Enhanced reliability, new opportunities

Transcription

1 Enhanced reliability, new opportunities Cabling for automation White Paper PRESS CONTACTS Céline Révillon Tel. : Pascale Strubel pascale.strubel@nexans.com Tel. : For more information :

2 CONTENTS I. INTRODUCTION: FROM THE FACTORY FLOOR TO THE SERVICE INDUSTRY 1. The place of automation in the world economy 2. Types and trends in machine tools and robotics 3. New challenges and opportunities 3.1 Mobility 3.2 Intelligence 3.3 Internet networking 3.4 Compactness 3.5 Standardization 3.6 Safety 4. Customer expectations of cable suppliers II. NEXANS: GLOBAL EXPERT IN MACHINE TOOLS AND AUTOMATION 1. Cable solutions for manufacturing 2. Cable solutions beyond manufacturing 3. Local service, innovation and reliability III. APPENDIX: Some recent Nexans success stories, innovations and references Tables from VDMA (machine tools) and UNECE Report: 2004 Robotics Survey Synopsis This report is intended to give a general overview of the machine tool and automation market which includes primarily industrial, and to a lesser degree, service and personal robotics and to provide information about how Nexans is serving this diverse and growing sector. The paper opens with a definition of the role automation plays in the world economy, and outlines recent trends in machine tool technology and robotics. New challenges and opportunities are presented in six key areas, each of which has important repercussions on cables and cabling. The expectations of customers are outlined. The second section presents Nexans overall solutions in the five key areas that apply to industrial automation, and then briefly reviews other nonmanufacturing capabilities applicable to new automation markets. Finally, it explains how customers benefit from the Nexans product and service approach. This report is followed by an Appendix containing a list of recent Nexans success stories, innovations and references. White Paper Automation 2/2

3 I. INTRODUCTION: FROM THE FACTORY FLOOR TO THE SERVICE INDUSTRY Never before have so many orders for industrial robots been placed by the European, North American and Asian industries, pointing towards an acceleration in the drive to automate. Jan Karlsson, United Nations Economic Commission for Europe (UNECE) 1. The place of automation in the world economy In 2004, investment in automation surged to record levels, especially in the area of industrial robots which grew 20% worldwide over the previous year. In Asia, which is traditionally dominated by Japan and Korea (and increasingly China), investment rose by 43%. This was followed by a 23% increase for North America and a 5% increase for Europe. The modest growth in the EU is not a sign of lagging behind, but rather a sign of significant advance, since it saw double-digit growth since However even within the Union, individual countries have seen dramatic increases; for example, there was a rise of 48% in the United Kingdom. 1 At present there are probably one million industrial robots in operation worldwide, with approximately 100,000 new units being installed each year. Once the world leader, Japan s position in automation has been eroding, with new activity moving to North America and Europe. Germany is the European leader in automation, with 112,700 units (on a par with the US), while Italy follows with 50,000 units, France with 26,000, Spain with 20,000, and the UK with 14,000. At present, there are probably one million industrial robots in operation worldwide, with approximately 100,000 new units being installed each year. In terms of robots per employee in manufacturing, Japan seems to be well ahead with 320 robots per 10,000 employees, compared with 148 in Germany, 116 in Italy, approximately 63 in the US, and 40 in the UK. However, since Japanese figures include all types of robots, (while the other countries are limited to multipurpose industrial robots), these figures are somewhat misleading. It is interesting to note that according to the UNECE report, the motor vehicle industry is still the world leader in terms of densities, with 1 robot for every 10 workers. Historically, it is the automotive industry that led the drive to robotize. In fact, a couple of decades ago, it was estimated that 90% of robots were used in car manufacturing, typically on assembly lines doing a variety of repetitive tasks. In 2000, there re was a significant turnaround, with nonautomotive industries increasing orders by 40% while orders from automotive assemblers and component manufacturers increased by only 3% and 19% respectively. 2 Today, only 50% are in automobile plants, with the other half spread out among other factories, laboratories, warehouses, energy plants, hospitals and many other industries. 1 All figures are based on the United Nations Economic Commission for Europe s 414-page report, entitled The 2004 World Robotics Survey. 2 See Industry Canada Report on Information and Commercial Technologies, available at White Paper Automation 3/3

4 In financial terms, diverse sources concur that robotics is a multi-billion dollar industry, with heavy R&D investment According to Honda s ASIMO website, robotics is currently an $8 billion industry globally The Japan Robot Association estimates that the robot industry could grow to $23 billion by The Robotics Institute at Carnegie Mellon University (Pittsburg, USA) has seen a significant 48 percent increase in Federal funding since 2000 and a 117 percent jump since It is only one among hundreds of research institutes worldwide. Testing machine for Automation cables within the Nexans test center in Nuremberg White Paper Automation 4/4

5 2. Types and trends in machine tools and robotics In this paper, we will consider two sectors of the automation market: the machine tool industry, and industrial automation, or robotics. Machine tools are powered mechanical devices, typically used to fabricate metal and plastic components of machines by the selective removal of material. They include industrial drills, gear shapers, hobbing machines, lathes, milling machines, shapers and grinders. 3 Generally confined to two-dimensional movements, some machine tools can also operate in three axes. A truly global market, the machine tool industry has seen a recent resurge after disappointing figures in According to the VDMA and the VDW (German Associations of the Machine Industry and Machine Tool Producers), the world export volume in 2004 for machine tools rose by nearly 12% to some EUR 20 billion. And so, machine tools are going to continue to be a steady and growing market worldwide, especially in the Far East. The 10 largest machine toolmakers in Europe are located in Germany, making it No. 1 in terms of production (21% of world production), followed by Japan (19%), then Italy (12%), Taiwan, Switzerland, the US, South Korea, UK, Belgium and Spain. Customers come mainly from the automotive, electronics, machinery and aircraft manufacturing industries. China is presently the prime importer of machine tools, with 24% share of the world import volume, worth nearly EUR 5 billion. The 10 largest machine toolmakers in Europe are located in Germany Machine toolmakers are highly dependent on quality cables and cabling in their products. As machine tools have moved from simple numerical control (NC) to computer numerical control (CNC), a new generation of cables has been developed by Nexans to deal with the higher energy and data demands, while innovations have improved performance and production chain reliability. As machine tools become more complex and intelligent they approach the second sector: industrial automation, or robotics, which takes machine control and production to new levels of sophistication, often by using the power of the Internet over Industrial Local Area Networks. Nothing could more strikingly illustrate the evolution of industrial automation and robotics than the crossing of Mojave Desert in California on 10 October 2005 by four driverless automobiles. Ironically, the industry that founded modern robotics made a historic breakthrough in autonomy, mobility and reliability under tough conditions. It was sponsored by the Pentagon s Defence Advanced Research Projects Agency (DARPA) which is one of the driving forces behind future robotics. Founded in 1958 in response to the Sputnik, DARPA is responsible for pioneering many technologies that have changed modern life, including the Internet and GPS. 3 From the Machine Tool Encyclopedia, avialable at: White Paper Automation 5/5

6 One of the trends highlighted by the fore-mentioned UNECE report is that aside from the strong growth in industrial automation, the next decade will see an upsurge of service and domestic (home-service) robots. IRobot s Roomba robot vacuum cleaner (which sells for under $300) has sold over 1 million units in the past three years. The UNECE report boldly predicts that the biggest growth over the next three years will be in service and domestic robots, with four million household robots being sold by The combined service and domestic market is expected to eventually equal in importance the industrial sector. Indeed, most experts like to categorize automation under three main categories: industrial, service and personal, with each having its own priorities. The older industrial robotics segment (which evolved in parallel with machine tools) was developed over the second half of the last century and consists of immobile, single or multiple task robots that have little interaction with humans or the surroundings. They are basically used in manufacturing and factory floor automation. According to ISO Standard 8373, they are an automatically controlled, reprogrammable, multipurpose manipulator programmable in three or more axes. 5 Recent models which use a 2D image to develop a 3D image can move through six axes: X,Y, Z, pitch, yaw and roll for precision handling. Mechanical design range from Cartesian or gantry robots to cylindrical, spherical, SCARA, articulated, parallel mechanical structures. Typical applications include welding, painting, ironing, assembly, palletizing, product inspection and testing. Advanced vision-guided robots can impart a wide range of benefits to factories. They can Be installed on current assembly lines to reduce equipment costs, downtime and workplace injuries. Because they can handle positioning variations, they eliminate the need for costly, custom-built fixtures. By spotting scattered parts in 3D space, they make manual loading unnecessary. In addition they support a high degree of customization. In the automotive industry they can identify different requirements, like different sized doorframes, and react to eliminate the need for multiple lines or time-consuming changeovers. Thus, the same line can assemble different model types on a common automobile platform. 6 From the point of view of cabling, the real trend here is to move from older types of Distributed Control Systems (CDSs) used in heavy process industries and continuous process applications towards Programmable Logic Controller (PLC) Systems, and Personal Computer (PC)-Based Control Systems, now often based on Industrial Ethernet platforms. Each of these control levels has its own special cabling needs and solutions. That is why the last three decades have seen the evolution of several levels of bus applications, from simple bus cables to the highly successful Profibus (in the automotive industry) and now PROFInet Industrial Ethernet cables. Nexans has often led the way in this important upgrade. 4 See Sizing and Seizing the Robotics Opportunity at 5 According to textsheet.com s online technical dictionary. 6 Consult Industrial Market Trends: Rise, Robot by Katrina C. Arabe at print/2005/03/rise_robot.html White Paper Automation 6/6

7 The second automation category comprises service robots: non-industrial, non-manufacturing applications of robotic technology in industries where work is repetitive, difficult or dangerous. Robots for defense and homeland security are undoubtedly the largest subclass of service robots, and its biggest sponsor. Unmanned Ground Vehicles, (UGV), Unmanned Underwater Vehicles (UUV) and Unmanned Aerial Vehicles (UAVs), or Drones, are now a top priority for armies and navies around the globe. Often linked to military robots are search and rescue, fire fighting, surveillance, bomb disposal, hazardous material handling, etc. Service automation often depends on extremely reliable cables which can enhance performance, or meet specific operational criteria: heat and cold, fire-performance, pressure, depth, torsion, vibration, chemical threats, flexibility, compactness, or the ability to increase data transmission speeds, wireless operation, etc. For years now, Nexans has been meeting the challenge of automation equipment that finds itself outside of the factory in a number of areas: like material handling, or umbilical cords used in the offshore business for remotely operated vehicles, like its own Capjet cable-laying vehicles. Where Nexans has been especially successful in the service sector is developing an entire range of sheathings and insulations which adapt to harsh conditions, both climactic and manmade. Nexans Capjet The third category of automation is personal robotics. These are robots or robotic technology purchased by individual buyers which educate, entertain or assist in the home. They range from child minders to complex security, automation and homecare services. Although qualitatively different from industrial and service automation, the UNECE targets this sector as a strong growth area for the future Personal robotics require efficient and compact cabling which can meet data and energy requirements at costs that will eventually make these products attractive to consumers. They also require numerous specialized cables that meet the needs of this sensor-rich, micro-environment. However, although certain to be a factor in shaping the coming automation landscape, they are not the subject of this paper. White Paper Automation 7/7

8 3. Challenges and opportunities 3.1 Mobility and sense Early machine tools and robots were often large, hydraulically-powered and immobile. Their movements were originally linear, two or three dimensional, and there was little scope for line flexibility or manipulative dexterity. For years, these dumb monsters were able to boost output only by accelerating speed or improving assembly precision; however, they were incapable of adjusting to any sort of change. If a part was a millimeter out of position, the machine would not recognize the fact, and grind to a halt, often with disastrous consequences. With the ability to process visual information, smarter industrial robots can move and adjust their axes so that they can handle parts with precision. These vision-guided robots are especially useful in assembling delicate or complex components. New generation robots will have a sense of touch as well, as force-feedback sensors are refined. This will enable them to identify texture, detect small pressure changes and carry out extremely precise tasks. Today s newest industrial robots are frequently mounted to an overhead rotary axis or to a linear rail to provide access to broader areas to process equipment below. For example, a single robot mounted overhead could tend three or more machining centers grouped in either a cluster or linear configuration. Ultimately, the restraining cords will be cut, and industrial robots will gain the autonomy predicted for service and domestic automation based on web-centric and wireless solutions. Thus, increased mobility is a trend for industrial robots which will have important repercussions on cables in terms of flexibility, reliability, simultaneous data and energy handling ability, and overall network complexity. 3.2 Higher intelligence Even with rudimentary intelligence, machine tools and robots showed an ability to generate gains in plant productivity, efficiency and quality. With advances in microprocessor speeds and artificial intelligence, automation will make further gains as flexible automation tools. Multiple sensors and advanced mechanics will make it possible to automate jobs that have never been attempted before, for example in semiconductor manufacturing where human assembly has reached its limits in terms of speed and quality. Higher intelligence will be achieved by harnessing powerful commercially available microprocessors to create platforms which can handle a host of sensors, actuators and servos. An Integrated Core Processing (ICP) system will probably support all of the embedded computing elements for several robots and subsystems, making it possible to handle more functions than ever before, and support multiple applications, making automation extremely flexible. Digital Signal Processing (DSP) will require the incorporation of more optical fiber on assembly lines, and the processor system will have to be designed with redundancies to protect against a single point of failure. If the new generation of automated equipment is going to last, it will have to be designed with technology refresh capabilities, meaning that it will have to be easily upgradeable in terms of processor boards and sensor options by using commercial off-the-shelf (COTS) products. White Paper Automation 8/8

9 Nexans has long advocated interoperability and shared standards and solutions. As a global company with a strong local presence it has recognized the customers concern with finding interchangeable components that are easily available everywhere, and do not lock users into technological dead-ends. Often, Nexans solutions are designed with backward compatibility in mind, especially in the area of copper LANs connectivity. Operators in Cabloswiss, a Nexans company specialised in the manufacture of Automation cables White Paper Automation 9/9

10 3.3 Internet networking Closely related to the above, is the question of networking. In the past, plant managers running automation control systems via programmable logic controllers (PLCs) were a world away from IT managers running Office Ethernet LANs for management. Today, all this is changing, with Ethernet rapidly becoming a common network connecting all devices, machine tools, robots and equipment on the factory floor with the front/back office. The result is greater efficiency and transparency along the entire production chain, with faster strategic decision-making. PC-based computer simulation and robot calibration packages enable managers to use off-line programming to develop and prove out their robot programs before downloading to the actual production line. Human Machine Interfaces (HMIs) are simpler to use, with full-color touch screens and Windows-type programs. Finally, marketing, financial analysis, Internet commerce, parts commerce and procurement, marketing, training and even maintenance are brought together in one continuum to increase productivity and competitiveness. This kind of high-speed integration can only be achieved through new generations of chain, control, bus and sensor cables on the machine, and Industrial Ethernet LANs and PROFInet solutions beyond the machine which combine management and production functions on a common platform over longer distances. Nexans has been working closely with PROFInet International to develop new interfaces and cabling, thereby ensuring reliability in the implementation of PROFInet. 7 Cabling and components used in Office LANs were often redesigned to endure vibration, heat, oil and acids, and EMI present on the factory floor. We developed special translation boxes between the office network and production equipment, and a whole range of cables offering the same reliability and much higher speeds and operational flexibility than the previous generation of bus cables. 7 See PROFInet sets new standards for Installation of Ethernet in Industry at data/artikel/00654/content.html White Paper Automation 10/10

11 3.4 Compactness Since the variety of functions involved with automation is going to expand, there is going to be a pressing need to accommodate more diversity in plants. This means smaller and lighter machines, often related to nanotechnology and nanoscale assembly. Micro-Electro-Mechanical Systems (MEMS) combined with nanotech sensors will not only be used for manufacturing purposes of ever smaller products, they will also be used within the smart products created (everything from inkjet printers and pressure sensors to optical switching technologies), and they will find their way into the machines themselves. As automation expands to create ever larger products, like passenger aircraft, locomotives and ships, at the other end of the scale a new world of Microsystems is developing which can sense and control the environment. Because MEMS devices are manufacturing using batch fabrication techniques similar to those used for integrated circuits, unprecedented levels of functionality can be placed on a small silicon chip at relatively low cost. The move towards compactness is already transforming the automotive, biomedical and electronics market. As an experienced cable manufacturer, Nexans has gained a reputation for working with both macroscopic and microscopic cabling. The new generation of compact industrial equipment is giving rise to smaller, lighter cables which make important space gains while delivering equal or superior levels of reliability and performance. Nexans specialist in the Research Center of Nuremberg (Germany) 3.5 Standardization A recent Japanese study 8 notes a transition from basic industrial robots towards the symbiotic robot, capable of more autonomy, learning, recognition and even human/machine interaction. 8 By Masayoshi Yokomachi of the Machinery System Technology Development Department of NEDO, the presentation is available at White Paper Automation 11/11

12 However, in a projected market of some $1.5 billion by 2010, it sees the greatest impediment to progress being a lack of standardization. Robots have been developed and manufactured using proprietary, integrated systems, so that each manufacturer has a different architecture and there is no common platform. A symbiotic industrial robot needs specific and complex application software in addition to open interfaces and modularized functional components. Once again, Nexans interoperable philosophy favors common platforms, interchangeable cabling, and shared connectivity. 3.6 Safety Safety is a growing concern among machine tool and robotic equipment manufacturers, other manufacturers, and the public at large, on several levels. The production line is a dynamic entity which requires nearly continuous operation to optimize the investment/output ratio, especially for variable production runs of customized products. Therefore, there must be no breakdowns or flowage stops, no matter what the product produced. Secondly, equipment must be capable of operating reliably in often dangerous and hazardous conditions (especially where dangerous materials are involved, or in tough environments, like undersea). They must be capable of surviving hot and cold, chemical threats, pressure, vibration, strain, etc. To ensure worker safety, automation equipment must be fire-safe, and not generate dangerous smoke and gases in case of fire. Finally, the entire production process must be environmentally safe. Wherever possible dangerous metals should be eliminated, and discarded materials recycled. To protect the dense electronic environment, with equipment and components should generate low Electromagnetic Interference (EMI). From the development of safe cables in conformity with the RoHS 9 for electrical materials, Nexans recycles everything from copper to plastics, and has been a pioneer in standards and designs for Halogen-Free Fire-Resistant cables. Cables fire testing 9 Directive 2002/95/EC: Restriction of Hazardous Substances in electrical and electronic equipment White Paper Automation 12/12

13 4. Customer expectations of cable suppliers Whether a wholesaler, a component and system supplier, a complete automation system manufacturer (OEM) or an end-user, all would like to see automation equipment which is more mobile, compact and intelligent, with the possibility of Internet networking. They would also like more control and data functions to facilitate operations and contribute to production, packaging and delivery. Above all, they want both commercial off-the-shelf (COTS) cable products that can assure interoperability and easy procurement, and high-end cables which can help lower expense per unit produced and enhance efficiency and reliability. Safety is also a prime concern, for the assembly line, for workers, and for the plant and its surroundings. The machine tool and automation/robotics industry also has specific expectations from cable manufacturers: High performance for efficient integration and distributed control Quality, reliability and durability to avoid costly breakdowns and stoppages Interconnectivity to merge both the analog and digital worlds Availability and fast delivery for production line flexibility Optimized conductor and insulation materials (no shrinkage and low hydrolysis) Safety for personnel, e.g. lead- and cadmium-free and easy recycling Conformity to international standards, and cross-industry compatibility Excellent service, from testing to support and maintenance Upgrades for current assembly lines, from Profibus to PROFInet and wireless Fire- and heat-resistance for safety and performance Specialized cables for the new generation of service and personal robotics White Paper Automation 13/13

14 II. NEXANS: THE GLOBAL EXPERT IN MACHINE TOOLS AND AUTOMATION One weak link can interrupt the production chain and delay the delivery of a product resulting in financial loss. To prevent this, Nexans manufactures a full range of reliable, dynamic cables to assure the interconnection, control and process efficiency of machine tools and automated equipment. We supply everything from miniaturized control cables to state-of-the-art industrial PROFInet cables to bring the office and the production floor closer together. Efficiency begins with an upfront requirement analysis. Then, our Nexans research centers test the cables currently used, and strive to surpass them in terms of performance, durability, chemical and oil-resistance, etc. This move from benchmarking to theory and then back to practical implementation results in customized designs, modularity and appropriate materials that can fit neatly into the entire production process. Thus, together with the world s leading machine tool, robot and industrial equipment manufacturers, we are creating standards to streamline automation worldwide. 1. Cable solutions for manufacturing For robotic applications, Nexans manufactures a range of special robotic cables which carry energy and data on one or several cores. These cables perform excellently under high torsion, and have low break susceptibility under factory conditions. Used mainly in the automotive industry these high-performance cables come in over a hundred different sizes and are available in several insulations, including polypropylene (PP), thermoplastic elastomer (TPE) and Nexan s own Thermoplastic Modified (TPM). Nexans is one of the few suppliers to offer a choice of insulations to meet the operating conditions (often extreme heat) in plants. For production chain applications, Nexans offers four main cable types for machine tools and automated equipment. Power cables are used to carry the mainly 600 to 1,000 volts to the machine either for direct contact or in some cases via a harness. These cables are extremely flexible and come in several categories according to fineness of the stranded cores. It contains a screened break pair, an important safety feature. This pair plays an important control function. Encoder cables link the central processing unit, or CPU, to the machine for 3-dimensional movement, and opening/closing functions. This cable is controlling the actual movement of the machine and has to meet all of the mechanical restrictions of a power cable, like tight bending radius. Although this cable could represent an infinitesimal part of a robots overall cost, its failure could bring production to a complete halt. That is why Nexans encoder cables are not only custom-designed, they are also tested to endure 10 million cycles of operation. When EMI is not a problem, unshielded power cables provide a cost-efficient solution for servo-motors operating under harsh conditions. Finally hybrid cables combine power, signal cores and Category 5 quads to deliver both energy and control capability to machines and robots. White Paper Automation 14/14

15 Power cables Encoder cables unshielded power cables hybrid cables For control applications, Nexans manufactures multi-strand miniature control cables have a small bending radius and a long life (up to 5 million cycles). These cables are used for simple onoff control for assembly line machines. Generally, so as not to disturb production when a machine is running, plant managers prefer to change these standard cables during the summer or downtime. As with the more complex encoder cables, these relatively low-cost cables are the critical connection on a costly robot, and must deliver reliable, consistent performance in what can be a very aggressive environment. As mentioned in the introduction to this paper, there is a definite trend from basic bus applications towards enhanced solutions and eventually wholly net-based control solutions. At the lower end of the scale are ASI-bus cables which provide signal transmission for wider control purposes beyond simple servo-motor functions. Co-developed with Siemens this is a convenient flat cable which fits into a special module with pins, making it fast and easy to connect with high security systems, like mail sorting equipment in post offices. Profibus cables come in a dozen designs for complex control. Delivering up to 12 Mbits/s, Profibus (also co-developed with Siemens) is now the leading standard in Europe and is widely used in the automotive industry. Superior mechanical and dynamic properties, as well as fast connections account for its continuing market dominance. This cable is available in a fast-connect version, which uses a special tool to remove the jacket, then cuts the braid and cores to a defined length. Finally, there are Nexans PROFInet cables for Industrial Ethernet LANs. To merge office and factory, a data transfer rate of 100 Mbit/s is assured by either a symmetrical copper cable, or copper/fiber, or all fiber networks. For all-fiber systems Power over Internet (PoI) solutions can deliver 12, 24, 48 and 230 volts to machines, robots, Internet phones and wireless access points. Also, Nexans offers active network systems and accessories, including central media converters and full connectivity, like the IP 67 connector which is impervious to dirt, dust, heat, vibration and shock. Plastic optical fibers provide more robustness and easier connectivity for many of the above applications. White Paper Automation 15/15

16 To meet the challenges of the sensor-rich assembly line, Nexans manufacturers a complete family of sensor cables to connect sensors to the electronics (i.e. the central control unit) so that critical measurements can be constantly exchanged to control automation, and assure safe and reliable operations. Note, that for most of the above cables, fire-reaction and fireresistant versions exist to prevent fire propagation, reduce smoke emission, and protect workers and equipment. For Lumberg Nexans developed the Lumflex sensor cable which created in two years a worldwide standard of flame retardant and halogenfree sensor cables. 2. Cable solutions beyond manufacturing Nexans not only produces numerous cables for machine tools, automation equipment and assembly lines, it also produces special cables for service robots. This is especially important as automation moves off the factory floor, and into public and office buildings (hospitals, laboratories, warehouses, etc.), undersea (oil and gas exploration, pipeline laying) and even into private homes: e.g. personal robot systems and home automation and protection based on VDI (Video-Data-Image) residential backbones. Drawing on a vast experience in everything from the infrastructure, industrial and building markets; telecommunications and energy networks; and specific market sectors like aeronautics, aerospace, shipbuilding, automobiles, railways, medicine and material handling, Nexans has constantly innovated to develop every type of cable imaginable for automation/robotic applications, including: - harnesses for aerospace, aviation and the automotive industry - compact plastic and conventional optical fiber cables - connectivity for both energy and data - active equipment for optical data systems, including media converters and switches - resistant coatings and insulations for special conditions When automation moves to a new level of personalized mobility and autonomy, Nexans will be there to provide it with the nerves and sinews that it needs. White Paper Automation 16/16

17 3. Local service, innovation, and reliability There are three keys that constitute a winning edge in today s global machine tool and automation/robotic market: global yet local services that can fully satisfy remote customers high-value-added products that can be tailored to customer needs products which are developed quickly and then constantly upgraded to adapt to new applications Global players want a global cable partner who can deliver the goods wherever highperformance robots are used. That is why Nexans fully complies with major standards, like VDE, UL and CSA, and the Chinese CCC. As supply chain managers in its own complex production activities, Nexans is doubly aware of its customers requirements. Based in countries who are major robotics producers and users, themselves, Nexans is highly sensitive to national needs, languages and cultures; and is committed to sharing expertise through problem-solving, adding value through cable design, and supporting local manufacturing practices. Nexans is an inventor and standard setter for robotics and automation. It is constantly reengineering, redesigning and improving products through better alloys, and more durable insulations capable of operating in high temperatures, and delivering superior fire performance. Nexans has automation teams at its Research Center in Nuremberg (Germany) and in Lyon (France), and a Competence Center dedicated to metallurgy in Lens (France). They draw on the collective knowledge of 450 researchers and engineers companywide. At Nuremberg, aside from developing new designs in close cooperation with its automation customers, Nexans measures the electrical properties of its cables under dynamic loads. These include torsion tests, mechanical resistance tests (alternate and roller bending), and temperature tests in both furnaces and low-temperature chambers. Researcher within the Nexans International Research Center (Lyon) Nexans innovations and expertise have won the approval of major machine-tool and automation/robotics manufacturers, and the Group is already serving new delocalized manufacturing countries. To support converters and design engineers in their daily work, Nexans has created a specific guide which divides ranges of cables into various application classes. This straightforward allocation allows the right cable to be found quickly, cutting a clear path through the data jungle. White Paper Automation 17/17

18 Above all, Nexans applications approach assures long-term cable reliability in actual operating conditions, assuring manufacturing continuity, product quality, and important costsavings. Based on proven technologies, Nexans cabling and solutions will last far into the future because of their own inherent durability, phased upgrades and seamless technological improvements. White Paper Automation 18/18

19 IV. APPENDIX: Some recent Nexans success stories, innovations and references Nexans provides a wide range of robotic cables for the German KUKA Robot Group, the largest producer of robots in Europe and #2 worldwide Low capacitance cables are being produced for SEW, a German supplier for robot and machine tool manufacturers. Schweiger GmbH integrates all Nexans families in its automated procurement system offering maximum technical and commercial benefits to customers like Inex, Grob or Fanuc Automation Lutze uses unshielded power cable in cranes for large production halls and port facilities Nexans developed special hybrid cables with leading German connector producers and harness makes to meet specific connector and environmental factors for all applications. With Nexans new Thermoplastic Modified (TPM) insulation, Nexans control cables have improved dielectric qualities which have made it popular with Bosch Rexroth, a prime supplier for the machine tool industry. For its mailing/sorting systems, instead of multicore cables, Siemens preferred an easy-toinstall cable which sends several control functions to various addresses via a simple two-core ASI-bus cable. Originally co-developed with Siemens in 1989, a new version of Nexans Profibus cable accommodates Drive-CliQ networking for servo drives and motors, allowing both flexibility and high dynamic performance for all multi-axis robot systems. Nexans is a member of the Profibus Association, developing cables with 14 other companies and connector manufacturers to create a complete system that assures interoperability. For Lumberg, a leader in automation connectors and components, Nexans provided a UL-certified HFFR cable for its Lumflex generation of sensor cables, capable of delivering 5 million flex cycles. White Paper Automation 19/19