Hannover Messe

Encompassing 13 trade shows and nearly 7,000 exhibitors, Hannover Messe is the world’s largest industrial trade fair. Sarah Pursey experienced firsthand some of the remarkable developments on show at Germany’s foremost fair for technological innovation.

While the drawings of Leonardo Da Vinci’s flying machines aspired to emulate bird flight, it would be another 500 years before this vision would be realised. Soaring high over the exhibition booths in Germany, FESTO’s SmartBird flying robot could easily have been mistaken for the real thing. Indeed, such remarkable technological developments were never far from sight at Hannover Messe 2011, which encompassed trade fairs in Industrial Automation; Motion, Drive & Automation; Energy; Power Plant Technology; Wind, Mobilitec; Digital Factory; ComVac; Industrial Supply; CoilTechnica; Surface Technology; MicroNanoTech; and Research & Development, and showcased the most important technological innovations in industry today. With nearly 7,000 businesses from 65 countries showcasing their goods, these innovations ranged from the world’s dirst DIY solar power plant, to advanced robotics, smart systems and high performance eVehicles.

The post-war establishment of Hannover Messe – an initiative of the British occupying forces in consultation with the commander-in-chief of the American zone – led to the emergence of Hanover as a leading trade fair centre, and Hannover Messe as the world’s largest industrial fair today. 64 years since the first Hanover fair, Germany’s Federal Chancellor Dr Angela Merkel, alongside French Prime Minister Francois Fillon (France being this year’s Partner Country), opened Hannover Messe 2011 – a show that attracted well over 230,000 visitors this year, representing a 10-15 percent increase over the 2009 event figures, with some 60,000 attendees coming from overseas.

Human-robot interaction

New mobile robot solutions for use in manufacturing and processing, the public sector and the services industry were on show in Hanover. Aside from its robotic bird, other bio-inspired robotics exhibited at FESTO’s stand included the Bionic Handling Assistant, with kinematics inspired by the elephant’s trunk. The robotic arm featured a hand axis that positions a gripper; positional measurement using sensors; force-lock, form-lock gripping fingers; and air chambers to enable extensions and angular displacement.

Safe human-robot interaction is a key focus for Fraunhofer’s R&D projects, meanwhile, with the institute’s robotics developments following a number of key concepts – collision avoidance, contact detection, and hazard assessment. With regards to the scope of contact detection innovations, Mr Andreas Teichert (Fraunhofer IPA) explained: “2D tactile sensors, when applied to a robot like an artificial skin, can reliably detect contact, measure active forces and safely stop a robot’s movements when necessary. The same sensor might also be employed as an input device to control and guide the robot by touch, without having to exert much force.”

Basic systems being developed by Fraunhofer to aid safe human-robot interaction include optical sensors that scan workplaces 3-dimensionally, tools that visualise and plan safe areas, and safe tactile sensors that detect collisions. It is also working on project ‘LiSA’, with the Federal Ministry of Education and Research, for the development of a mobile assistant robot for utilisation in life sciences (for transporting multi-plates and loading stations, for example).

Renewable developments

The recent nuclear crisis in Japan, combined with the unrest (and resulting oil spikes) in the North Africa-Middle East region, have led countries to re-evaluate their energy policies, with focus now shifting towards renewable energies as a result.

With the launch of the world’s first DIY solar power plant, GP JOULE could well instigate a solar revolution, by enabling domestic generation of power at an incredibly low outlay cost (just US$800, making it the world’s cheapest PV power plant). The so-called ‘miniJOULE’ consists of just one module mounted onto two metal brackets, which can be set up in the garden, or on your carport or roof terrace. An XS-format inverter transforms solar-generated electricity into alternating current compatible with the mains. What makes miniJOULE unique is its simple self-assembly – no previous experience is required; an electrician is just needed for hook-up. “One miniJOULE on its own won’t have the power to make a difference,” remarked GP JOULE’s CEO, André Steinau, “but many miniJOULEs together will. Recent events have shown us just how important it is for us to think ahead, towards finding solutions. That’s our strength.”

In windpower, the number of offshore farms is predicted to increase significantly over the coming year – while Europe saw a 7.5 percent fall in new wind installations in 2010, offshore wind saw 50 percent growth in countries such as the UK, Denmark and Belgium, indicating the direction in which the market is now going. “The German government’s wind energy expansion plans are an enormous opportunity for us,” remarked Uwe Gierer of Alstom Windpower Offshore, whose firm has over 20 projects in the pipeline (with building permits in place).

Alstom has developed a special floating, self-contained substation platform concept that eliminates the need for expensive, offshore cranes or lifting devices in the installation process. The company has just been awarded a project to build, install and connect to the grid a 155/33 kV substation for an 80-turbine, 288 MW offshore wind farm –‘EnBW Baltic 2’, located in the German Baltic Sea. This is the second offshore substation contract that Alstom has won, informed Michel Augonnet, Senior VP at Alstom Grid. “We expect this floating substation technology to become a standard in the rapidly developing offshore wind market in the years to come.”

Playing a key role in increasing wind turbine performance are companies like Fiber Check, which integrates extra-flat sensors into wind turbine rotor blades. “These embroidered sensors are laminated into the blade structure,” explained CEO Tobias Meyhofer. “It enables us to constantly monitor the condition of the blade so that we can see what is happening to it, and how it moves in the wind. From this information we can work out how it will perform long-term.”

Elsewhere in the renewables sector, Imtech showcased a more efficient technology for creating heat and power from waste. “Conventional waste incineration plants are designed to operate continuously – meaning, for instance, that they continue to burn valuable fuel during the summer months when not all of the energy produced can be used,” outlined Peter Eilers of Imtech Germany. “Yet in the summer, heat given off by these plants cannot be fed into district heating networks and therefore goes to waste.” Imtech’s new technology addresses that inefficiency – as the waste is first processed into fuel, energy production can be fully tailored to fluctuations in household energy demand.

Smart systems for greater performance

Next door, Siemens showcased its state-of-the-art Smart Grid solutions, it being the only supplier of products, services and solutions across the entire energy conversion chain – from consulting and planning, to products and services, to implementation.

Reducing operating costs and primary energy use is clearly a priority for companies, yet, in most cases, preset modes of controlling energy supply systems are not called into question. Limón’s smart energy control of production plants, ‘é.VARIO’ allows for an automatised, energy-efficient and optimised control of various energy systems. Simultaneously, demand is co-ordinated according to individual, underlying circumstances. é.VARIO is able to automatically record key figures and error reports in one single system. Moreover, the smart energy control can be implemented for both new and existing plants.

In the area of flow measurement, HEINRICHS new compact Vortex Flowmeter DVH, with integrated temperature and pressure sensor, can measure mass, and can be used for energy consumption measurements. DVH has a fully welded design and requires no seals for the velocity sensor. Maintenance-free (and thus reducing service costs), the unit not only measures the volumetric flow of liquids and gases, but calculates steam flow, permitting real-time mass flow measurement. Equipped with a flow-computer and second separate temperature sensor, energy consumption can be calculated. The meter can be programmed for steam, hot water or chilled water. The all-in-one measurement makes the DVH very cost effective and allows much more accurate process measurement.

Electromobility innovations

“Our goal is simple, to make Germany the leading electro-mobility market and provider, and to have at least one million electric vehicles on our roads by 2020.” This was the ambitious pledge of one Udo Bünnagel, a representative from Germany’s Federal Ministry for Environment and Nature Protection, with electro-mobility clearly one of the major buzzwords at the country’s premier industrial event.

The all-electric BMW Activ E is powered by a zero emission electric motor that puts out an astonishing 170 HP, while the battery in the Mercedes BlueTec range can be refuelled using electro-magnetic induction. Indeed, in the future, you will be able to refuel your car just by parking it – an electromagnetic induction platform will recharge quickly and easily, with no power cable required. “This is the ultimate in driver convenience,” said Dr Jochen Mahlein of SEW Eurodrive. “The driver simply parks and locks the car in order to activate the system, which then recharges the car overnight when it is in the garage.”

Both BMW and Mercedes Benz aim to start testing the first prototypes of their electric cars on Germany’s streets by as early as October 2011. Of course, to be truly viable, electro-mobility requires the supporting infrastructure like charging stations, both commercial and at home. “We have developed a solution especially for home charging,” informed Mr Thorsten Frieb-Preis, of Rhode & Schwarz. “It runs on a standard 230 Volt domestic supply, which is important, and it has its own easy-to-use, built-in charging cable, so that users don’t need to search for one in the trunk.”

Aside from the supply of energy and the weight of the cars, a successful shift to electro-mobility will also depend crucially on the ability of intelligent drive systems to offer maximum efficiency (range). “As a global player in the hi-tech market for eMobile drive solutions, Wittenstein learned to master this interaction between electrical and mechanical components several decades ago,” remarked Dr Manfred Wittenstein, whose group’s eMobile drive technology made its debut at the Hannover Messe expo, with motors on show in three different sizes for small, mid-range and racing cars, as well as for the commercial vehicles segment.

Carplane GmbH, meanwhile, promoted a more far-flung vision for future mobility through its concept vehicle – part car, part aeroplane. “You can use it like a normal car – exactly like the car that you drive today,” advised Director, Angela Fleck. “You can even park it in the garage. You can also drive it to an air field – any small runway will do – and then take to the skies!” Carplane is powered by an electric motor in road mode, and boasts a top speed of 170 km per hour.

Built to last

With factory hardware investments now on the rise again, as markets regain momentum, a key concern will be ensuring that new equipment is not only up for the job, but built to last, so that lifecycle costs are kept to a minimum. Waltec – the world’s market leader for high quality, high technology glass production lines – implemented the world’s first 6,000 Nm direct, gearless drive for a turntable press back in 2000. After several years of research and development, the breakthrough for the high thrust ram came in 2009. Waltec has found a motor principle, delivering a thrust of 40 kN, complying with the required limited ram volumes and sturdy enough to stand very rough working conditions as found in the heavy industry of glass forming.

The latest technological highlight from Zeitlauf, meanwhile, is the robust and powerful Performax Plus gearmotor concept. Best suited to tough, difficult conditions where its extremely high torques and particularly robust design come into their own, Performax Plus completes the circle, in terms of output ranges where particularly high output power is required.

After more than 40 years’ experience, and as the world’s leading supplier of high-precision drive systems, Maxon Motor AG launched its EC 22 HD (Heavy Duty) at this year’s Hannover Messe. Developed for the exceptionally high requirements found in deep drilling technology, the electronically-communicated motor resists even the most extreme conditions, opening up new possibilities in a number of applications where the requirements are high – mining, power plants and space travel.

Tomorrow’s opportunities

Due to the volatility in energy prices, proactive companies will undoubtedly continue to develop and invest in more energy efficient technologies to reduce input costs, while minimising lifecycle costs will also be crucial in helping to gain the edge in areas of increased competition and squeezed margins.

Increasing the integration of monitors and sensors will create a safer working environment. And developments in robotics could well remove the need for human labour completely in certain areas, or, alternatively, help to increase the ease of human-robotic integration, where such needs exist.

With electro-mobility now edging into the mainstream, getting the infrastructure in place to accommodate this game-changer will be key to achieving an ‘e-revolution’. In relation to this, the challenges posed by burgeoning urban centres – for industry, research, urban planners, financial institutions and public authorities alike – will require the development and implementation of environmentally friendly infrastructure technologies. This year, around 30 exhibitors showcased such technological subsystems and components for the cities of the future, including energy, mobility-infrastructure and water/sewerage-related solutions – and there are plans to expand the scope of this ‘Metropolitan Solutions’ cluster for next year’s event.

Furthermore, the addition in 2012 of a brand new show, ‘Industrial GreenTec’, will focus on “innovative solutions for recycling, waste disposal, and clean air and water at every link of the industrial value chain,” explained Hannover Messe’s organiser, Wolfram von Fritsch. “The motto will be ‘by industry, for industry.”

The 65th edition of Hannover Messe will take place from 23-27 April 2012 – see you there!