Innovation at Schaeffler revolutionizes detent bearing design – combining the bearing support and locking function

Double clutch transmissions attract a high level of attention worldwide and increasingly lead the automotive industry to new and efficient design envelope solutions. Often there is simply insufficient space to apply the locking contours to the gearshift forks and install the detent pins in the transmission housing. This is why Schaeffler offers an integral solution for the bearing support of gearshift elements without affecting the design envelope.

“Schaeffler's new detent bearing offers an alternative solution for locking gearshift forks in situations where the available design space and using conventional detent pins and locking contours is difficult. The detent bearing complements the Schaeffler product portfolio and allows customers to be more flexible when defining transmission specifications,” explains Stanislav Massini, Director of Advance Development and Mechatronics at the Shift Systems Product Line at Schaeffler. The new combination comprising a locking function and a bearing for rotary and linear motion (RLF) provides an interesting alternative for designers, as detent bearings can be integrated into both the outer and center walls of transmissions. Balls used as rolling elements are guided in the stationary cage and ensure a low level of friction in the bearing support. The thin-walled, deep-drawn cup serves as a raceway for the rolling elements at the same time. The integrated spring functions as the detent pin and locks the shifting movement into place by means of the contours on both sides of the shift rod. The spring is preloaded in order to generate a specific retention force that can be adapted to suit requirements.

Even after 4 million load cycles, which equate to more than double the operating life of a gearshift fork, no wear of any kind is visible on the component. The detent bearing continues to function without any problems. The hysteresis characteristics of he new detent bearing correspond approximately to those of a conventional solution– e.g. a rolling bearing support, plain bearing ball detent pin, and locking contour – thus making it a significantly better solution than designs that use plain bearings. The level of integration can be further increased by implementing a sensor in the detent bearing if the gear position of the gearshift fork has also to be detected and the shift travel measured. Measurement takes place in the bearing itself, resulting in
high linearity and measurement accuracy. The integrated connector can be connected both inside and outside of the transmission. This sensor bearing is particularly suited to use in automated manual transmissions such as DCTs and ASGs. The sensor bearing is currently being tested and shows excellent results.

Schaeffler’s new detent bearing offers an integral solution for the

bearing support of gearshift elements without affecting the design envelope.

Opportunities in Indian Railways Infrastructure

Proposed FDI policy could boost the pace of project implementation

Author: Nideshna Naidu

Indian Railways – Overused and underinvested
Indian Railways is the world's second largest rail network and fourth largest freight carrier controlled by a single management. The country's railway network route stretches over more than 64,600 kilometers (km), of which 23,541 km is electrified. The sector plays a critical role in transportation within the country — it operates 19,000 trains every day, moving 2.6 million metric tons (MT) of freight and 23 million passengers.

Though Indian Railways is one of the mightiest networks in the world, it is currently facing capacity constraints and funding limitations. For reasons such as partly improved road infrastructure and lower freight transport costs, road transport is preferred over rail network for freight movement in India and for its last mile connectivity. This is evident from the fact that the share of rail freight movement has dropped from 89 percent in 1950-1951 to 31 percent in 2010-2011. High rail freight cost (approximately 9.1 percent more than road transport) is another factor for this loss. The situation is the same for passenger movement, too.

Exhibit 1: Rail versus Road Freight Movement, India, 1950–2011

Considering the growth of India's commerce and economy and corresponding transport infrastructure needs, the railway sector has always been inadequately funded. Since Independence in 1947, India has added only 11,864 km of new lines according to the Planning Commission of India, with much of the expansion happening in the northern, western, and peninsular parts of the country. Much of the northeastern states in India and regions in the Himalayan foothills lack rail connectivity. Capacity enhancements in the railway sector have always lagged the demand generated by passengers and freight traffic. The railway sector needs investments for adding new lines and associated infrastructure, exhaustive modernization, speed enhancement, electrification, and technological changes to improve services and attract more passenger and freight traffic movement.

Although 72.3 percent of the total rail capacity is utilized for passenger movement, this segment accounts to only 31.2 percent of the total railway revenues. The passenger segment is highly subsidized in India. On the other hand, freight utilizes only 27.7 percent of the capacity but generates 68.8 percent of the total revenues. Most of the revenues earned through freight movement are used to cross-subsidize the passenger segment. This results in low funds to be reinvested in to the system for infrastructure development. In addition, lack of dedicated corridors for freight movement has resulted in low speed of freight transportation, which adds to the loss of revenues, as customers prefer road transport.

Foreign Direct Investments (FDI) – A Catalyst for Growth
Given the current financial scene of the Indian Railways, proposed Foreign Direct Investments (FDI) could bring the much-needed funds for improving the railway infrastructure in India. Although FDI is already allowed in railway component manufacturing, infrastructure development was solely with the Indian Railways. However, with the supply being inversely proportional to the demand, the proposed FDI could boost investments and result in fast implementation of infrastructure projects.

FDI in Indian Railways would facilitate the following:

• Faster implementation of rail infrastructure projects
• Easy movement of goods from mines to ports
• Reliable transport facility for industrial and export growth

Business Opportunities — Aplenty in Rail Infrastructure
The proposed FDI in rail infrastructure would create a huge wave of opportunities for the private sector. So far, Engineering Procurement and Construction (EPC) contractors were executing rail infrastructure projects through turnkey contract awarded by Indian Railways. The major issues in developing railway infrastructure include project delays and cost overrun. Hence, Public-private Partnerships (PPP) is encouraged to bring in investments and, currently, the PPP model funds only 20 percent of the railway projects. PPP based projects are executed by EPC contractors as well. Thus, EPC contractors stand to reap maximum benefits from the proposed FDI, as this would result in fund generation and faster rate of project implementation.
Private sector participation is encouraged in the areas of port connectivity and other infrastructure work, modernization of railway stations, commercial utilization of land, and construction of dedicated freight corridors, multi-modal logistics parks and private sidings, inland container depots, rail side warehouses, and high-speed passenger rail corridors.
While the proposed FDI policy would help in overcoming project delays and cost overruns, enormous opportunities would arise in areas of automation, signal systems, traffic designs and systems, and newer technologies for better and improved efficiency. Key railway segments that could benefit from the proposed FDI include:

• Sub-urban corridors
• High-speed train systems
• Dedicated freight corridors
• Elevated rail corridors
• Rail-port connectivity
• Station development

When the Government of India (GoI) clears the new FDI policy, it would create opportunities for EPC contractors, component manufacturers, technology companies, etc. Though a few phases of the dedicated freight corridors project have already been awarded on turnkey contract model, the project suffers from time delays. The high-speed train systems are also facing similar delays. With the help of FDI, each of these projects would get the required investment, which would translate to business opportunities for EPC contractors.

Application Segments With High Potential for Electronics Manufacturing and Exports

Author: Sagarina Rai

Indian Electronics Manufacturing Market - An Overview
To the Indian Electronics Manufacturing Services (EMS) market, a nation known for its high electronics consumption presents a huge opportunity. EMS is expected to emerge as a vital contributor to the nation's economy.  Expecting the electronics consumption to reach $400 billion by 2020, the government has trained its focus on electronics manufacturing and laid down various initiatives to drive the domestic electronics manufacturing ecosystem to new heights. With a market size of $3.79 billion in 2012, the Indian EMS market is expected to reach a size of $5.39 billion in 2015. The major contribution to the market comes from segments, such as telecom, industrial and consumer goods; the other segments that add to the revenue are healthcare, information technology and office automation (IT/OA), aerospace and defense and automotive.

Indian Automotive Electronics Market Analysis
The Indian automotive industry has made a name for itself as the hub of small car manufacturing destination in the world. India stands second in two-wheeler (2W) manufacturing and fourth in commercial vehicle manufacturing in the world. With a total of 18.3 million vehicles produced in 2011 and 2.0 million exports, India is the sixth largest automobile manufacturing economy in the world, housing 15 manufacturers of passenger vehicles (PV), 9 manufacturers of commercial vehicles (CV) and 16 manufacturers producing 2W.

The Indian 2W industry has shown a strong growth over the last year having grown by 13% in 2011 and is expected to grow at a volume CAGR of 12% by 2015. The passenger vehicle industry is expected to grow at a volume CAGR of 10.8% by 2015 and become the world's fourth largest passenger vehicle market.

Automotive Electronics - Opportunity Analysis
The value of electronics used in an automobile depends on:

• The type of the vehicle: two wheelers (2W), three wheelers (3W), passenger cars, commercial vehicles, electric vehicles, etc.
• The segment the vehicle caters to: entry-level, midsize, premier or luxury vehicle
• Level of automation in the vehicle: manual, power-steering, etc.

Indian-made entry-level cars and 2W have limited electronic content, such as engine monitoring, dashboard display, and few other basic switching controls, which is amply compensated by the high volume 2W and car sales. Premier or luxury vehicles are largely imported as are the high quality electronics used in them.
On an average, the value of electronics that goes into a midsize car manufactured in the country stands at $2,313.19, which is 13.04% of the total value of the car. This value is expected to become higher due to the implementation of stricter emission norms and safety features, such as ECU for 2W and air bags in all passenger cars. Exhibit 1.1 presents the key market drivers and restraints for the automotive electronics market.

Exhibit1.1
Automotive Electronics Market: Market Drivers and Restraints, India, 2014-2018
The total market refers to the demand and supply of automotive electronics in India; this includes both imports and exports. Domestic manufacturing refers to indigenously manufactured electronics, including exports.
The revenues from the total AEM market and domestic AE manufacturing segment were estimated to be $2.87B and $1.54B, respectively, in 2011. The total AEM market and domestic AE manufacturing segment are expected to grow to $4.23B and $2.65B, respectively, by 2015. Indigenous capability augmentation in product segments such as 2W ignition, instrument clusters, 4W engine management systems (EMS), car radios, power windows, flashers, regulators, etc., help sustain the growth in domestic manufacturing revenue.
Exhibit 1.2 depicts the revenue forecast from 2010 to 2015 for the total AEM market and the domestic AEM segment.

Exhibit1.2
Automotive Electronics Market: Revenue Forecast of Total Market and Domestic AE Manufacturing Segment, India, 2010-2015

Ecosystem
India's automotive market has a well-developed ecosystem. From design, development, IP creation, manufacturing, components sourcing, etc., India has developed strengths in all aspects of the automotive industry. High manufacturing and assembly activity in the Indian automotive market continues to set new benchmarks. The following automotive products have been considered top priority, based on the following scope:

• High revenue generation
• High domestic manufacturing
• High value addition - raw material sourcing, R&D capability, IP creation in India

Future Outlook for Automotive Electronics Market in India

• Owing to the huge untapped rural market, the demand for automotive electronic is like to rise, presenting a large domestic market.
• India is an emerging small car manufacturing hub with great R&D capabilities.
• Introduction of new technologies, inclusion of more electronics switches, lighting, shift from CDI to ECU in 2W, analog to digital controls and growth of EMS and ABS are the new additions which will spur the consumption of automotive electronics.
• Increasing uncertainty in fuel pricing is expected to boost the demand for electric vehicles during the forecast period, thereby leading to greater consumption of automotive electronics.
• The Indian Government's initiative in mandating Bharat Stage IV norms and fuel efficiency labelling for all vehicle categories has encouraged manufacturers to discontinue or modify their older engines to suit new norms, thereby, creating fresh avenues for automotive ignition electronics market.
• With 100% Foreign Direct Investment permissible in the automotive sector, there is increasing investment in both 2W and 4W segments, be it the setting up of new plants or R&D centers, etc.; this increases the demand for auto electronic components. 

Renishaw inspires new generation of scientists and engineers

Renishaw, the internationally recognised engineering company, has renewed its sponsorship of The Big Bang Fair as part of its ongoing commitment to develop the UK's next generation of engineers and scientists.

The Big Bang (UK Young Scientists & Engineers) Fair, which this year takes place at the NEC, Birmingham from 13 – 16 March, is the largest celebration of science, technology, engineering and maths (STEM) for young people in the UK (primarily aged 7 to 19), and aims to highlight the many exciting and rewarding opportunities available with the right experience and qualifications. At the fair, visitors will experience a wide range of entertaining theatre shows and interactive exhibits, as well as having the opportunity to meet some of the country's leading scientists and engineers.

In sponsoring the Big Bang Fair, Renishaw is continuing its commitment to raising awareness surrounding Engineering as a career. The Company's Education Liaison Executive, Julie Collins, explains, “It is increasingly important that we encourage young people to study subjects that will give them the qualifications that they will require for an interesting and rewarding career in engineering and science. Events like the Big Bang Fair really help to spark the interest of young people and inspire them to keep studying STEM subjects.”

This year the Renishaw stand will feature a Renishaw Equator gauging system, enabling young people and their teachers to interact with measurement machinery rarely seen outside of an industrial facility. Visitors will be encouraged to directly control the machine with the aim of navigating a 3 dimensional maze in the shortest amount of time; a prize will be given for the fastest time each day.

In 2013, the Big Bang Fair hosted 65,000 visitors of all ages, who both enjoyed and learned from their experiences. The organisers reported that over 76% of 12 – 14 year olds viewed engineering more positively as a result of their visit. Renishaw is working with education establishments and national skills providers to both promote the importance of STEM subjects and careers in science and engineering to help combat the nationwide shortage of skilled individuals.

The Big Bang Fair is delivered by over 170 organisations from the public, private and voluntary sectors, including EngineeringUK, the British Science Associate and the Institute of Physics. Booking is now available online at www.thebigbangfair.co.uk.

HANNOVER MESSE 2014: The road to the factory of the future

HANNOVER MESSE 2014: "Hannover is one of the main stops along the road to the factory of the future"

The ripples of change are spreading far and wide as the pace of innovation and development in the industrial sector moves into overdrive. “2014 will see a great shift towards automation in industrial manufacturing and the ongoing transformation of the world’s energy systems,” said Dr. Jochen Köckler, a member of the Managing Board of Deutsche Messe.

“To remain competitive, companies need to make their manufacturing processes more efficient, and that means greater investment in state-of-the-art automation technology. Their competitiveness also hinges on access to a reliable, sustainable energy supply. The world’s leading providers of automation solutions and energy technology will be showcasing solutions to precisely these challenges at HANNOVER MESSE 2014.”

With Industrial Automation & IT, Energy & Environmental technology, Industrial Supply and R&D among its keynote themes, “Integrated Industry – NEXT STEPS” as its overarching motto and the Netherlands at center stage as its Partner Country, this year’s HANNOVER MESSE will be true to form as the world’s leading trade fair for industrial technology and the No. 1 go-to event for international decision makers from the manufacturing and energy industries. Dr. Köckler: “A visit to HANNOVER MESSE is an absolute must for anyone in industry who wants to remain competitive. Hannover is one of the main stops along the road to the factory of the future.”

“HANNOVER MESSE’s leading position is reflected in the high number of exhibitor registrations confirmed to date. At this stage it seems that we will top the outstanding result achieved in 2012, which, with its even-year exhibition lineup, is the most recent directly comparable HANNOVER MESSE year,” Dr. Köckler added. HANNOVER MESSE 2012 featured 4,872 exhibitors from 69 nations.

Step by step to the integrated, Industry 4.0 factory
With “Integrated Industry – NEXT STEPS” as its lead theme and official motto for 2014, HANNOVER MESSE will maintain its focus on integration as a challenge of pivotal importance for the future of industry and will map out the next steps along the road to tomorrow’s intelligent, self-organizing factories.

To stay competitive, manufacturers need to make their factories as efficient as possible. They need to be able to respond swiftly to changes in the market, while at the same time satisfying the growing demand for product individualization and customization. In short: they need flexible, intelligent factories – factories of the future, in which machines, plant and products can talk to each other. This interaction relieves the skilled workers in physical labor and puts him in a position to focus on controlling and optimizing the production process. Many technologies for achieving this have been developed over recent years. The next steps are about integrating these technologies into industrial production in such a way that they form a harmonized and fully networked whole. Precisely this is the focus of HANNOVER MESSE 2014. The upcoming fair looks at the steps which industry needs to take in order to get from its smart-factory vision to a real-life, integrated Industry 4.0 factory.

There are a number of challenges along the road to achieving this reality that necessitate intensive information sharing, investments and coordination. For example, if all robots, work-pieces and machines in the production process end up being able to share information with each other, then, somehow, there will also need to be IT systems that are capable of analyzing and making sense of these massive data flows. And if networking and integration extend beyond the factory by, for instance, encompassing subcontractors and suppliers, then what about data security? Another of the big challenges is standardization - ensuring software compatibility across all the components, machines and factories that are to be networked with each other. All of these challenges will be addressed at HANNOVER MESSE 2014. Dr Köckler: “Under the banner of ‘Integrated Industry – NEXT Steps,’ HANNOVER MESSE 2014 will present the latest solutions to the challenges of Industry 4.0.”

From inflexible energy monolith to nimble, intelligent energy network
“Integrated Industry – NEXT STEPS” also signals the way forward in the ongoing transformation of the world’s energy systems. In this process, the main next steps are to upgrade and expand energy transmission and data networks and to find viable ways of replacing the current energy system, which is based on mere dozens of central power stations, with a decentralized system comprising hundreds of thousands of small natural-gas, solar, wind and biomass-powered generation units. Dr. Köckler: “In the future, the smart grids that carry energy and the end devices that consume it will communicate with each other, unlocking enormous potential for energy savings. Making this vision a reality requires collaboration and coordination across an incredibly diverse range of industries. For all companies and organizations with a stake in this process, HANNOVER MESSE is the perfect technological and political platform for marshaling future-defining technologies and concrete solutions in the interests of facilitating the transformation from an outmoded, inflexible energy monolith to a nimble, intelligent energy network.”

Hi-tech nation Holland as Partner Country at HANNOVER MESSE
“Global Challenges, Smart Solutions.” That’s the motto for the Netherlands’ Partner Country showcase at HANNOVER MESSE 2014 this April.

Köckler: “The Netherlands’ mechanical engineering sector is enjoying steady growth and is made up predominantly of highly specialized small and medium enterprises. The country also has an extremely competitive industrial subcontracting sector which supplies components, modules and made-to-order solutions to customers all around the world. The Netherlands are also a shining example of European cross-border industry partnership. Exhibitors and visitors from around the world seeking cooperative ventures with Dutch companies in these sectors will be extremely well positioned to do so at HANNOVER MESSE.”

The Netherlands will have a central Partner County pavilion in Hall 3 and national pavilions in all of HANNOVER MESSE’s main theme areas. "The current registration status from the Netherlands already exceeds the 2012 event. The number of exhibitors has grown strongly and the exhibition space has more than doubled”, Köckler adds. For comparison: HANNOVER MESSE in 2012 saw 80 Dutch companies on an area of 2 200 square meters.

HANNOVER MESSE – Get new technology first!

The world’s leading trade fair for industrial technology is staged annually in Hannover, Germany. The next HANNOVER MESSE will run from 7 to 11 April 2014 and feature the Netherlands as its official Partner Country. The upcoming event will place a strong emphasis on Industrial Automation and IT, Energy and Environmental Technologies, Industrial Subcontracting, Production Engineering and Services and Research & Development.

EMAG promotes development of production at METAV 2014

Shorter cycle times, flexible batch size machining and greater component quality are all demands that increase the pressure on the metalworking industry to innovate. Key sectors, such as the automotive industry, are changing rapidly. That tailor-made production solutions play an important role in this, is demonstrated by the machine builders at EMAG on Stand A17 in Hall 17 of this year’s METAV in Düsseldorf. Their technology provides an example of how to boost productivity. 

How close innovation and the success of a company are connected is clearly illustrated by a study PricewaterhouseCooper (pwc) undertook last year. It established that the growth rate of the most innovative companies increased at a speed 16 percent faster than that of the rest. Against this background, this year’s METAV represents an important platform for the specialists from EMAG. As Jürgen Müller, Managing Director of EMAG Salach GmbH explains: “We want to emphasise the important role innovative production technologies play in the key sectors – for instance in the automotive industry and in power engineering. The manufacture of chucked components, shafts and similar workpieces allows for gigantic leaps in component quality and productivity.“
  
The starting point for this is the pick-up automation, as perfected – over the last few years – by EMAG. All the turning machines and grinders shown at the exhibition feature this integrated automation concept, where the main spindle conveys the workpieces into the tooling zone of the machine quicker, with greater precision and with a higher degree of process integrity than any other solution:

  

• The VL 2 Vertical Pick-Up Turning Machine for soft and hard turning, available at an advantageous price-performance ratio. It guarantees a massive reduction in the production costs for small chucked components.
• The VL 3 Vertical Pick-Up Turning Centre is characterised by its high degree of precision and minimal resetting times in the machining of chucked components (using a chuck with 160 mm diameter). 
• The VT 4-4 Vertical Turning Machine impresses with its 4-axis high-performance processing capability. Shafts of up to 1050 mm length and 200 mm diameter are here machined from two sides and at high speed.
•  The eldec MIND-M is a compact, highly precise and very reliable component hardening system and an ideal solution for the simpler heat treatment job.

   
“This selection offers an ideal overview of the extensive EMAG knowhow“, explains Jürgen Müller. “All these systems can be used for the implementation of demanding machining work – and at a massive cost saving. We also offer this type of quality for a large variety of applications. And we are very much looking forward to welcoming our visitors at the METAV.”

Konecranes lifting equipment for all power needs

Cranes and other lifting equipment are an important aspect at power generation plants, especially during the erection phase and in the maintenance process. To attend the unique demands of the power industry, cranes and lifting equipment must be able to operate in demanding environments with precision, safety, and absolute reliability. Konecranes provides lifting solutions for all types of power plants — from a traditional coal power plant to a massive hydro power plant or a remote wind farm.

Konecranes designs and manufactures a broad range of suitable equipment to cover the specific needs of the various types of power generation facilities. Konecranes lifting solutions provide reliable service, promote reaching higher uptime and lower life time costs, as well as increase safety.

Wide product range tailored to customers’ needs

Furthermore, Konecranes customizes the cranes to deliver the utility and features required for the productive operation of a power generation facility. The range comprises, among others:

•    Turbine hall cranes that facilitate the installation and accurate adjustment of turbines, generators and auxiliaries
•    Coal handling cranes with clamshell buckets
•    Compact, lightweight chain hoists that provide fast hoisting speeds inside wind turbine nacelles
•    Intake gantry cranes for lifting the gates of hydroelectric dams
•    SMARTON® maintenance cranes
•    CXT® cranes for workshops, as well as jib cranes and monorails for smaller lifting tasks

Apart from the wide range of lifting equipment, Konecranes also offers patented Smart Solutions. These technologies include Sway Control, Micro Speed, and Inching that simplify crane operation, elevating safety and productivity.

Konecranes also greatly lowers the risk of equipment breakdowns through preventive maintenance programs that are customized to operational requirements. Konecranes’ patented TRUCONNECT® Remote Monitoring and Reporting service, for example, continually keeps track of the usage and condition of the lifting equipment.
Konecranes created high-value applications to cover the needs of the different kinds of power facilities.

Hydro Power Cranes — Highest life-cycle value

Konecranes provides cranes for hydro power plants, such as turbine hall cranes, intake, and draft tube gantry cranes. The product range varies with hydro power stations cranes for up to 1000 tons and with maintenance and workshop cranes for 1 to 80 tons.

Thermal Power Cranes — Application design based on requirements

Konecranes provides cranes for all kinds of thermal power plants, such as turbine hall cranes and boiler room cranes and hoists. The product range varies with thermal power stations cranes for up to 1000 tons and with maintenance and workshop cranes for 1 to 80 tons.

Wind turbine electric chain hoist — Optimizing the space

Konecranes supplies a light-weight and compact electric hoist for wind turbine applications. The tXN Electric Chain Hoist is mounted within the nacelle of the turbine. Using the hoist for service applications allows maintenance staff to safely raise and lower turbine appliances for repair or replacement.
In addition, Konecranes offers maintenance services as well as spare parts, and also modernizations of all makes. Worldwide service by Konecranes minimizes ownership costs and helps achieve the highest life-cycle value through decades of experience in power generation.

Konecranes provides lifting solutions for all types of power plants. © Konecranes

Konecranes provides lifting solutions for all types of power plants. © Konecranes

Konecranes provides lifting solutions for all types of power plants.© Konecranes