However, the ongoing maintenance costs should not be underestimated which rise with increasing age due to unscheduled maintenance measures such as the exchange of cable trees or individual robot axes.

Under certain circumstances, the complete replacement of a robot pays off at time ‘x’, not least in order to be up-to-date in terms of control technology.

KELLER offers the replacement of robots within a very short time and ensures the ongoing function of the new robots without having to re-edit already existing formats.

The application is recorded exactly in advance and all necessary calibration points are determined. Then, the robot is exchanged, which is discussed in detail with the customer in advance.

The robot is exchanged within one day. Production can therefore already be started after a short time.

This also works for all brands, as KELLER recently demonstrated in Serbia. Here, industrial robots from various manufacturers were successfully replaced.

From 28th February till 02nd March, KELLER ITS participated as exhibitor at the IFEX 2020 in India. The meanwhile 16th edition of the fair for foundry technology took place this year in Chennai. With totally six halls, IFEX is the largest exhibition in India and trendsetter in the field of iron and steel production. Again, an attractive lecture program accompanied the fair on current developments with the main topic of digitalization in foundries.

KELLER ITS presented the newly developed pyrometer CellaCast with IO-Link interface for the optical temperature measurement of liquid metals at the booth. Gone are the days when only the analogue measuring signal was evaluated. In 2007, a consortium of PLC manufacturers and fieldbus providers joined and created a worldwide standard with the IO-Link interface technology. This step became necessary because the increase of data to be transmitted also requires a higher transmission speed. IO-Link is characterised by the simplest installation and the very high operational reliability. Devices with IO-Link can be integrated into all common fieldbuses.

With the new CellaCast pyrometer, not only the temperature value of the liquid metal, but also signals and data for monitoring the contamination of the optics, diagnostic data of the measuring system and the internal temperature are transmitted to the PLC via the digital interface. Furthermore, IO-Link offers the possibility of configuring the device via the PLC. This allows the individually adjustment of the measurement parameters during the production depending on the production batch according to the alloy of the melt.

With the new KITS App, also presented for the first time, KELLER offers a solution for the digitalisation of the service. The App provides online all information required for commissioning, configuration and maintenance of the measuring system. With the integrated emissivity calculator and field-of-view calculator, the required setting parameters for commissioning are determined on site. For personal technical support, the direct contact details of the service department are available.

With more than 100 visitors at our stand, the exhibition was a great success for KELLER ITS India. Thus, we have already decided to participate in the IFEX 2021 in Calcutta.

The implementation of integrated networking and communication from the machine level to the ERP software is a high challenge for automation technology in machine and plant construction as well as for the manufacturers of sensors and actuators in this extremely rapidly developing technology, in order to be able to follow the state of the art and the innovative machine concepts. In order to be able to manage the large amount of new process data of the "smart" sensors, a new interface technology with higher transmission rates had to be created.

In this context, the world’s leading manufacturers of control and fieldbus systems joined forces 2007 years ago to create a uniform, system and company independent new standard. The result was the invention of the IO-Link interface technology. Sensors and actuators with IO-Link communication interface can be operated in all common fieldbuses such as Profibus, Profinet, Modbus, EtherCAT or CAN-bus and thereby solve one of the still largest problems of bus specific device interfaces.

When specifying the IO-Link interface in accordance with IEC 61131-9, particular emphasis was placed on standardization, operational safety and simple hardware and software commissioning and cabling of the intelligent and complex sensors and actuators. Therefore, IO-Link is rightly called the industry's USB interface for controlling machinery and equipment. It was also important that the IO devices could also be easily implemented in existing systems.

Several measured values, diagnostic information for demand-oriented maintenance, information on operating states or fault messages can be transmitted in parallel via IO-Link. Parameterization takes place flexibly during operation via the control system, depending on the production conditions.

The central parameterization of the devices from the highest level of process control contributes to operational safety. When changing a sensor, the identification is automatically checked and the configuration parameters stored in the IO-Link master are transferred to the sensor. The connection of a wrong device or a faulty configuration is therefore excluded.

To follow this technological progress, KELLER ITS - one of the leading companies in the field of optical temperature measurement - has developed the new instrument series CellaTemp® PX. The focusable precision pyrometers are the first instruments of their kind worldwide to be equipped with the revolutionary IO-Link interface technology.

Altogether, the new CellaTemp® PX series has 22 basic models with measuring ranges from 0 – 3000 °C. In combination with the 5 focusable lenses, the more than 100 device versions can be used for various measuring distances and object sizes. You can choose between a through-the-lens sighting device, a laser pilot light or an HD video camera. The variety of variants covers the complete application ranges of optical temperature measurement from the iron and steel industry, the cement, glass or ceramic industry to combustion plants.

In order to be able to use the devices in existing process control systems with analogue signal transmission, the devices of the CellaTemp® PX series have the classic 0(4) – 20 mA analogue output as well as two switching outputs in parallel.

Modern information and communication technology offers innovative solutions for providing information and data regardless of the location far beyond the current practice. Digitalization thus opens interesting fields of action for companies, especially in terms of service.

KELLER ITS – one of the leading manufacturers of optical temperature measuring devices – follows this development and presents the new information and service app “KITS”. The App implements the different possibilities of a modern digital service concept.

The Industrial Solution Guide in KITS helps prospective customers in selecting the most suitable device and accessories for their industry and application. All information available on a product, such as technical data, operating and commissioning instructions or dimensional drawings are directly available on site via the app on the smartphone or tablet. For this purpose, you simply scan the barcode or enter the type of instrument. For the electrical connection, the setup of the measuring system or in case of any malfunctions it is no longer necessary to search for the documents.

The field-of-view calculator is a useful tool for selecting the optical property of the instrument as well as for setting the appropriate focus distance of the pyrometer during commissioning. The emissivity calculator is an important tool for setting the parameter of the device to find the correct emissivity setting. In addition, you are able to determine the real measurement uncertainty under the given measurement conditions.

For quick help, our service hotline is directly available. The KITS App currently supports 8 languages and meets the requirements for a modern service management to get all necessary information quickly, easily, at any time and worldwide.

Optical temperature measurement has meanwhile established itself in many applications. Within milliseconds, a pyrometer detects the infrared or thermal radiation emitted by the measuring object and calculates the temperature based on the Planck distribution curve. The optical measuring method allows a temperature measurement from a safe distance, on moving objects or on sensitive surfaces such as paint layers or liquids. Even temperatures above 2,000 °C or inaccessible objects such as encapsulated kilns are typical applications for optical temperature measurement.

At the infrared temperature measurement, the emissivity of the measured object has a great influence on the accuracy of the measurement. The emissivity is a material property and a measure of the ability to radiate heat. The value is specified as a ratio to the radiation of an ideal "black" radiator with a range of 0 to 100 %.

The emissivity depends on the measuring object, the surface condition, the wavelength of the radiation and on the ambient conditions. In the literature, you only find approximate, theoretical values. For precise determination of emissivity, a comparative measurement with a contact thermometer is recommended. However, the contact measurement can also be faulty and a comparison measurement at the same time and place is often not possible to realise in practice. Then it is helpful if at least the error about the maximum possible measurement deviation can be estimated.

For this purpose, KELLER Infrared Temperature Solutions (ITS) – one of the leading manufacturers of optical temperature measurement devices – has developed an emissivity calculator. This calculator is available as online tool on www.keller.de/its and for mobile devices via the “KITS” App. If the real object temperature is known, the emissivity to be set for the selected pyrometer can be determined by the calculator. A second calculation method determines the influence and the deviation of the measured temperature by varying the possible emissivity.

Today’s demands on the mechanical, forming and machining properties of foundry products have increased significantly in recent years. This is due both to the complexity of the components and to the objective of saving material and weight. In addition, the market is being flooded by low-cost suppliers. Efficient production in the foundry sector only possible by focusing and specializing on high-quality products.
This, however, requires that demands on quality are defined, checked and adhered to from the raw material through to the entire production process. Especially the prescribed temperature of the liquid metal when pouring into the mould must be ensured.

The optical temperature measuring method with pyrometers has meanwhile established itself in steel mills and foundries. For this purpose, KELLER Infrared Temperature Solutions - who is one of the innovative leading companies in the field of optical temperature measurement -has developed a unique measuring method with the CellaCast measuring system. By means of a CSD (Clean Surface Detection) function and a rectangular measuring field, the pyrometers are able to filter the correct temperature of the liquid steel and iron even with slag and oxide on top of the surface.

The measuring system is used to monitor continuously the temperature in the runner of blast furnaces or cupola furnaces. At automatic casting machines, the temperature of each production part is detected and recorded at the critical process point, i.e. when filling the mould. Faulty production parts can be sorted out directly or the casting process can be stopped immediately when reaching the minimum permissible limit temperature.

The CellaCast System can be integrated into the plant control system or can be used as stand-alone solution to display the measured values with the number and analysis of the production parts on a PC and save them automatically in a database.

As a novelty, KELLER ITS presents the CellaCast PX measuring system with the cutting-edge IO-Link interface technology. When specifying the IO-Link interface in accordance with IEC 61131-9, particular emphasis was placed on standardization, operational safety and simple hardware and software commissioning and cabling. Therefore, IO-Link is rightly called the industry's USB interface for controlling machinery and equipment. Several measured values, diagnostic information for demand-oriented maintenance, information on operating states or fault messages can be transmitted in parallel via the digital interface. It is also possible to dynamically adapt the device parameters with the PLC to the material during operation via the interface.

The trade fair "Domestic Construction Materials" OCM in Moscow is a unique project in the Russian area of influence, which is focused on the production of building materials. The OCM has become an important trade event in the building industry and is actually the only trade fair in Russia that reflects the realities of the Russian building materials market.

At the same time, the Russian Association of Manufacturers of Ceramic Wall Material invites to participate in the special exhibition “CERAMBRICKTECH – Exhibition of Machinery and Equipment for the Heavy Clay Industry, Technologies and Raw Materials”.

This year’s CERAMBRICKTECH 2020 again offered a unique focus on the business objectives of the KELLER Division in the Russian Federation and CIS. In addition to the very good project discussions and successful contract negotiations with long-standing business partners, very interesting new customers from the Central Asian states of the former Soviet Republic could be acquired.

Currently, brick manufacturers in the CIS states are faced with the need to modernize their machinery and equipment. The economic shortage of high-quality building materials in the CIS countries is a great opportunity for the KELLER Division to conclude further good business transactions.

We will face the new challenges with great pleasure.

In 2018 a record number of participants could already be noted, this was even exceeded in 2019. In their lectures, speakers from industry and research presented innovations, trends and research results on various topics to an interested audience of experts.
Everyone talked about the biggest challenges facing our industry, such as CO2 emissions, energy consumption and automation technology, which were discussed controversially. Anyone who talks about energy consumption and CO2 emissions will of course not be able to avoid the question of alternative, preferably regenerative forms of energy. Here again, the brick and tile industry is urgently looking for solutions from the mechanical and plant engineering sectors.
For KELLER, Lutz Jankowski gave a lecture on the topic “Keller implements intelligent industrial robot plant concepts”. A brick mixing plant, the unlocking of pallet stacks with integrated quality control and some applications outside the heavy clay industry were presented. The presentations were followed with great interest, as these solutions could be the answer to the shortage of skilled workers. It is becoming increasingly difficult for our customers to find qualified and motivated personnel.
"Robots also perform unpleasant tasks with a consistently high level of motivation!”

Simple gripping tasks can be managed with standardized grippers. However, the gripping of complex components and the handling of automation jobs outside of this standard require the use of special grippers.

KELLER IMS “Intelligent Machinery Solutions” is a manufacturer of special machinery and plants with many years of experience in a wide variety of industries.

Our worldwide approved and innovative gripper systems perform a wide range of automation and handling tasks. Industrial or portal robots, regardless of which system you use, our innovative tools and grippers increase automation and flexibility, accelerate processes and reduce your operating costs.

The variety and individuality of the products to be handled require special tools and solutions. We offer the optimum solution for your application and always keep an eye on the total costs.

Our grippers are not only limited to “opening” and “closing”, they also “turn, space and group” your products during the handling and robot cycle, thus replacing some of the additional equipment and machines required.

With the feeling of what is feasible, our highly qualified engineers plan, develop, design and assemble not only the most complex gripping systems. Complete solutions and deliveries including industrial or portal robots and their assembly and commissioning as well as the respective safety equipment are part of our core competencies. For example, the working areas of industrial robots can be extended by our linear axes, which are adapted to your application.

Based on many years of experience, our engineers support you with:
- Feasibility studies and simulations
- The adaptation of new robot grippers in your plant
- Programming and commissioning
- Supply of complete solutions including e.g. inlet and outlet transport and grouping equipment

Challenge our high level of competence to create an efficient solution for your automation and handling task.

On 22 and 23 October 2019, around 60 students of process engineering, materials technology and ceramics informed themselves at the Röben Klinkerwerk Bannberscheid about brick production and career opportunities in the brick industry.
Lutz Jankowski, KELLER, gave a lecture on "Intelligent industrial robots - plant concepts using the example of a mixing plant as stand-alone solution".
The get-together at the evening of the first excursion day gave the opportunity for personal discussions between students and industry representatives. First contacts were established and here and there a possible cooperation was discussed.

The forum offers brick manufacturers and plant manufacturers the opportunity to review the past time and to discuss the future.
This year, the focus was on production-related presentations on raw material preparation, extrusion, drying
and firing.
The accompanying exhibition and training sessions provided information about new and existing product solutions.
The forum closes every evening with a hospitality event that offers participants the opportunity to exchange the upcoming topics intensively.
The extensive technical programme was completed by the traditional Steak Cookout on Wednesday evening.
This year KELLER was represented by Ulrich Hagemann and Holger Rottmann.
As in previous years, we received support from our US representative MECO - The Manufacturers
Equipment Company from Middletown, Ohio.

Intelligent robot solution for the unlocking of pallet stacks

Pallet logistics is becoming increasingly important in many industrial sectors, especially in the building materials industry. Increasing requirements on building sites, resource efficiency, load securing requirements and internal transport are constantly confronting the companies with new challenges. A flexible system for handling return pallets would increase productivity and provide the necessary process reliability.

You can read more at
https://www.keller.de/en/ims/machines-ims/pallet-handling.htm

In many different industrial branches products are nowadays extruded and cut to the requested length. For this purpose, a variety of cutting and punching systems of manual, semi-automatic or automatic type are available.

Based on its long experience in the manufacture of cutting systems for the ceramic industry, KELLER IMS developed a cutter for such products according to the principle of universal cutters, which meets the requirements in terms of technology and investment.

You can read more at
https://www.keller.de/en/ims/machines-ims/cutter.htm

Innovative KELLER grinding technology

The KELLER grinding technology is one of our product segments in which we are constantly developing and facing the challenges of the market. The targets and needs of our customers are the driving force for our work.

The Vario 900 grinding machine is our answer to the requirements of our times for plane brick production. It represents the coming generation of KELLER grinding machines and continues the successful history of KELLER grinding technologies.

Read more
https://www.keller.de/en/ics/machines/grinding-machines.htm