Cool Stuff for Geeks & Industry at Hannover Messe |

Cool Stuff for Geeks & Industry at Hannover Messe

June 042012
Cool Stuff for Geeks & Industry at Hannover Messe
June 2012
By Bill Lydon
I wanted to share some really interesting, innovative and cool applications of technology shown at Hannover Messe (Fair) 2012 that grabbed my attention.
Volkswagen Golf Blue-e-Motion Vehicles
On the Sunday press tour of Hannover Messe we were driven between halls in prototype Volkswagen Golf Blue-e-MotionVehicles. The Golf blue-e-motion prototype is powered by lithium-ion batteries weighing 80 kilograms and the car is silently powered by an 85 kW electric motor in the front engine compartment.   The Golf goes from 0 to 100 km/h (62 MPH) in 11.8 seconds. The maximum speed is limited to 135 km/h (83.9 miles per hour). Like all electric motors, the motor used in the Golf also outputs a very high maximum torque (270 Newton-meter) right from a stop. The electricity for driving the electric motor is stored in a lithium-ion battery with a capacity of 26.5 kilowatt-hours and charges in 3 hours.  A driving range of up to 150 kilometers (about 93 miles) can be realized in the Golf blue-e-motion; the specific range depends on driving style and factors such as use of the air conditioning and heating system.
In line with the central topic of this year's Hannover Messe, "Greentelligence," Volkswagen displayed their ideas of the resource conserving automobile production processes of the future, the "Think Blue Factory." I had a discussion with Volkswagen experts about their use of steel hot forming and stamping to reduce weight while maintaining strength. Volkswagen has developed their own processes and refinements to this manufacturing method and has their own in-house process production lines for hot formed steel producing 80,000 hot formed parts per day in one plant. Volkswagen also presented an advanced production technology that helps conserve resources in a sustainable way. The process uses dry machining which does not require any cooling and lubricating emulsion thanks to the use of new machines and tools and modified machining processes to significantly reduce carbon dioxide emissions at Volkswagen plants.
The Volkswagen Group has made a commitment to a fundamental environmental transformation with an investment over 5 years of more than two thirds of its entire €62.4 billion investment program. The investment is directly or indirectly into ever more efficient vehicles, new powertrain concepts and environmentally compatible production at Volkswagen plants throughout the world. By 2018, the goal is to reduce the environmental impact of all Volkswagen plants by 25 percent. This especially includes energy consumption, waste volumes, air pollution, water use and CO2 emissions.  At its Hannover Messe stand, Volkswagen gave an indication of the technical approach they adopted to achieve these targets.
Festo Demonstrates Control Using the Mind
Festo always has some intriguing demonstrations at Hannover Messe. This year they demonstrated a person controlling motion using a brain-computer interface (BCI) that measures voltage fluctuations on the surface of the head via attached electrodes.
CogniGame is a reinterpretation of a well-known video game that was launched on the market in the 1970s. Based on the game of table tennis, players used a joystick to move a paddle up and down on the screen to return the ball to their opponent. For CogniGame, the developers at Festo implemented the virtual game on a real court built using Festo components. Two linear axes whose drives move to the left and right along the baselines move the racquets to return the ball and keep it in play. One player controls his racquet by thought alone via a brain-computer interface (BCI). This measures voltage fluctuations on the surface of the head, as with electroencephalography (EEG), via attached electrodes.  Opposite, a second player moves the racquet by maneuvering a lever with their hand.  For the game, Festo worked with CogniWare to develop a software solution for controlling a racquet using thoughts and biosignals. It establishes a communication channel between the brain and hardware without any interaction from the user via voice or input devices.
Festo believes the work on CogniGame has practical applications for the factory of the future by addressing the question of how people and machines can interact more efficiently in the face of constantly changing technologies. Even in the factory of tomorrow, not all work sequences will be fully automated.
Linde Go Kart sets Record
Linde Material Handling presented four impressive examples of its electromobility initiatives at Hannover Messe’s MobiliTec.  The most dramatic demonstration was their electric Go Kart - a world record holder in the Guinness Book of Records with 0 to 100 km/h (approximately 63 mph) in 3.45 seconds. The technology of the electric kart E1 is based on electric forklift components of the lift series E20-E50: lift motor, power units, display, steering shifter and software.
Linde Material Handling has 40 years of experience in electromobility pointing out that electromobility is new to the automotive industry but not to the truck manufacturer. Linde Material Handling has manufactured more than 3.5 million electric drives for mobile work machinery during this time.   Two years ago, Linde also made its expertise in electric drive and control technology available to external customers through its Electronic Systems & Drives (ES&D) division. Within a very short period of time, Linde has been able to enter new fields of application, ranging from electric rail trolleys and airport ramp equipment to electric road vehicles. Linde Material Handling is now bundling these products and services under the eMotion label.
Eisemann Green Painting
As part of the IndustrialGreenTec initiative at Hannover Messe, Eisenmann showcased its green engineering portfolio in their 5,000+ square feet booth. Eisenmann illustrated their methods to be an energy- and resource-efficient supplier of industrial solutions.  Eisenmann is a leading international systems supplier for finishing technology, material flow automation, and for environmental and thermal process technology. Dr. Matthias von Krauland, Chairman of the Executive Board explained, “Our goal is to show manufacturers what is technically possible and available today, to raise their awareness of relevant technologies.”   Eisenmann’s centerpiece was a fully operational demonstration of their dip-coating E-Shuttle system.
This video illustrates first a conventional dip line and then Eisenmann E-shuttle System that uses less chemicals.
Visitors were offered information on a range of ideas for green manufacturing including biogas plants, waste incineration, recycling and reuse of waste materials, waste water treatment, and exhaust air purification.
Composite Bike Wheel
Bicycle wheels weighing 1.199g were displayed by bike ahead Composites GmbH.   The new wheels were developed from carbon fiber-reinforced plastic (CFRP) and is especially constructed for off-road biking conditions. Based on innovative composite technology, the full-carbon models form a lightweight, extremely solid and low-maintenance product.
Sercos Makes Music
The Sercos keyboard and guitar made its debut as an ensemble at Hannover Messe 2012. Mechatronic students from the University of Stuttgart, led by graduate engineer Jan Schlechtendahl with involvement from the Institute for Control Engineering and Bosch Rexroth, implemented these systems to robotically play a guitar and keyboard.
The Sercos robotic guitar is played by a system that interprets MIDI files using the Sercos automation bus. It uses an MLP industrial control from Bosch Rexroth and bus terminals from Phoenix Contact to actuate a group of lifting solenoids via Sercos commands. Six solenoids pluck the strings and 24 operate the finger board. The system played a number of tunes from its repertoire at the fair.
Robotic Guitar
A robotic keyboard joined the Sercos guitar in the Sercos Robotic Band.  The keyboard has two hands, each with 16 fingers. The fingers move across the keyboard on separate rails, allowing them to cross each other. To exactly hit the keys, fast horizontal movements with precise stops were a special challenge. The students installed Bosch Rexroth linear inverters, IndraDrive CS drives and bus couplers. The complex sequences are coordinated by the Sercos automation bus.
Robotic Keyboard
A CD containing 26 classical selections played by the Sercos guitar is available. Order a free copy of the CD.
Beckhoff Automation’s XTS – Liberated Motion
Beckhoff introduced the new XTS drive system (eXtended Transport System) that combines the advantages of two proven drive principles: rotary and linear systems. The new drive system effectively turns the previous linear motor principle around eliminating complex wiring and drag chains. The motor is completely integrated together with power electronics and displacement measurement. One or more wireless movers can be individually controlled with high dynamics at up to 4 m/s on an almost arbitrary and flexible path.
The XTS system is simple and modularly configurable: the motor modules form a complete unit with the movers and guide rails. The guide rails contain the electromagnetic coils and all other active functions necessary for the operation of the system. The systems require a power supply and an EtherCAT connection. The motor modules contain no moving parts, simply permanent magnets and are not subject to any wear. The mover contains magnetic plates which, together with the coils in the motor modules, can generate propulsive forces. It absorbs the attractive forces of the magnets on both sides and compensates them as far as possible. This means that the rollers on the movers, which are equipped with a particularly low-wear plastic surface, can move at high speed in the guide rails. A mechanically robust encoder flag conveys the mover position to the motor module. The estimated market release of the XTS is expected in 4th quarter of 2012. More information on XTS.
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