including pharmaceutical equipment manufacturing.

One of these developments is the growing role of Additive Manufacturing, or 3D printing, in metal fabrication. This technology is being increasingly utilised to create customised pharmaceutical equipment, offering a high level of flexibility and precision. Friction Stir Welding (FSW) is another notable advancement. Its exceptional strength and precision make it an excellent choice for welding pharmaceutical machinery, ensuring durability and reliability in the equipment.

Hybrid welding is an innovative approach that combines different welding methods with laser technology. This integration improves the speed of welding and enhances the overall quality of the welds, which is crucial in pharmaceutical manufacturing.

Remote Robotic welding is becoming increasingly important, especially in hazardous or sterile environments within the pharmaceutical sector. Robots can work with precision and without risks to human workers.

High-purity welding is a critical technology to watch for in pharmaceutical manufacturing. It’s all about using advanced techniques to ensure that welding processes remain free from contamination, which is of utmost importance in pharmaceutical production.

Welding Data Analytics plays a significant role, offering real-time monitoring and analytical tools. These tools help maintain the quality of welds and provide traceability in the manufacturing process, which is essential for quality control and compliance.

For welding small pharmaceutical components and devices, Microjoining with Laser Welding is gaining importance due to its precision and suitability for these specialised applications.

Adapting welding processes to extreme conditions, such as space exploration, is also an exciting prospect. Space and Extreme Environment Welding will be essential for enabling human missions for space and the manufacturing of equipment designed for harsh conditions. Sustainable welding practices are in alignment with the pharmaceutical industry’s sustainability goals. These practices focus on reducing emissions and minimising waste in welding processes, contributing to a greener and more environmentally friendly approach.

Lastly, the evolution of welding methods to accommodate Advanced Materials and Coatings is crucial. As the pharmaceutical industry embraces high-tech materials, welding processes must adapt to ensure the reliability and integrity of the final products.

What are the applications of welding technology in the Pharma manufacturing sector, and what potential market do you see shortly? 
Welding technology is used in the pharma industry to fabricate equipment such as tanks, vessels, and pipelines. High-purity welding is essential to prevent contaminating pharmaceutical components from the outside environment. As the pharma sector continues to expand, the market for specialised welding consumables is expected to grow significantly.

Highlighting technology and productivity evolving the welding industry, Nimesh Chinoy, Director of Sales & Marketing SigmaWeld, explains how advancements in welding technology, automation, and training are reshaping the industry as we explore innovations, sustainability, and the skills needed for a brighter future.

How are advancements in welding technologies impacting productivity in the manufacturing industry?
Productivity and data analysis are the key drivers for welding technologies behind the transformative impact of welding technologies on the manufacturing industry.

Achieving a “first-time-right” outcome in welding becomes achievable when the appropriate parameters are employed according to the Welding Procedure Specification (WPS). A novel trend in welding equipment involves the capability to retrieve WPS data from a server, recognise the welder, and automatically configure the equipment to operate within the specified current and voltage range.

There is a growing emphasis on faster TIG processes like Keyhole Gas Tungsten Arc Welding (GTAW), often referred to as SWAT, and advancements in more productive Submerged Arc Welding (SAW) techniques. The manufacturing industry is increasingly turning to automation, robots, and collaborative robots (cobots) due to the shortage of skilled workforce.

Additionally, handheld laser welding is gaining popularity for low-thickness materials.

How are advanced welding materials and techniques, including the SWAT method and automation, revolutionising the welding industry?
Contemporary welding relies heavily on advanced materials and techniques, serving as the bedrock of innovation. Specialised welding techniques are essential to accommodate high-strength alloys, exotic metals, and composite materials, ensuring the durability and long-term performance of welded structures. The SWAT technique, known for its unmatched precision, is crucial when working on intricate components. These approaches, when combined with automation and robotics, boost efficiency and also minimise the risk of errors. We leverage the potential of these advanced materials and techniques to ensure that our clients reap the full benefits of state-of-the-art welding technology, delivering robust, dependable, and high-performance results.

How do innovative technologies like SWAT welding contribute to a more sustainable and efficient future in the welding industry?
Our team is committed to ongoing exploration of innovative approaches aimed at reducing emissions and minimising energy consumption. Our SigmaWeld Induction Heaters are purpose-built for Pre Weld, Post Weld, and PWHT applications, effectively replacing conventional gas burner systems while achieving remarkable energy savings of up to 40% compared to resistance heating. This induction-based process is not only environmentally friendly but also incredibly energy-efficient, generating heat through the induction of eddy currents within the material, making it the most efficient preheating method.

In GTAW welding, the time-consuming need for edge preparation results in material waste. However, with SWAT technology, we can weld materials up to 12 mm thick without edge preparation, completing the welding in a single pass. This translates to a 90 percent reduction in the required passes, an 89 percent decrease in consumables for welding, a 77 percent reduction in gas usage, and nearly 100 percent less time spent on edge preparation.

Through our commitment to continuous improvement and responsible decision-making, we meet industry standards and surpass them, contributing to a greener and sustainable future.

How is SigmaWeld’s integration of IoT and data-driven technology into welding systems revolutionising the industry?
In the age of Industry 4.0, we take the lead in seamlessly merging welding technology with digitalisation and data-driven procedures. Our intelligent welding systems, equipped with sensors and IoT connectivity, collect real-time data for analysis. This data is processed using AI algorithms, enabling predictive maintenance to reduce downtime and enhance overall operational efficiency. Remote monitoring capabilities ensure swift responses to functional variations, guaranteeing uninterrupted production.

Recently, SigmaWeld has developed a range of welding machines that connect to the server through GPS/LAN/WIFI. The welding supervisor can configure parameters and assign WPS to the welder through the server software. When the welder logs attendance with their card, the parameters are transferred to the card. Subsequently, at the designated welding location, the welder scans their card on the welding machine, and the parameters are loaded onto the equipment. The welder can only adjust within the specified WPS range the supervisor sets. During welding, real-time data, including current, voltage, arcing time, welder details, and various other parameters, is logged and transmitted to the server. Remarkably, a single server software can connect to over 40 pieces of equipment.

How is strategic implementation of automation reshaping the welding industry to improve productivity?
We bring about a revolution in welding processes by strategically implementing automation, which enhances both productivity and the quality of the end product. Our automated welding systems are intricately designed to optimise operations, reducing manual errors and ensuring consistent, high-quality welds. Through the automation of repetitive tasks, we significantly increase production efficiency, allowing for faster turnaround times without compromising precision.

Our primary focus is on GTAW, known as one of the most critical and widely used processes in the industry, even though it’s considered slower. With years of experience and the development of AVC, Weavers, and Cold Wire Feeders, we can support various welding automation needs for this process. Our standard auto-tig heads can be easily integrated into existing automation equipment, such as seamers and column booms. This accelerates project delivery, and it also guarantees uniformity, meeting the most stringent quality standards.

To reiterate, the SWAT technique, a keyhole variant of GTAW, is the industry’s workhorse, significantly accelerating TIG welding, making it ten times faster than traditional methods. This approach is exceptionally cost-effective for welding stainless steel and exotic materials. One of our customers completed more than 4500 meters of welding 6mm of C276 nickel alloy without using a single consumable at speeds upwards of 400mm/min. This had a profound positive impact on their bottom line, saving them several months in production time.

How is the increasing demand for skilled welders in the manufacturing sector being addressed through automation and training programs?
The demand for skilled welders is steadily growing globally, particularly as the manufacturing sector thrives. With automation plays a significant role; it serves as a means to elevate the skills of welders to become operators. Nevertheless, having a solid foundation in welding knowledge remains a prerequisite for operating automation.

While automation handles repetitive tasks, there is a growing need in the industry for highly skilled welders who can proficiently manage complex machinery and ensure optimal performance. Training programs have adapted to this demand, focusing on advanced welding technologies, robotics, and programming. We acknowledge the critical role of a skilled workforce in this digital age. Our training initiatives are thoughtfully designed to guide welders in acquiring and staying current with the latest trends in the field, empowering them with the expertise necessary to operate advanced equipment effectively.

What transformations in productivity can we expect in the welding industry due to technological advancements, and what opportunities lie ahead for the future?
Achieving greater productivity with fewer resources is the goal, and we are seeing advancements in technologies like Friction Stir Welding, Key Hole Tig, and Plasma Welding that are driving these improvements. An intriguing development on the horizon is the use of travelling vacuum (localised) electron beam welding, which has the potential to enhance productivity significantly. However, cost and adaptability will be pivotal in its widespread adoption. The industry also moves toward more hybrid processes, leading to further innovations.

In the ever-evolving world of welding, emerging technologies are reshaping the industry. From automation and environmental considerations to skill development and the integration of data analytics are improving welding outcomes and their impact on the welding landscape.

What are the latest trends and solutions in welding technologies that are transforming the manufacturing industry?
One of the innovative welding technologies making waves in the manufacturing industry is Laser Beam Welding (LBW). This method harnesses a powerful laser to create a focused beam of light, which is used to melt and join metals. The precision of LBW allows for exact control over weld penetration and heat input, resulting in consistently clean welds. Additionally, the decision to use filler material is tailored to each application’s specific needs.

Another noteworthy trend is Hybrid Welding, which integrates various welding techniques, such as laser welding, GTAW (Gas Tungsten Arc Welding), or MIG welding. By combining the strengths of these methods and mitigating their weaknesses, hybrid welding establishes a precise and stable welding process. For instance, laser welding excels at heat control and metal melting, while GTAW or GMAW can introduce additional filler material and effectively manage the weld pool. This highly adaptable approach accommodates a wide range of materials and thicknesses, resulting in high-quality welds with minimal distortion and porosity.

Can you offer insights into the role of advanced materials and techniques in modern welding processes?
In contemporary welding processes, advanced materials play a crucial role in various industries, particularly in applications involving aerospace components. These advanced materials encompass a range of substances, including titanium aluminide intermetallics, nickel aluminide intermetallic alloys, iron aluminide intermetallic alloys, oxide dispersion strengthened (ODS) alloys, metal matrix composites (MMCs), nickel-based superalloys, aluminium alloys (including aluminium-lithium alloys), magnesium alloys, and super martensitic stainless steel.

The aerospace sector, in particular, relies heavily on these advanced alloys for their exceptional properties. While welding has not historically been as prevalent in aerospace manufacturing as in some other industries, there has been a notable increase in its usage over the past decade, thanks to advancements in welding techniques.

When working with these advanced materials in welding, welders face unique challenges. They must carefully manage heat input to prevent material degradation, reduce splatter, enhance control over the welding arc, and ensure the highest possible weld quality. These efforts are essential to meet the stringent demands for performance, durability, and safety in aerospace applications.

How are you addressing environmental and sustainability considerations associated with welding technologies?
Equipment with inverter-based technology is 30 percent more energy efficient than old thyristor-based and transformer-based equipment. Hence, the market has shifted to this latest technology-based equipment.

Electronic components and machine parts adhere to ROHS regulations to safeguard the environment. These regulations prohibit using hazardous materials such as Lead, Mercury, Cadmium, and other ten elements that are harmful to health and challenging to dispose of. Additionally, recyclable plastics are utilised for these components. Engine-driven welding machines must also conform to noise and pollution emission standards established by the Central Pollution Board to minimise environmental impact.

With the rise of Industry 4.0, how is welding technology evolving to integrate with digitalisation and data-driven processes?
The Fourth Industrial Revolution, called Industry 4.0, is ushering in a wave of automation and data exchange within manufacturing processes. This transformation, characterised by the aid of cyber-physical systems (CPS), IoT, cloud computing, cognitive computing, and artificial intelligence, profoundly impacts the welding industry. Increased automation and the integration of data analytics are improving welding outcomes. New welding technologies, driven by AI and precise control, are opening doors in industries that demand top-notch weld quality for the latest and most intricate metals. The industry is set to witness similar strides in safety and quality as it continues to evolve. 

Please discuss implementing automation in welding to improve productivity and product quality.
The Fourth Industrial Revolution (Industry 4.0) is the trend towards automation and data exchange in manufacturing technologies and processes, including cyber-physical systems (CPS), IoT, the industrial internet of things, cloud computing, cognitive computing, and artificial intelligence.

The welding sector is undergoing significant changes due to the influence of Industry 4.0. This includes the growing adoption of automation and robotics and the utilisation of data analytics to enhance future welding processes. The integration of AI and emerging welding technologies is also opening up fresh opportunities in industries working with advanced and highly sensitive metals that demand precise control during welding. As the industry progresses, we anticipate innovations in welding methods that will boost safety, elevate quality, and enhance productivity.

Compared to manual welding, automated welding processes can minimise the chance of errors and inconsistent welding, increasing speed, precision, and quality.

How the demand for skilled welders is changing in light of automation and technological advancements?
The need for proficient welders will remain constant, even with automation and advanced welding techniques. Instead of focusing solely on improving welders’ general manual welding skills, customised welding training programs are designed to address the precise requirements of individual welders or specific organisations. These programs aim to transform participants into experts in their field. These specialists can fine-tune automated welding stations’ fundamental parameters and timing settings. This ensures a consistent quality of the finished product, reduces the need for post-weld cleaning, and facilitates seamless parts fitting for complete assemblies or subassemblies.

What emerging welding technologies and applications deserve attention in the near future?
Welding Cobots or collaborative welding robots are designed to complement human welders during the welding process. Equipped with sensors and programming, these robots work in tandem with human welders without the need for safety barriers or enclosures. They help with repetitive or physically demanding aspects of welding, significantly enhancing safety and ergonomics.

Welding drones, or unmanned aerial vehicles (UAVs), are equipped with cameras, sensors, and robotic arms to conduct welding duties and inspections. They excel in accessing hard-to-reach or hazardous locations, such as tall buildings, bridges, or offshore oil platforms, where human welders face the greatest risks. Operated remotely by humans, these drones can monitor and adjust the welding process. Their use removes the need for scaffolding or other access equipment, saving time and money. 

Sougandh, K.M., Country Manager of India, states Universal Robots’ mission is to make automation accessible to all. Its approach to automation and collaborative platform envisions a future where any company, regardless of location, can embrace automation.

How is the integration of technologies impacting manufacturing sustainability?
The environment has emerged as a prominent concern for businesses globally. In light of the ever-evolving technological advancements, industries increasingly prioritise sustainable objectives. The integration of technologies such as artificial intelligence, robots, and Industry 4.0 is substantially impacting the manufacturing sector. While traditional industrial robots play a role, collaborative robots (cobots) developed by UR are specifically designed to enhance productivity and efficiency in the manufacturing industry. The manufacturing industries have reaped multiple benefits by integrating these cutting-edge technologies such as:

Reduced Energy Consumption: Using AI and robots to optimise industrial processes may decrease energy usage. Cobots may be operated remotely, reducing trip expenses and maximising energy use. Cobot digitisation and effective programming can further cut production-related power use.

Waste reduction: Cobots excel in carrying out repetitive tasks with exceptional precision and quality control, thereby minimising the occurrence of waste. Moreover, cobots exhibit versatility and have a longer lifespan than industrial robots. They can automate diverse applications and easily adjust to evolving production processes. By lasting longer, cobots reduce the necessity for frequent machinery replacements, decreasing the overall utilisation of machines and a lower volume of discarded heavy industrial equipment.

Employee Well-being and Safety: Employee well-being is one of the most debated topics. As mentioned, cobots are specialised to perform repetitive tasks so that humans can contribute to more value-added tasks, contributing to employee’s physical well-being. They are safe to work alongside humans, promoting a healthy and safe work environment for employees.

In what ways robotics has transformed the face of manufacturing?
The manufacturing industry has transformed by advancing and integrating state-of-the-art technologies, particularly in robotics. Cobots have emerged as crucial contributors in addressing manufacturing challenges. Below are various ways in which cobots are impacting the manufacturing sector:

Flexibility: Cobots are designed to work alongside humans. They exhibit adaptability and agility in manufacturing processes as they can be easily programmed and reprogrammed for various tasks. This enables manufacturers to respond swiftly to changing demands and trends, fostering flexible production lines that save time and resources.

Worker safety and ergonomics: Cobots offer the advantage of safely working alongside human workers. Equipped with advanced sensors and safety features, they can detect human presence and avoid accidents. Additionally, cobots alleviate the physical strain and ergonomic issues associated with demanding or repetitive tasks, contributing to a healthier and more sustainable work environment.

Product customisation: Unlike traditional robots that occupy significant floor space and are limited to specific tasks, cobots are cost-effective, space-saving, and versatile. They are well-suited for FMCG (Fast Moving Consumer Goods) industries that rely on seasonal demand, changing consumer preferences, and dynamic environments. Cobots enable high-mix, low-volume production and can be easily deployed and redeployed to perform various tasks, ensuring a rapid return on investment.

Cost-effectiveness: Cobots generally incur lower costs and require less infrastructure investment than standard industrial robots. They can be quickly programmed without the need for extensive robotics expertise. Furthermore, cobots optimise resource utilisation, reduce waste, and eliminate duplicate efforts or errors, resulting in cost savings and improved overall operational efficiency.

Cobots are revolutionising the manufacturing sector by enhancing workforce development, flexibility, worker safety, productivity, scalability, and cost-effectiveness. They play a vital role in maintaining a competitive edge in the industry by promoting collaboration and adaptability to emerging trends.

In what manner is industrial automation transforming the outlook of the robotic market?
The market for industrial automation is evolving at a very fast pace. According to Research and Markets, the global industrial robotics market was $37,876 million in 2020 and is expected to reach $116,848.7 million by 2030, with a CAGR of 11.7 per cent from 2021 to 2030. 

 The industrial automation sector has undergone a profound transformation due to the integrating of emerging technologies such as AI, ML, IIoT, 5G, and more. Technological advancements have driven the evolution of industrial robots, leading to significant developments in the following areas.

Collaborative robots: They are specialised in performing dull, mundane, and repetitive tasks. Cobots are versatile, easy to use and compact. They are becoming more popular across sectors because of their capacity to support human employees in activities including palletising, welding, machine tending, assembly, and material handling. 

Machine learning: Recently, robotic performance has been improved by machine learning algorithms through ongoing learning and improvement. AI-powered robots enhance industrial automation’s productivity, effectiveness, and capacity for handling challenging jobs.

Mobile and autonomous robots: The robotics industry is witnessing the emergence of mobile and autonomous robots that can operate and navigate in dynamic environments independently, without human involvement. Mobile robots are utilised in logistics, warehousing, and material handling scenarios, whereas autonomous robots are deployed for inspection, maintenance, and surveillance tasks. These advanced robots are enhancing efficiency, minimising costs, and expanding the scope of automation across various industries.

Which robots are in great demand for various processes with arising needs?
As technology advances, the landscape of industrial robot adoption is transforming. Many robots are emerging, including cobots, mobile, and service robots. Cobots have gained significant popularity among these due to their versatility and suitability for various industrial processes. Cobots are compact, require minimal space, can be installed on the ceiling, offer flexibility, and greatly enhance efficiency and productivity in production units. One of the most significant used processes where cobots are used is:

Palletising: Palletising, or arranging goods on pallets, is essential to supply chain and logistical processes. Cobots have become important instruments in palletising applications, revolutionising the speed and adaptability of the procedure. 

Cobots eliminate the necessity for physical barriers by using advanced sensors and safety features, ensuring a safe workspace. Their easy setup and straightforward programming enable efficient customisation for various palletising tasks. By automating repetitive operations, cobots enhance productivity by reducing cycle times.

Cobots eliminate the need for physical barriers by ensuring a safe working environment with cutting-edge sensors and safety features. Quick setup and simple programming allow for effective customisation for various palletising jobs. By automating routine operations, cobots increase productivity by reducing cycle times. They are also more affordable than typical industrial robots since they require less infrastructure and upkeep.

Machine tending: Loading and unloading workpieces onto machines, such as CNC machines or assembly lines, is called machine tending. Cobots in applications like machine tending provide versatility and flexibility to manage various machines and parts. Cobots may be swiftly deployed for machine tending chores and are simple to programme. Automating time-consuming and repetitive operations boost productivity by freeing workers to concentrate on more complex tasks. Cobots simplify the machine tending procedure, increase effectiveness, and raise industrial productivity.

Welding: Cobots have found extensive application in welding, which is a hazardous task requiring precision and efficiency. These tasks are ideally suited for cobots. Manual welding demands high dexterity and skilled human judgment, particularly for complex welds. However, the integration of automated welding technology is increasingly significant in meeting demand and overcoming the shortage of qualified welders in the industry.

What are your objectives for the year 2023?
UR’s mission is to make automation accessible by offering cost-effective, flexible, safe, and user-friendly collaborative robots that work harmoniously alongside humans in manufacturing settings. Through its approach to automation and collaborative platform, UR envisions a future where any company, regardless of location, can embrace automation. The objectives for the year 2023 are as follows.

Since its beginning, the company has concentrated on making automation easier for small and medium-sized enterprises. The company will re-orient its efforts in 2023 to attract more substantial clients, emphasising large businesses while continuing to make automation affordable for smaller businesses.

In 2023, UR will focus on leveraging cobots for welding, palletising, and machine tending applications. These areas offer extensive use cases for cobots and bring numerous benefits to organisations, such as enhanced productivity, reduced labour costs, increased efficiency and quality, and improved adaptability. By emphasising these applications, Universal Robots aims to achieve its goal of widespread automation.

UR emphasises delivering the utmost customer satisfaction and post-sale services, considering it a top priority. They serve as trusted advisors, committed to establishing enduring partnerships with their clients. Through a thorough understanding of each customer’s unique requirements and obstacles, UR leverages its extensive partner network, innovative technologies, and industry expertise to offer solutions that bring tangible value and sustained success. The company strives to streamline the purchasing process, implementing and utilising its automation solutions, ensuring a seamless customer experience. Universal Robots believes in ‘Our success lies in our customers’ success’.

Amit Deokule, Director – Sales & Marketing, NORD Drivesystems, explains how NORD DRIVESYSTEMS is shaping the future of manufacturing with energy-efficient geared motors, automation solutions, and a commitment to environmental sustainability.

Please explain the latest advancements and innovations in gear technology and how they enhance machinery’s performance and efficiency.
We are committed to delivering complete system solutions to our customers through our highly energy-efficient drive technology. We focus on application engineering to provide the best possible solutions. Our gearboxes, designed with the UNICASE design and exceptional leak protection, ensure the highest overall efficiency. We now offer IE4 and IE5 motor options, along with innovative products like NORDAC Link, Duo Drive, and our decentralised drives, enabling us to provide highly efficient solutions.

Our decentralised drive is a unique product combining a gear box, motor, and inverters. The NORDAC FLEX, a versatile decentralised frequency inverter, has established itself in various engineering and industry applications.

What are the emerging trends in motor technology, and how are these advancements contributing to energy efficiency and sustainability in manufacturing processes?
We are seeing a rising trend where customers increasingly embrace automation practices and prefer energy-efficient and sustainable products. Given that India is a big consumer market, we see promising opportunities within various end-user sectors.

Our commitment to environmental preservation is an integral aspect of our corporate policy, which provides a more comprehensive outline of our sustainability approach. To quote – Environment Economic, profit-oriented development and protection of our environment and energy savings are not understood as conflicting interests but rather a common goal. For this reason, we are committed to protecting the environment and preventing environmental pollution to the best of our ability. 

Our environmental management system is focused on the following aspects of our business activities: 

· Reduction and substitution, or careful handling of water pollutants, particularly in production processes such as painting.

· Resource-efficient product design of new products and packaging materials

· Reduction of greenhouse gases in logistics processes, the use of heating methods, electricity consumption or business trips

· Reduction of waste, in particular, hazardous waste from production processes

· Coordination of manufacturing methods for purchased components and their delivery.

Our environmental management system involves setting specific environmental improvements in developing new products or production methods. In product development, we ensure that our products are designed to promote energy and resource efficiency when used by our customers. Whenever possible, we make concerted efforts to minimise emissions, waste products, energy consumption, water usage, and other resource utilisation in our production and logistical operations.

Within the framework of our management system, we regularly monitor our resource consumption and emissions, which encompass aspects like noise and air pollution, and provide regular reports on our progress and specific developments.

How does technology impact the efficiency and effectiveness of the machinery or equipment involved?
Our emphasis is on providing energy-efficient helical bevel geared motors to conserve energy compared to less efficient geared motors. With their Unicase design, the NORD geared motors are designed to deliver higher torque in a compact form. The Quadra lip sealing technology employs three sealing lips and an additional layer of oil and grease as a barrier to prevent oil leakage. Additionally, we prioritise focus on system efficiency by using energy-efficient products.

How are your geared motors designed to be environmentally friendly and comply with relevant emissions regulations?

We at NORD are committed to the Go Green mission. To comply with it, we always push energy-efficient products against inefficient, obsolete products, coupled with premium efficiency motors (IE3), and Super Premium efficiency motors (IE4). All our geared motors comply with CE and BIS marking.

How do gear and motor technologies support the automation of production lines and improve precision and reliability in robotic systems?
The integrated PLC within NORD drive electronics enables each drive unit to operate independently, allowing for local data preprocessing and external data communication. Moreover, these units can decentralise process and motion control tasks, thereby reducing the central control system’s workload.

NORD DRIVESYSTEMS drive units can manipulate processes by controlling actuators in conveyor systems or production facilities through their analogue and digital input interfaces. They can also receive, process, and transmit internal and external sensor signals and data (such as those from photocell barriers, temperature sensors, or vibration sensors) via the input interfaces of the inverter PLC.

NORD DRIVESYSTEMS’ drive electronics come with built-in interfaces compatible with commonly used field bus types, allowing them to communicate with various automation environments. This enables internal or global networking within the Industrial Internet of Things (IIoT) and connections to cloud solutions, opening up the full potential of Industry 4.0.

In recent years, emerging technologies have begun to reshape the welding landscape, bringing unprecedented precision, efficiency, and safety to this age-old craft. From Laser Beam Welding to Augmented Reality, this story explores the innovative future of joining metals.

Welding, which combines the art and science of joining metals, has played a vital role in modern industrialisation and infrastructure development for well over a century. From towering skyscrapers to intricate automobile parts, the world we know today has been built with the help of welding. Further, welding technologies have a substantial impact on pharmaceutical manufacturing, with current advancements focusing on using advanced welding materials to achieve precise, contamination-free connections. The welding and cutting sector is poised for significant expansion, primarily due to India’s heightened focus on infrastructure advancement. India’s infrastructure initiatives drive a growing need for welding and cutting services across various industries. Notably, infrastructure development emphasises projects like road construction, bridge building, and architectural construction, all of which require welding skills to ensure structural durability and integrity.

Nimesh Chinoy, Director of Sales & Marketing at SigmaWeld, emphasises that productivity and data analysis are the key drivers behind the transformative impact of welding technologies on the manufacturing industry. Technological innovations, from augmented reality welding to laser beam welding in space, are poised to revolutionise the industry, contributing to broader automation trends, sustainability, and globalisation. One of the innovative welding technologies making waves in the manufacturing industry is Laser Beam Welding (LBW). This method harnesses a powerful laser to create a focused beam of light, which is used to melt and join metals.

A novel trend in welding equipment involves the capability to retrieve Welding Procedure Specification (WPS) data from a server, recognise the welder, and automatically configure the equipment to operate within the specified current and voltage range. Another noteworthy trend is Hybrid Welding, which integrates various welding techniques, such as laser welding, Gas Tungsten Arc Welding, or MIG welding. By combining the strengths of these methods and mitigating their weaknesses, hybrid welding establishes a precise and stable welding process. The use of automation, robotics, and data analytics is further reshaping the welding landscape, reducing the reliance on manual labour and improving the quality and sustainability of welding processes.

Automation and robotics: the rise of welding machines
Automation and robotics are on the rise in the welding industry. The integration of welding automation and robotics is improving efficiency and safety within the sector. The sector is undergoing significant changes due to the influence of Industry 4.0, which includes the growing adoption of automation and robotics, as well as the utilisation of data analytics to enhance future welding processes. The manufacturing industry is increasingly turning to automation, robots, and collaborative robots due to the need for more skilled workforce. Automation is increasingly being integrated into welding processes, enhancing productivity and ensuring consistent weld quality, which is crucial for industrial applications.

While automation handles repetitive tasks, there is a growing need in the industry for highly skilled welders who can proficiently manage complex machinery and ensure optimal performance. Automation and robotics are playing an increasingly significant role in the welding industry. These machines can operate continuously, reducing the need for human welders to perform monotonous, physically demanding work.

Dr. T.J. Prasadarao, Executive Director (Technical) at D&H Sécheron, highlights the importance of remote robotic welding, especially in hazardous or sterile environments within the pharmaceutical sector. Robots can work with precision and without risks to human workers. Robotic welding arms, equipped with sensors and adaptive control systems, can seamlessly adjust to variations in materials and joint configurations, ensuring consistently high-quality welds. These robots are also more resistant to the physical strains of manual welding, making them ideal for tasks in challenging environments such as offshore oil platforms or nuclear facilities.

Furthermore, automation is contributing to a more sustainable welding industry. Robotic welders are programmed to optimise material use and minimise waste, a crucial factor in the context of growing environmental concerns. As we strive to reduce the carbon footprint of manufacturing, automation offers an elegant solution to minimise resource consumption while maintaining high-quality standards. Furthermore, augmented reality welding is one of the most exciting developments in welding technology.

Emerging welding technologies
Emerging welding technologies represent the forefront of innovation in the manufacturing sector. The initial preparation of metal for welding frequently involves cutting, fitting, and beveling the base material, mentions Ravichandran Duriaswamy, AGM- Product management, Messer Cutting Systems India. The meticulousness and care invested in the initial cut can significantly reduce the need for extensive post-processing. These state-of-the-art techniques and methodologies are meticulously crafted to elevate precision, efficiency, and safety throughout the welding process.

From the integration of augmented reality to the adoption of Laser Beam Welding (LBW) and Friction Stir Welding (FSW), and the incorporation of artificial intelligence (AI) into welding practices, these breakthroughs are driving a transformation in industries such as aerospace and pharmaceuticals. Irrespective of the application, effective metal preparation for welding remains paramount for delivering top-notch results, sustaining consistent productivity levels, and curtailing expenses, particularly those linked to rework and downtime. As technology continues to evolve, these emerging welding technologies promise to drive excellence in welding practices.

Augmented reality welding
Augmented reality welding systems have the potential to revolutionise the way welders work, making their jobs safer, more precise, and more efficient. The introduction of AR welding helmets, equipped with sensors and cameras, provides welders with real-time data and visual overlays that enhance their abilities. These smart helmets can display critical information, such as weld parameters, joint alignment, and work instructions, directly in the welder’s line of sight. Moreover, AR welding systems also assist in training new welders. By simulating welding scenarios in a virtual environment, apprentices can practice their skills without the risk of damage or injury.

Laser beam welding: precision beyond measure
Laser beam welding (LBW) is another emerging technology, making it suitable for applications where exacting tolerances are required. One of the key advantages of LBW is its ability to weld thin materials without distortion. This is particularly valuable in industries like electronics and medical devices, where delicate components must be joined without compromising their integrity. Additionally, the heat-affected zone in LBW is minimal, reducing the risk of thermal stress and distortion in the welded materials. LBW, excelling in joining dissimilar materials, opens up new possibilities for lightweight and high-performance material combinations in various applications.

Friction Stir welding: a new dimension in joining
Friction Stir Welding (FSW) is another notable advancement in welding technology. Its exceptional strength and precision make it an excellent choice for welding pharmaceutical machinery, ensuring durability and reliability in the equipment. FSW is a groundbreaking joining process quickly gaining traction in various industries. Creating a strong and defect-free bond, this process is particularly useful for joining dissimilar materials, which is often a significant challenge in traditional welding.

FSW offers several advantages, such as reduced distortion, improved fatigue properties, and enhanced corrosion resistance. It’s an ideal choice for industries like aerospace, where lightweight materials like aluminium and composites must be joined without compromising structural integrity. Furthermore, FSW generates significantly less heat, creating a safer working environment. Friction stir welding has found its way into space missions, where its ability to create robust and precise welds in zero-gravity environments is invaluable. As humanity continues to explore the cosmos, FSW will play an integral role in constructing spacecraft and habitats for future space travellers.

Nanotechnology and welding in space
Nanotechnology is reshaping the future of materials science and engineering, and welding is no exception. Researchers are exploring the integration of nanomaterials into welding processes, opening up new possibilities for enhanced weld properties. Nanoparticles can be added to welding materials to improve their strength, durability, and resistance to environmental factors. For example, adding carbon nanotubes or graphene to welding filler materials can create super-strong welds that are also highly corrosion-resistant.

Welding technology is playing a crucial role in the construction of spacecraft and habitats for space exploration. The unique challenges of welding in space, where there is no atmosphere and extreme temperature variations, require innovative solutions. A notable development in space welding is using electron beam welding (EBW) and laser beam welding. Moreover, 3D printing technology is being explored for in-situ welding on celestial bodies like the Moon or Mars.

Industry 4.0 and skilled welders
The welding industry is undergoing its own Industry 4.0 transformation, integrating digital technologies, automation, and data-driven decision-making into manufacturing processes. The worldwide demand for proficient welders is steadily rising, especially with the thriving manufacturing sector. Automation is a key factor in enhancing welders’ capabilities to transition into operator roles. Nevertheless, a strong fundamental understanding of welding remains essential for operating automation. Vishwanath Kamath, Managing Director, Fronius India, underscores that the increasing need for welding services is creating a call for skilled welders and specialists in robotic welding, offering employment opportunities and avenues for career advancement. The demand for skilled welders is steadily growing globally, particularly as the manufacturing sector thrives. Automation plays a significant role in elevating welders’ skills to become operators. However, having a solid foundation in welding knowledge remains a prerequisite for operating automation.

The need for proficient welders will remain constant, even with automation and advanced welding techniques. Instead of focusing solely on improving welders’ general manual welding skills, customised welding training programs are designed to address the precise requirements of individual welders or specific organisations. These programs aim to transform participants into experts in their field. Welding cobots or collaborative welding robots are designed to complement human welders during the welding process. The economic viability of implementing robotic welding systems, including cobots, versus manual welding operations depends on various factors, primarily production volume, labour costs, and quality requirements. Government-sponsored skill development and vocational training programmes, such as the Pradhan Mantri Kaushal Vikas Yojana (PMKVY), aim to improve employability by providing extensive welding training.

Welding technologies for modern industry
Modern welding is firmly rooted in cutting-edge materials and techniques, serving as the cornerstone of innovation in various industries. Specialised welding methods are crucial for accommodating high-strength alloys, exotic metals, and composite materials, ensuring the longevity and performance of welded structures. Sustainable welding practices and consumables play a vital role in reducing the environmental impact of contemporary manufacturing while upholding stringent production standards.

Furthermore, utilising specialised consumables with characteristics such as minimal carbon and remarkably low sulfur content has become instrumental in minimising the risk of contamination. Techniques like orbital welding and laser welding are gaining prominence due to their precision and the absence of impurities, particularly in critical applications. In the realm of welding small pharmaceutical components and devices, Microjoining with Laser Welding has gained significant importance owing to its precision and suitability for these specialised tasks. The overarching goal is to achieve higher productivity with fewer resources while maintaining quality.

Conclusively, integrating AI and emerging welding technologies presents new horizons, especially for industries working with advanced and highly sensitive metals that demand precise control during the welding process. As the industry advances, these innovations in welding methods are poised to enhance safety, elevate quality, and boost overall productivity. With AI and precise control driving new welding technologies, doors are opening in industries that demand top-tier weld quality for the latest and most intricate metals.

The welding industry is on the cusp of making significant strides in safety and quality as it continues to evolve and adapt to the ever-changing landscape of technology and innovation.

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Dr. T.J. Prasadarao, Executive Director (Technical), D&H Sécheron.
“Sustainable welding techniques and consumables help reduce the environmental footprint of modern manufacturing while maintaining high production standards.”

Sunando Kumar Palit, Head – Strategy & Customer Experience, Ador Welding Ltd.
“Integrating AI and emerging welding technologies also opens fresh opportunities in industries with advanced and susceptible metals.”

Nimesh Chinoy, Director Sales & Marketing, SigmaWeld.              
“Productivity and data analysis are the key drivers for welding technologies behind the transformative impact of welding technologies on the manufacturing industry.”

Vishwanath Kamath, Managing Director, Fronius India Pvt. Ltd.
“Integration of welding automation and robotics improves efficiency and safety, and growing demand for welding services generates demand for robotic welding experts.”

Ravichandran Duriaswamy, AGM- Product management, Messer Cutting Systems India Pvt. Ltd.
“Preparing metal for welding is critical to producing high-quality results, consistent productivity and minimising costs related to rework and downtime.”

In the material handling world, technological innovations are reshaping industries and providing cost-effective solutions. This article explores how automation, artificial intelligence, and robotics are playing a pivotal role in revolutionising the way we move and manage goods, with a focus on sustainability and efficiency.

The material handling industry is undergoing a transformative shift driven by technology, aiming to boost efficiency, safety, and sustainability. Automation is vital for managing complex orders and sustainability concerns, like reducing energy consumption with automated overhead cranes.

Prem Kalliath, CEO of Blue Star Engineering & Electronics, highlights automation’s impact on complexity management, order efficiency, and rapid turnaround times in the food and beverage, automotive, and pharmaceutical sectors.

Sustainable equipment reduces emissions, noise, and fossil fuel reliance. Neville Mevawala, Head of Sales & Marketing at Godrej Material Handling, stresses its importance in achieving sustainability goals amid government and industry efforts. Infrastructure projects demand advanced material-handling solutions, favouring automation, IoT integration, and intelligent handling methods, aligning with industrial and infrastructure trends.

AI and Machine learning in material handling
Automated warehouses lead this transformation by integrating cutting-edge technologies such as robotics, IoT, and artificial intelligence to enhance storage, retrieval, and distribution processes. These advanced systems minimise the necessity for human intervention and streamline operations effectively. A. Ashok, the Director of Amsak Cranes, remarks, “The adoption of cutting-edge technologies, IoT sensors, and automation has established new standards in the crane industry.” This incorporation allows for real-time monitoring, predictive maintenance, and heightened operational efficiency.

Furthermore, AI and machine learning are bolstering automation in material handling through various avenues. These technologies can optimise inventory management by forecasting demand, reducing waste, and mitigating the risks of overstocking or understocking. Machine learning algorithms refine routing and scheduling for delivery vehicles, reducing transportation costs. Additionally, AI facilitates predictive maintenance by identifying potential equipment issues before they manifest, leading to cost savings in maintenance expenses. Automation is essential for managing complexity, order fulfilment, and rapid turnaround times, especially in sectors like food and beverages, automotive, and pharmaceuticals.

Sensors optimising AGVs performance
Automated Guided Vehicles (AGVs) are enhanced with sensors and predictive maintenance, reducing downtime and improving operational efficiency. Advanced technologies play a pivotal role in enhancing various aspects of industrial operations. Automated Guided Vehicles (AGVs), for instance, can autonomously navigate, reducing the necessity for manual intervention. Sensors and predictive maintenance are critical elements in optimising AGVs. To elaborate further, Neville emphasises that AGVs are equipped with embedded sensors, functioning as the system’s sensory apparatus, capturing real-time data on various operational parameters. Predictive maintenance leverages the data gathered by these sensors to anticipate potential issues before they escalate into major failures. Through the analysis of sensor data for patterns and trends, maintenance teams can detect early signs of wear, component deterioration, or potential problems.

Cobots and conveyor systems
Cobots collaborate with humans, boosting productivity, ergonomics, and material handling safety. IoT aids real-time decision-making, streamlining workflows. Automation enhances precision and control.

Advanced conveyors, with sensors and RFID tech, are cost-effective and versatile. According to Volker Nicolai, Chief Revenue Officer at GEBHARDT Intralogistics Group, spare parts systems involve various components for material movement and order fulfilment.

Automation and Robotics 
Robotics plays a vital role in the automation of material handling tasks. Robots efficiently manage activities like item selection, packaging, and the transportation of goods within warehouses and manufacturing facilities. Collaborative robots, often called “cobots,” collaborate with human workers, enhancing productivity and safety. In the ongoing pursuit of improved operational efficiency, web-based platforms and mobile applications have become indispensable tools. These technologies allow for the remote monitoring and control of EOT cranes, bolstering operational safety and providing real-time insights to enhance crane operations. According to Ashok, automated EOT cranes are a prime example of operational precision and come equipped with features tailored for exact and repetitive tasks, including automatic load handling and collision avoidance systems.

Overhead cranes for material handling
Automation transforms traditional overhead cranes, enhancing efficiency, safety, and cost-effectiveness in material handling across industries. Automated cranes execute precise, high-speed tasks, speeding up production and ensuring accuracy. Equipped with sensors, they detect obstacles and enhance safety. Programmable for energy efficiency, they reduce operational costs and downtime. Existing overhead crane equipment can be upgraded for an extended lifespan. Nirag Chokshi, Managing Partner at Techno Industries, emphasizes that maintenance and modernization can significantly prolong an inefficient crane’s operational life. Manufacturers offer updated components to uphold safety standards, creating secure work environments for employees.

Future trends
The future involves advanced automation and robotics, energy-efficient power systems, IoT sensors, digital twins, and cybersecurity measures. A significant development is incorporating advanced automation and robotics technologies, including autonomous navigation and collaborative robotics. Robotics, in its various forms, will play a crucial role in enhancing the efficiency and adaptability of material handling processes. Sustainability is a driving force, leading to innovations in energy-efficient power systems for Material Handling Equipment. Future components may feature advanced battery technologies and hybrid power solutions, aligning with environmental objectives and reducing operational costs.

IoT sensors for real-time data monitoring, predictive maintenance analytics, and remote monitoring systems enable effective long-distance control of cranes. Digital twin technology allows for comprehensive simulations and optimisations. These cranes have user-friendly human-machine interfaces, energy-efficient components, and robust cybersecurity measures, ensuring optimal performance and security. Investments in R&D, labour costs, and the need for skilled workers drive market growth.

The global warehouse automation system market is expanding rapidly, offering opportunities for enhanced productivity and sustainability. Embracing automation transforms roles and reduces fuel consumption while addressing cybersecurity concerns. Rising investments in extensive R&D activities, lack of skilled workers, high labour costs, and growing awareness of the advantages offered by warehouse automation are some of the factors driving the market growth.

Conclusion
Opportunities arise from the push to expand manufacturing capacity. The global warehouse automation market is growing rapidly, boosting productivity and safety. Automation of overhead cranes is set to play a significant role. Automation transforms roles, requiring employees to operate and maintain equipment, analyze data, and focus on tasks demanding human judgment. Optimized routing and algorithms reduce fuel consumption and carbon footprint. Cybersecurity is vital due to susceptibility to hacking. Companies must invest in robust measures to safeguard information and operational integrity. The future brings innovations like drones and 3D printing. Businesses, regardless of size, can benefit from cost-effective automation solutions. Success lies in embracing these advancements and addressing their challenges.

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Neville Mevawala, Head of Sales & Marketing, Godrej Material Handling.
“Sustainable material handling equipment is pivotal in diminishing carbon emissions, mitigating noise pollution, and reducing dependence on fossil fuels.”

Nirag Chokshi, Managing Partner, Techno Industries.
“Any inefficient overhead crane can be significantly extended in its operational life through maintenance and upgrades.”

Volker Nicolai, Chief Revenue Officer, GEBHARDT Intralogistics Group GmbH & Co. KG
“The spare parts encompass a conveying system responsible for moving materials from the goods-in area to storage locations, whether these are automated or manually operated.”

Prem Kalliath, Chief Executive Officer, Blue Star Engineering & Electronics Ltd.
“In the three critical areas: complexity management, order fulfillment efficiency, and rapid turnaround times, automation can make a substantial impact.”

A.Ashok, Director, Amsak Cranes
“The adoption of cutting-edge technologies, IoT sensors, and automation has established new standards in the crane industry.”

In a world increasingly focused on sustainability, Neville Mevawala, Head of Sales & Marketing, Godrej Material Handling, explores how Godrej Material Handling is at the forefront of eco-friendly material handling solutions. Their innovative practices and dedication to sustainability are reshaping the logistics and infrastructure industry.

Please explain how automation in MHE represents a transformative leap in efficiency.
Automation in MHE forklifts represents a transformative leap in material handling efficiency. Incorporating advanced technologies is pivotal to improving various aspects of industrial operations. AGVs, the Automated Guided Vehicles, can navigate autonomously, reducing the need for manual intervention. IoT, the Internet of Things, plays a crucial role by providing real-time data insights, enabling quick decision-making. Collaborative robotics strengthens the interaction between humans and machines, making workflows more efficient. Advanced material identification and cloud-based management of vehicle fleets also enhance precision and centralised control. The incorporation of automation increases productivity and also promotes a safer and more effective workplace.

What impact have cobots had on your logistics and warehouse operations regarding safety, efficiency, and human interaction?
Collaborative robots, or cobots, prove to be invaluable assets in the domain of material handling within logistics and warehouse operations. They offer many benefits, with a primary emphasis on enhancing safety and operational efficiency. The collaborative nature of cobots facilitates seamless interaction with human operators. It establishes a synergistic partnership that optimally leverages the strengths of both entities. This collaborative approach boosts productivity by automating repetitive tasks. It also empowers human workers to redirect their efforts toward more intricate and strategic aspects of the operation.

Cobots, or collaborative robots, are highly flexible and adaptable, essential in busy warehouses where tasks can change quickly. They can be easily programmed and reconfigured, making them excellent at handling shifts in materials or tasks, and this helps improve the overall agility of warehouse operations. Cobots are crucial for enhancing workplace ergonomics. They take on physically demanding tasks, reducing the chances of worker fatigue and injuries.

The integration of cobots into material handling processes elevates efficiency. This also establishes a safer and more ergonomic working environment. Since 2009, Godrej & Boyce has been a leader in robotics and automation. They have integrated articulated 6-axis robots into their manufacturing processes. With over 50 robots operating, these machines are used for repetitive and labour-intensive tasks. Their dedication to advancing robotics also includes exploring collaborative robots (COBOTS) in various areas, including welding, pick-and-place, and assembly.

How do you evaluate the market for MHE with infrastructure growth?
The demand for MHE is intricately linked to the pace and scale of infrastructure development. As infrastructure projects expand, there is typically a concurrent need for advanced material handling solutions to facilitate construction, transportation, and logistics. The technological landscape within the MHE sector is crucial.

The market prefers innovations like automation, integration of IoT (Internet of Things), and smart material handling solutions. These preferences align with the larger trends seen in industrial and infrastructure progress.

What role do sensors and predictive maintenance play in optimising the performance of AGVs to reduce downtime?
Sensors and predictive maintenance play crucial roles in optimising AGVs, thus significantly reducing downtime in industrial operations. AGV-embedded sensors act as the system’s eyes and ears, capturing real-time data on various operational parameters. This data is then employed for predictive maintenance, enhancing the overall reliability and efficiency of AGVs. Sensors have a wide range of applications, including proximity sensors for tasks such as navigation and obstacle detection, ensuring the safe operation of AGVs within their surroundings.

Predictive maintenance uses the sensor data gathered to predict possible problems before they become major failures. By analysing sensor data for patterns and trends, maintenance teams can spot early indications of wear, component deterioration, or potential issues. This early insight enables proactive maintenance actions, like scheduled component replacement or repairs, upon detecting early warnings, thus preventing unexpected breakdowns and minimising downtime.

Godrej Material Handling has introduced a fleet management system called SafeLog. The main goal of SafeLog is to offer customers real-time data and initial analysis, providing them with valuable insights into their Material Handling Equipment operations.

What are your predictions for the future trends in material handling equipment components?
One significant trajectory involves the integration of advanced automation and robotics technologies. Robotics, which encompasses autonomous navigation and collaborative robotics, will play a pivotal role in optimising the efficiency and flexibility of material handling processes. Sustainability is a key driver, leading to innovations in energy-efficient power systems for MHE. Future components may showcase advanced battery technologies and hybrid power solutions, aligning with environmental goals while reducing operational costs.

How does Godrej Material Handling’s commitment to sustainability and eco-friendly equipment align with the global shift towards greener solutions in the logistics and infrastructure sector?
The escalating demand for efficient and eco-friendly material handling solutions aligns with the global shift toward sustainability and environmental awareness. Sustainable material handling equipment is pivotal in diminishing carbon emissions, mitigating noise pollution, and reducing dependence on fossil fuels.

In light of government and industry efforts to reduce environmental impact, adopting sustainable equipment emerges as a cornerstone for achieving overarching sustainability objectives.

In recent years, Godrej Material Handling has concentrated on reducing carbon emissions by adopting sustainable practices, creating innovative products, using eco-friendly production methods, and contributing to national biodiversity conservation.

By integrating sustainable technologies and design concepts into our range of material handling equipment, we present solutions that minimise environmental impact. By integrating sustainable technologies and design principles into our range of material handling equipment, we present solutions that minimise environmental impact. The solutions also enhance operational efficiency—a testament to our commitment to sustainability. Our company is actively moving towards reducing its environmental impact and promoting a more sustainable future for India’s manufacturing sector, with a particular emphasis on eco-friendly forklifts. In our lineup, customers can choose from the UNO, Bravo, and NEO—three distinct models of electric forklifts offered by Godrej Material Handling.

In a technical interview, Shyam Padwal, Branch Head – Mumbai and Pharmaceutical Expert, B&R Automation, discusses the transformative impact of automation, robotics, and adaptive manufacturing, along with dynamic solutions by B&R.

How are automation and robotics transforming manufacturing by enhancing flexibility, precision, and adaptability in response to industry challenges?
Manufacturing faces day-to-day challenges. However, there’s a significant and ongoing transformation in the industry through the rise of automation. This transformation is not merely a passing trend; it’s a continuous process. With a shortage of skilled labour and a growing consumer demand, intelligent and interconnected automation represents the future of manufacturing. This surge in automation promises to address various issues, ranging from meeting production targets to saving time and enhancing safety for machine users. As robots perform repetitive tasks, manufacturers can redirect their focus toward groundbreaking technologies. This shift enables them to adapt swiftly to the ever-changing business landscape, making them more agile and competitive.

Automation and robots have the potential to deliver unparalleled levels of machine flexibility and precision. Integrating robotics with automation through a single machine control system is a significant development. This integration allows manufacturers to embrace the trend of mass customisation and optimise their processes for one-of-a-kind production runs with ease.

How is automation technology of B&R revolutionising pharmaceutical manufacturing, specifically in robotics integration, and what benefits does this bring to the industry?
Pharmaceutical companies increasingly turn to automation to address manufacturing challenges and are poised for substantial growth. Also, pharma packaging is set to undergo a significant transformation through greater automation and robotics solutions. B&R offers a comprehensive portfolio of solutions, including PLCs, IPCs, IOs, drives, and motors. Furthermore, we have introduced advanced automation products such as mechatronics track systems, machine vision systems including smart lights, and a range of delta robots tailored to meet the specific needs of the pharmaceutical industry. These innovations enable manufacturers to enhance flexibility throughout the entire production and packaging process, ultimately supporting shorter product cycles. Integrating robots into the machine automation system, known as machine-centric robotics, revolutionises the industry by achieving an unparalleled level of synchronisation between robotics and machine control. This eliminates the need for a dedicated controller for the robot, streamlining interfaces between the machine and the robot. All axes and sensors now communicate seamlessly on a common network, enhancing precision to an unprecedented microsecond range.

How is adaptive manufacturing reshaping production processes and addressing key challenges of the pharmaceutical industry?
The new generation of machines, known as adaptive machines, are exceptionally efficient at automating dynamic changes, and they are making significant inroads into the pharmaceutical industry. They result from a constructive collaboration of key technological breakthroughs integrated into a single system. B&R has been globally developing hardware and software solutions for over 40 years. For the past 25 years, it has been a pioneer in the Indian manufacturing sector, providing industrial automation solutions. Our extensive automation expertise, customer-centric approach, and innovative culture position us as the ideal technology partner for adaptive manufacturing in the medical and pharmaceutical industries.

Adaptive manufacturing opens doors to entirely new solutions for challenges. Considering costly cleanroom installations, it is a solution that pays for itself through significant footprint savings. Adaptive manufacturing possesses the ability to produce small batches of medical devices and procedural kits with the same level of efficiency as high-volume production. Products from the B&R portfolio, like the ACOPOStrak, SuperTrak, and ACOPOS 6D systems, provide many distinctive movement possibilities to enhance production processes. Divergent material flows can merge on the fly to form small batches of medical devices or custom kits and packs at full production speed; a central control system with seamless monitoring can orchestrate all of these. This is the future of pharmaceutical manufacturing: adaptive, efficient, and profitable.

Can you tell us how the pharmaceutical industry harnesses advanced technology to improve efficiency and compliance in production processes?
The pharmaceutical industry is utilising the power of AI and collectively scrutinising the data. Pharma manufacturers are integrating digital platforms into their production lines, which are equipped with integrated pharma solutions to help users optimise the performance of their automation systems while simultaneously improving cost and energy efficiency. Multiple control systems for process control, SCADA, energy monitoring, and condition monitoring are bygone. The users now get all this functionality in a single, integrated system with built-in cybersecurity origin specifically designed for pharma industries.

B&R has in its product basket an out-of-the-box solution known as PharmaEdge, which consists of a B&R industrial PC running a hypervisor solution with both Linux and Automation Runtime operating systems. It offers machine and process automation libraries for easy configuration. There are no limitations to internal tags and no incremental costs for additional tags. Built-in features support easy reporting and historical data retrieval. With this one-box solution, users can monitor and control their entire operations. This is the modern application of artificial intelligence and the Internet of Things. PharmaEdge provides a quick and easy way to implement and customise audit trails with quality, regulatory compliance, safety, easy track-and-trace, and efficient data access, all trademarks of a world-class pharmaceutical facility.

In the heart of India’s pharmaceutical landscape, a quiet revolution is taking place. With a keen eye for innovation and efficiency, the industry harnesses cutting-edge technologies, such as robotics, automation, data analytics, and AI, to transform how medicines are produced and delivered. This cover story delves into the strategic adoption of automation, the role of data analytics, the synergy between AI and IoT, and the unique challenges the pharmaceutical sector faces in upholding quality and compliance.

The pharma industry is making commendable strides in harnessing cutting-edge technologies related to robotics and automation. They have adopted a prudent approach by urging original equipment manufacturers (OEMs) responsible for providing essential equipment in pharmaceutical manufacturing setups – such as those involved in tablet production – to not only supply the core machinery but also integrate advanced automation capabilities through their in-house automation teams and technological expertise.

Pharmaceutical companies are being smart by teaming up with original equipment manufacturers (OEMs) who provide the necessary machinery and promote automation in that machinery. India has a strong history and a promising future in pharmaceuticals, and the industry is managing its finances wisely by cost-effectively adopting automation getting high-tech results with minimal investment.

Robot density
From a national point of view, we use a metric called “robot density” to measure our level of automation. Mr. Guru Prasad, Assistant Vice President, CSSR and Electronics, Robotics and Discrete, ABB India adds “Robot density shows how many industrial robots are being used for every 10,000 employees in the formal manufacturing sector, not including casual labour. A few years ago, our robot density was low, staying in the single digits. Now, we’ve improved and are in the higher single digits, maybe around the 7th or 8th place globally. It’s important to remember that this doesn’t directly compare to larger countries like Iran, but it helps us understand how much our country has progressed in automation.”

The reason behind the increasing adoption of robotics is its ability to enhance productivity without compromising safety, hygiene, or the crucial aspect of traceability, especially vital in the pharmaceutical industry. Combining the concept of robot density with the drive for automation and improved productivity, it’s a distinctive solution that’s been in use for many years and is becoming even more unique thanks to cutting-edge sensors, 2D and 3D vision systems, and AMRS AGVS technology. Automation is a driving force for boosting productivity, enhancing quality and hygiene, and ensuring robust traceability. In a nutshell, it’s all about achieving these goals.

Sensors
Mr. Nitin Davessar, Chief Manager, Sales, Addverb adds that if you’re dealing with a drug that can be produced at room temperature without much complexity, conveyor systems tend to be the more cost-effective and efficient choice. They offer higher throughput and are budget-friendly. However, in cases involving temperature-sensitive Active Pharmaceutical Ingredients (APIs) with a need for minimal human interaction and where you don’t want to restrict access on the shop floor, AGVs and AMRs become the preferred solution. These automated vehicles provide flexibility, allowing products to move without obstructing the workspace. It’s essential to note that this isn’t limited to the pharmaceutical industry; AMRs are increasingly finding applications in cutting-edge manufacturing locations.

Data analytics
In today’s digital age, the adage that “data is the new oil” rings true, especially when considering the practices of tech giants like Google, Facebook, and LinkedIn. Mr Prasad says that these companies harness user data not only to boost their sales but also to assist individuals in their pursuit of a better quality of life. However, the significance of data and data analytics becomes even more pronounced in manufacturing. The data generated at various levels of automation, from basic sensors to advanced cloud-based algorithms, plays a pivotal role.

Specifically, in the context of automation, the data we collect, such as information from 2D or 3D vision systems, proves invaluable for machine learning. This data enables robots to sort products efficiently, recognise new items, and develop improved methods for handling them. As machine learning evolves into artificial intelligence, the critical role of data and data analytics in the world of automation cannot be overstated. It has already become an integral part of modern manufacturing.

AI and IoT  
In artificial intelligence (AI), there’s a natural connection to the concept of digital twins. AI inevitably brings us to digital twins because they address a specific limitation in the use of AI in the pharmaceutical industry, particularly in automation. However, when AI and digital twins work in tandem, this limitation becomes almost nonexistent. This collaboration allows you to have a virtual replica of your entire factory on your computer screen. This means that any issues, mixing or tracking, can be monitored in real-time on your computer.

Moreover, with the help of the Internet of Things and high-speed connections like 5G, you can make real-time adjustments to your factory equipment from your computer. The improvement in connection speeds, whether it’s due to 5G or high-speed fibre-optic cables, combined with digital twins, is transforming how plants are operated, equipment is maintained, and maintenance needs are predicted. It also facilitates rapid responses in case of equipment failures.

According to Mr. Davessar, IoT can be as straightforward as receiving sensor data to monitor conditions while creating a pharmaceutical formula. This data includes checking if the temperature inside a vessel is at the correct level and ensuring that it’s consistent in different parts of the vessel. It also involves confirming if the humidity in the facility meets the required standards during processes like bottle filling and product packaging. Once you have access to data from various sensors, the key question becomes how to make the right decisions based on that information. For instance, if you identify that a single bottle in the production line is underweight, can you track and remove that specific bottle from the packaging process to prevent it from reaching the customer? Similarly, in the event of a faulty batch, IoT can help prevent it from entering the market and causing problems for both the customers and the company.

Efficiency improvements  
Efficiency, sometimes called technical availability, measures how well equipment performs during its designated operational time. For instance, if a piece of equipment is supposed to run for 22.5 hours and produce 20 million items, but it has 18 million, it’s considered 90% efficient.

When we talk about adopting newer technologies, especially in the context of automation, the primary goal is to enhance this efficiency. Whether it’s through robotics, conveyor-based automation, or the use of AMRS and AGVs, the overarching aim is to boost efficiency from, say, 90% to 95%, 96%, 97%, or even 98%, whatever is realistically attainable. When we engage with pharmaceutical clients looking to implement automation, their primary objective is to improve efficiency, and this is how they justify their return on investment. Ultimately, the core focus is on enhancing productivity and overall efficiency.

The main idea here is to figure out how to maximise the output from a manufacturing facility, which can be visualised as a box. The goal is to increase the number of products produced within a given time frame, whether it’s per day, per hour, and so on. This is what we consider efficiency. The challenge is to achieve this without increasing the workforce or the time involved.

We approach this by tackling it in two ways. First, we aim to remove any limitations within the system. For example, suppose the manufacturing process is manual and involves passing a formula from point A to B to C. In that case, we work on expediting this process, such as reducing the time between these steps. We also look for and address any bottlenecks in the system to enhance efficiency.

Pharma logistics
The logistics aspect of pharma is quite a complex challenge, similar to the Fast-Moving Consumer Goods (FMCG) industry’s approach to efficient milk run deliveries. Mr. Ravikiran Pothukuchi, Director – Sales | Data Science, Manufacturing & Logistics, INDIA, Dassault Systemes, notes that the goal is to optimise the most efficient delivery routes to retailers and warehouses. The process involves optimisation along with planning. The first step consists in creating a comprehensive network diagram that lays out the locations of your warehouses, retailers, and daily delivery volumes.

Once you have this network in place, you employ an optimisation tool to figure out the best methods for distributing the goods. Logistics is not just about profitability; it also has significant implications for sustainability. Running trucks and delivery vehicles incurs not only costs for the organisation but also environmental costs due to fuel consumption. This adds another layer of complexity, as organisations need to balance economic and sustainability considerations.

Challenges faced by pharma 
The challenges facing the pharmaceutical industry share similarities with other sectors, but what sets it apart is the unique processes and stringent regulations it must adhere to. This distinctiveness makes it a prime candidate for various forms of automation. According to Mr. Davessar, the first and foremost challenge is impeccable hygiene and traceability. These are products meant to improve health, often complex chemical or biological formulations. The key is to manufacture them correctly and maintain the highest hygiene standards throughout the process.

Additionally, ensuring traceability is crucial to guarantee that the correct materials are used in the right quantities and under the right conditions. To tackle these challenges, IoT (Internet of Things) technology and various sensors play a significant role. They help monitor essential factors like temperature and humidity, as well as other environmental conditions. Moreover, serialisation is a critical aspect of traceability. Companies dealing with numerous raw materials and APIs must ensure that every item is correctly recorded and labelled. Many businesses have transitioned from paper-based systems to more advanced methods, such as barcodes and RFID tags, which provide precise tracking and immediate action in case of any discrepancies in material quantities.

Compliance with pharmaceutical industry regulations, including CFR and GMP standards, is crucial. Companies aiming to serve this sector must have robust processes in place to meet these stringent requirements effectively.

India’s pharmaceutical industry is a global powerhouse, but it faces the critical challenge of upholding high-quality standards while meeting colossal production demands. The key lies in establishing processes that ensure right-first-time production, relying on a combination of manual and advanced inspections, including vision-based systems. Equally essential is implementing a robust preventive maintenance system to sustain the industry’s success. As the industry continues to evolve, maintaining quality and reliability will be paramount to meet both domestic and international healthcare needs.

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Mr. Nitin Davessar, Chief Manager, Sales, Addverb.
“In the pharmaceutical industry, data analytics is crucial for tasks like serialisation, diversion, and decision-making on the factory floor, heavily relying on data. As we advance, software becomes even more crucial than hardware in these processes.”

Ravikiran Pothukuchi, Director – Sales | Data Science, Manufacturing & Logistics, INDIA, Dassault Systemes.
“Efficient logistics in the context of optimising delivery routes for retailers and warehouses is a multifaceted challenge that requires comprehensive network diagramming and optimisation tools to balance economic and sustainability considerations.”

Mr. Guru Prasad, Assistant Vice President, CSSR and Electronics, Robotics and Discrete, ABB India.
“Automation, with its unique blend of robot density, cutting-edge sensors, and AMRS AGVS technology, is a driving force for boosting productivity, quality, hygiene, and traceability.”

Shyam Padwal, Branch Head – Mumbai and Pharmaceutical Expert.
“Automation and robotics in manufacturing offer unprecedented levels of machine flexibility and precision, enabling manufacturers to embrace mass customization and optimize lot size one processes with ease.”

Murata’s LLC series sets new standards in automotive capacitors, offering the world’s smallest 1µF capacitance with low ESL and ESR. These advanced components enhance circuit performance for ADAS applications.

Murata has extended their lead in the manufacture of multi-layer ceramic capacitors for automotive applications with the release of their LLC series. The components feature a reversed termination for low ESL and are in a world’s-first 0.18mm profile package. Footprint is just 0.5 x 1.0mm for 1µF capacitance making the parts the smallest in the market.

The LLC series uses Murata’s proprietary thin-layer forming and high-precision lamination technology, along with advanced material atomization and homogenization techniques to achieve about 20% reduction in component height compared with existing parts. This opens up the potential to more-easily fit the capacitors on the back-side of circuit boards, even amongst solder ball terminations, locating the parts in optimum positions for decoupling of processor power rails, close to the die. This in turn allows fewer capacitors to be used, saving cost, and increasing system reliability.

Along with their low ESR, the reduction in ESL achieved reduces the high-frequency impedance of the capacitors. This improves circuit performance to meet the requirements of modern, low-voltage, compute-intensive applications such as automotive advanced driver-assistance systems (ADAS).

The automotive-grade LLC series complies with AEC-Q200 requirements, passing the 1000 temperature cycle test and temperature/humidity endurance test of 85°C at 80-85% humidity for 1000 hours.

Schuler Group, a metal forming solutions provider, has introduced a cutting-edge drawing edge monitoring system that enhances part quality and reduces scrap, contributing to sustainability goals in metalworking processes.

Deep drawing, in particular at high drawing levels and for small radii, is an especially demanding metal forming process. Insufficient material flow during the deep drawing process can lead to thinning and cracks in the part, and if too much material flows, folding can be an undesired consequence. The material remaining after the forming process – the so-called flange or drawing edge – thus directly affects the part quality. Schuler therefore developed a drawing edge monitoring capability that helps to immediately assess the part quality.

“The number one priority for our customers is reducing scrap – not just to save costs, but increasingly also to meet sustainability goals”, explains Michael Werbs, Director of Edge Solutions. “Schuler is making an important contribution to this with its new development”. An application of this type is already in use in the Smart Press Shop, the joint venture of Porsche and Schuler in Halle (Saale).

Using a forming simulation, the drawing edge at critical locations can be determined in advance and compared with the values obtained in practice. The associated data together with a unique identification number for the part are stored in a database. Based on the insights thereby obtained, modifications to the process or changes to the oiling or drawing cushion forces can be made even before the part shows visible quality defects such as cracks or folds.

Previously it was necessary to use special dies with expensive material flow measurement systems integrated into them, and the additional connections required for this. The drawing edge monitoring capability developed by Schuler is based on cameras mounted in the press space, which is why the system is die-independent and can monitor the drawing process in any die used on the press. In a fraction of a second, the system provides information on whether or not a good part was produced.

For more details – www.schulergroup.com

ENGIMACH, a premier trade show for engineering machinery, manufacturing, and automation, is set to showcase cutting-edge technology and innovation in Gandhinagar, Gujarat, from December 6-10, 2023.

The 16^th edition of ENGIMACH, the marquee biennial trade show for technology and innovation in engineering machinery, manufacturing and automation is slated to be held from 6-10 December at the Helipad Exhibition Centre, Gandhinagar, Gujarat.

In step with the unstoppable march of the Indian economy towards its avowed target of USD 5 Trillion by 2026-27, the 16^th ENGIMACH will provide a much needed platform for the tripartite meeting of the suppliers of the best-in-class manufacturing tools and technologies, the top buyers and influencers of the end user manufacturing industries, as well as the policy makers in the industry and government.

ENGIMACH 2023 officially recognized as a PRE-VIBRANT GUJARAT EVENT will help to identify, showcase and promote the latest developments and innovations in modern manufacturing technologies and automation essential to the success of ‘Make in India’ for India and the world!

The earlier edition in 2021, also designated a Pre-Vibrant Gujarat Event, was inaugurated by Shri Bhupendrabhai Patel, the Hon’able Chief Minister of Gujarat, featured 427 Exhibitors from 15 Exhibiting Countries, attracted 72,503 Visitors and generated business inquiries worth approximately INR 1,545 Crores. This despite being held in challenging post-Covid times when the discovery of the Omicron variant had begun to cause concern!

The 16^th ENGIMACH to be held in better climate of Health and Economy promises to set new records! Particularly because this edition features several highly attractive concurrent shows such as Casting & Foundries Expo, Vibrant Gujarat Startup Conclave & Exhibition and India Smarttech Manufacturing Conference & Exhibition.

The CASTINGS & FOUNDRIES EXPO which will create synergy between manufacturers of engineering products and castings as both buyers and seller of castings will be at the same venue as exhibitors for 5 days! Secondly the VIBRANT GUJARAT STARTUP CONCLAVE & EXHIBITION will bring the enthusiasm and energy of young entrepreneurs and their innovations! Again, the INDIA SMARTTECH MANUFACTURING CONFERENCE & EXHIBITION will feature numerous distinguished international thought and industry leaders as speakers and they will enlighten the participants about the latest in use of Information Technology in modern manufacturing.

The 16^th ENGIMACH will be spread over a whopping 72,000 square meters of gross exhibition area and 12 centrally air-conditioned halls. It will feature 1200+ confirmed participants including 200 innovators and a display of 100,000+ innovative products. Further 100 Global Speakers are slated to feature in 50 Tech Seminars! 50 International buyers are likely to participate in the supporting programs like the Buyer Seller meets.

Conservatively 100,000+ visitors are expected at the 16^th ENGIMACH making it a mega technology showcase! It will bring together the best and brightest minds from the manufacturing and engineering sectors and be an exemplary showcase of ideas, innovation, and cutting-edge technology, fostering a vibrant ecosystem where industry leaders, stakeholders, and enthusiasts converge, collaborate, and celebrate the world of manufacturing.

Altogether, the 16^th ENGIMACH is truly an unmissable opportunity for those looking to the future of Indian manufacturing. In fact, the 16th Engimach is more than just an exhibition; it’s an opportunity to witness and participate in India’s exciting journey towards becoming an economic powerhouse and a global manufacturing hub.

Online Registration: engimach.com